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LAYING AND ASSOCIATEDWORKS FOR ONGC BANTUMILLITO ULLAMPARU PIPELINE Project No. P.011947Document No. P..011947 R11050 101E - Tender No. 8000013032

GAIL (India) LimitedNoida | INDIA

PUBLIC

8 May 2018

TECHNICAL DOCUMENTATIONTechnical - Piping & Pipeline, Vol II C, Rev. 0

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GAIL (INDIA) LIMITED

BANTUMILLI TO ULLAMPARU PIPELINE PROJECT KG BASING

TRACTEBEL ENGINEERING PVT. LTD.

PIPELINE & PIPING DESIGN BASIS

NATURAL GAS PIPELINE FROM ONGC BANTUMILLI TO ULLAMPARU

DOC. NO. : P.011947 D 11017 101

0 01.05.2018 Issued for Procurement MS NC SKH

Rev. Date Description Prepared By Checked By Approved By

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Rev. 0 ONGC Bantumilli to Ullamparu Pipeline Page 1 of 1

TABLE OF CONTENTS

1.0 INTRODUCTION .................................................................................................................... 1

2.0 PROJECT SCOPE .................................................................................................................... 1

3.0 CODES/ STANDARDS AND DOCUMENTS ............................................................................... 2

4.0 BASIC DESIGN DATA ............................................................................................................. 3

5.0 PIPELINE SYSTEM CONFIGURATION .................................................................................... 4

6.0 PIPELINE DESIGN ................................................................................................................. 5

7.0 STATION PIPING / FACILITIES design ............................................................................... 19

8.0 CATHODIC PROTECTION ..................................................................................................... 22

9.0 WELDING ............................................................................................................................ 22

10.0 TESTING .............................................................................................................................. 23

11.0 FIRE FIGHTING ................................................................................................................... 23

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Rev. 0 ONGC Bantumilli to Ullamparu Pipeline Project Page 1 of 24

1.0 INTRODUCTION

GAIL India Limited (GAIL) is operating a network of Natural gas pipelines in the KG Basin area of

Andhra Pradesh, with total length spanning approx. 880 kms, for supplying gas to various customers in the

region. GAIL receiving gas from suppliers like ONGC, and transports it to various industrial customers /

load centres, through its existing Pipeline network.

GAIL is planning to receive a supply of 0.7 MMSCMD (approx.) of Natural Gas from ONGC Bantumilli.

GAIL is planning to lay a new 12” NB dia x 38.0 kms length (approx.) cross country Pipeline from ONGC

Bantumilli to its existing station at Ullamparu, for transporting this gas upto Ullamparu, where it will be

fed into existing GAIL network.

The proposed 12” pipeline, with a flow capacity of 0.7 MMSCMD, will have a dispatch Terminal at

Bantumilli, & a Receipt cum Hook-up terminal at Ullamparu. The downstream of the new pipeline, at

Ullamparu, will be hooked up to the existing 18” NB Pipeline of GAIL, which passes through Ullamparu

station premises, for feeding this gas into the existing GAIL network.

The proposed 12’ Pipeline will be laid partly in new ROU (21 Kms from Bantumilli to DPML,

Vendra) & balance in existing ROU of GAIL (20 kms approx.. from DPML to Ullamparu). The proposed

gas pipeline route runs cross-country, through marshy soil, paddy fields and fish ponds on either side and

crosses areas falling under Location Class 1, 2 and 3.

This document establishes the basis for Design and Detail Engineering for the proposed 12” inch x 38 km

Pipeline from Bantumilli to Ullamparu, and the associated equipment/ station facilities proposed to be

installed, along with the Pipeline.

2.0 PROJECT SCOPE

The scope of this project comprises Engineering, Procurement, Fabrication, Construction, Installation,

Testing, Pre-commissioning and Commissioning of 12” diameter x approximately 38 kilometers long,

Natural Gas Pipeline and associated station facilities, from ONGC’s upcoming supply terminal at

Bantumilli, to proposed receiving station at GAIL’s existing terminal at Ullamparu, in Andhra Pradesh.

Following are the pipeline details:

Mainline

Bantumilli to Ullamparru

Nominal Diameter : 12” NB

Length : 38.0 Kms. (approx.)

Brief Scope of work, for the construction of pipelines and associated station facilities, shall be as

summarized below :

• Construction of New Dispatch Facility at Bantumilli, adjacent to the upcoming supply facility of

ONGC, in the plot / land provided by ONGC within their premises, or adjacent to ONGC plot. Gas

supply for the proposed pipeline will be taken from Tap-Off Valve provided by ONGC within their

premises.

• Construction of 1 No. SV station at plot provided by GAIL, along the proposed pipeline Route. A plot

has been identified by GAIL for the same, at a tentative location approximately 16.00 kms from

Ullamparru terminal. The exact location shall depend on plot finalization by GAIL.

• Construction of Receiving facility at Ullamparru. The new Receiving station shall be developed

adjacent to existing Ullamparu station of GAIL, in a new plot, to be provided by GAIL.

• All associated Civil, Mechanical, Electrical, Instrumentation & Control, and Cathodic Protection

related works and associated facilities etc, are included in scope of project.

For further details on station facilities and Pipeline system Configuration, please refer Section 5.0 :

‘Pipeline System Configuration’, of this document.

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3.0 CODES/ STANDARDS AND DOCUMENTS

The Codes, Rules and Standards that are mandatory by law in India shall be applied.

Basically, the following are applicable :

� Laws - Codes & Rules as mandatory under the legislation of India

� The set of Laws - Codes & Rules that have been agreed between GAIL and the Authorities for the

implementation of the high-pressure system wherever applicable.

GUIDING CODES & STANDARDS

Latest applicable editions of the following Codes, Standards, Regulations and Guidelines shall be followed

for the Design of this Pipeline system, as the Guiding Codes & Standards :

• PNGRB Notification – G.S.R. 808 (E), Nov’2009. : PNGRB (Technical Standards and

Specifications including Safety Standards for Natural Gas Pipelines) Regulations

• ASME (ANSI) B 31.8 - American Code "Gas Transmission and Distribution Piping Systems" and

relating US codes applicable to similar facilities;

• "OISD 226" : "Oil Industry Safety Directorate" – Natural Gas transmission Pipelines Water & Gas

ROU (Acquisition) Act, 2000;

• Railways/Highways/Forest/Other Pipelines – Statutory Regulations, Terms & Conditions as

applicable;

• Petroleum Rules;

In case of discrepancies, whichever is stringent, shall prevail.

APPLICABLE CODES & STANDARDS

In addition, latest editions of the following codes and standards shall be followed for the design of various

aspects of Pipeline and associated facilities, as per PNGRB regulations :

This standard shall be read in conjunction with the following standards, codes and publications:

(i) ASME B31.8 Gas Transmission and Distribution Piping Systems. (ASME 3 Park

Avenue, New York, NY USA 10016. (www.asme.org) (latest edition)

(ii) API 1102 Recommended Practice for Steel Pipelines Crossing Railroads and

Highways.

(iii) API 1104 Standard for Welding Pipelines and Related Facilities.

(iv) API 1107 Recommended Pipeline Maintenance Welding Practices.

(v) API- 5L Specification for Line pipes

(vi) API- 6D Pipeline Valves

(vii) API 500C Classification of Locations for Electrical Installations at Pipeline

Transportation Facilites.

(viii) ASME Section VIII Boiler and Pressure Vessel Code

Division 1 Pressure Vessels

Division 2 Alternate Rules for Pressure Vessels

(ix) ASME Section IX Welding Qualifications

(x) NACE-RP-01-69 Recommended Practice Control of External Corrosion on Underground or

Submerged Metallic Piping Systems.

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(xi) NACE-RP-01-75 Recommended Practice - Control of Internal Corrosion in Steel Pipelines

Systems.

(xii) IEC - 79 Electrical Apparatus for Explosive Gas Atmosphere

(xiii) IEC - 529 Degree of protection Provided by Enclosures.

REFERENCE CODES & STANDARDS

(i) IS-5572 - Electrical area classification of Installation for selection of Electrical

Equipment

(ii) IS - 5571- Guide for selection of Electrical Equipment for Hazardous Area.

(iii) IS 3043 - For earthing of all electrical equipment, systems, structures and fencing,

etc.

(iv) IS:2309 - Lightening protection

(v) ISO 14313 Valves

(vi) NACE SP-0177 Mitigation of AC and lightening effects

4.0 BASIC DESIGN DATA Following basic data are to be considered for pipeline and associated facilities design :

Design Data Value

Design Gas Flow 0.7 MMSCMD

Design Pressure, bar g 72

Design

Temperature,

(oC)

Underground Services (-) 20 to 60 (min / max)

Aboveground Services - CS (-) 20 to 65 (min / max)

Aboveground& Underground

Services - LTCS (-) 45 to 65 (min / max)

Design Life, Years 25

4.1. Pipeline Design Parameters Pipeline Facilities :

• Gas Supply Point : Bantumilli (ONGC Tap Off Point)

• Receiving Points : Ullamparu

• No. of Dispatch Station : 1 (at Bantumilli)

• No. of Receiving Station : 1 (at Ullamparu)

• Total No. of SV Stations : 1 no.

• Total No. of Tap Off Points : 2 nos. (at Ullamparu)

Process Parameters :

• Pipe Line Length : 37.6 km (approx.)

• Pipeline Size : 12” Inch

• Design Flow : 0.7 MMSCMD

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• Gas Supply Pressure : 40-50 barg (max. at Bantumilli)

• Gas Supply Temperature : 40-45 ° C (at Bantumilli)

• Design Pressure : as listed in Section 4.0 above

• Design Temp : as listed in Section 4.0 above

• Material Grade of Mainline Pipe : API 5L Gr. X 70, PSL 2 (size = 12”).

• Material Grade of Station Piping : - API 5L Gr. X 70, PSL 2 (for size 12”)

- ASTM A 333, Gr.6 (Seamless) (for size ≤ 10”).

• Location Class : 1, 2, 3 and 4

Location Class 1 & 2 and 3 shall be used for :

- Pipeline laying along the proposed Pipe route,

which falls in Location Class-1, 2 and 3

respectively.

Location Class-3 shall also be used for :

- all Station Piping

- all crossings by HDD

- some crossing in Class-2 which require design

factor of 0.5

Location Class-4 shall be used for :

- Railway crossing, and for pipeline laid within

the ‘risk radius’ on both sides of Railway

Crossing.

• Corrosion Allowance : ‘2.0’ mm for 12” Mainline Pipe

(API 5L Grade X 70 & Grade X 65 Pipes)

: ‘2.0’ mm for ASTM A 333 , Grade 6 Piping

(all Station Piping 10” and below)

• External Coating : 3LPE as per PTS /GTS coating

• Internal coating : Yes, Liquid Epoxy Paint (for Mainline)

• Manufacturing Tolerance for Wall : ‘Zero’ Negative tolerance for 12” Mainline Pipe

Thickness (API 5L Grade X 70 Pipes)

: (+/-) 12.5% for ASTM A 333 , Grade 6 Piping


• Coating/Painting for Station Piping : Refer Section 7.1

5.0 PIPELINE SYSTEM CONFIGURATION

The Pipeline System configuration was finalized based on Route Survey details, and no. and location of

SV Station, was determined based on ASME B 31.8 requirements, and tentative location of plot identified

by GAIL for SV Station.

Based on spacing requirements of SV stations, as per ASME B 31.8, one SV Station (SV-1) is proposed to

be constructed along the Proposed Pipeline route, in a plot identified by GAIL, at a location tentatively,

16.00 kms from Ullamparru station. In addition some equipment is proposed to be installed at various

stations.

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The Table below summarizes the Location Chainage of each station, and a summary of equipment /

facilities proposed at each station, along the proposed 38 km Pipeline from Bantumilli to Ullamparru :

S. No. Station Description Chainage

(km. - approx. from

Bantumilli)

Proposed Facilities

1 Dispatch Station,

Bantumilli 00.0

Dispatch Facility with Pig Launcher, and

Filtering, Metering, Gas Chromatograph,

Pressure & Flow regulating skid

2 SV – 1 21.6 SV with 1 no. 12” Tap Off for future

3 Receiving Station,

Ullamparu 37.6

Receiving station with Pig Receiver, Check

Metering skid, and 2 nos. 12” future tap off

valves (one for future tap-off, & the other for

future connectivity with 8” and 12” Pipelines),

Hook-up with existing 18” Pipeline of GAIL

Note : The location & chainage of SV station shall be finalized, based on plot finalization by GAIL.

5.1. Stations / Facilities on the Pipeline

Following is a summary of facilities planned at the stations:

• Dispatch station: It includes Pig launcher facilities, Hook-up with Tap-Off Valve (to be provided by

ONGC) within ONGC premises, installation of a Filtering, Metering, Pressure and Flow Regulating

Skid with Gas Chromatograph, all associated valves and Piping, Instrumentation and Controls, and

facility to depressurize the pipeline, if necessary..

• Sectionalizing Valve (SV) Station : SV Station shall be provided with bypass and venting

arrangement. In addition a 12” Tap Off shall be provided for Future. The location and plot for SV

station shall be as finalized by GAIL.

• Receiving station : Receiving station shall include Pig receiver facility, a Check metering skid, Hook-

up with existing 18” Pipeline of GAIL, which passes through the Ullamparu plot, for feeding the gas

in existing GAIL network, (the Hook-up to 18” Pipeline, shall be done with a barred tee, to ensure

piggability of the 18” pipeline), all associated, valves and Piping, Instrumentation and Controls, and

facility to depressurize the pipeline, if necessary..

• Future Tap Off Points : 3 Nos. 12” NB Tap Off Points (TOP) shall be provided on the pipeline, 1 at

SV station, and 2 nos at Ullamparru Receiving Station, (one for future connectivity, and the other for

future interconnection of 12” and 8” pipelines running parallel to 18” Pipelines.

6.0 PIPELINE DESIGN

6.1. General

Mainline, Dispatch terminal, Receiving terminal and SV Station, to be installed as a part of this project,

shall be designed and engineered in accordance with all applicable codes, standards and approved

drawings/documents.

6.2. Design Life The Pipeline, Station Piping and mainline valve assemblies are designed for an economic service life of 25

years. Generally, consideration should be given to the fatigue life of a steel pipeline, in order to ensure that

minor defects, associated with any welded structure, which survive the proof test, do not grow to a critical

size under the influence of pressure cycling.

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6.3. Pipeline Design

Pipeline and its associated facilities shall be designed as per design pressure/ temperature rating and shall

comply with the requirements of PNGRB Regulation (GSR – 808 (E), Nov 2009), ASME B31.8 (latest

edition) and other applicable regulations, Codes and standards :

The Basic Design Parameters considered for the Pipeline, and its associated facilities shall be as listed

below :

S.No. Design Parameter Value to be considered for Design

of Pipeline

1. Design Temp :

1.1 for Underground CS Pipeline (-) 20°C / 60° C

1.2 for Above Ground CS Piping (-) 20°C / 65° C

1.3 for all LTCS Piping (both UG and AG) (-) 45°C / 65° C

2. Design Pressure 72 Barg

3. Burial Depth 1.2 meter (minimum)

4. Pipeline Operating life 25 Years

5. Material of Construction :

5.1 Mainline Pipe - 12” NB API 5L Gr. X 70, PSL 2

5.2 Station Pipes - 12” NB API 5L Gr. X 70, PSL 2

5.3 Station Piping – 10” NB and Below ASTM A 333, Gr.6 (Seamless) (LTCS)

6. Corrosion Allowance :

6.1 Mainline Pipe - 12” NB 2.0 mm

6.2 All Station Piping 2.0 mm

Mainline (12”) shall be provided with pigging facilities suitable for handling intelligent pigs/ Caliper,

cleaning and displacement pigs.

Mainline shall be provided with sectionalizing valve at spacing as per the requirements of ASME B31.8 &

PNGRB regulations. In addition, the Valve location selected should also ensure, that the valve installation

is in an accessible location, with continuous accessibility being the prime consideration.

6.4. Pipeline Bends

Induction bend shall be used wherever space constraint is there and at stations. The bending radius shall be

as long as possible to match the route but in no way below six (6) times the diameter.

In Mainline 6D bends are acceptable at entry to stations and at transition point where pipeline is coming

aboveground from underground near pig launcher/receiver.

In no case pipe thickness after bending shall be less than the specified line pipe thickness. Therefore higher

class pipe is recommended for 6D bends.

On field cold bending, if required, shall be in accordance with codes, and have minimum bend radius 40D,

when sufficient space is available for carrying out the operation.

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6.5. Design Loads

Pipeline shall be designed to withstand all installation, testing and operating conditions/loads. All

necessary calculations shall be carried out to verify structural integrity and stability of the pipeline for the

combined effect of pressure, temperature, bending, external loads and other environmental parameters as

applicable. Allowable stress limit shall be as per ASME B31.8. Such calculations shall include but are not

limited to following:

- Buoyancy control and stability analysis for pipeline section to be installed in areas subjected to

flooding/submerged areas. Unless specified, specific gravity of surrounding water in water body

crossings shall be at least 1.2 with pipe empty during installation.

- Stress calculation at crossing of major rivers, railway and highway.

- Crossing analysis for HDD river/canal crossings.

- Pipeline expansion/contraction and its effect on station piping (above-ground/below-ground). As far

as possible, expansion of pipeline shall be absorbed by allowing the scrapper trap to move on its

supports. If required, at such transition points, adequate areas around the underground pipeline shall

be provided with a select backfill to ensure flexibility. Alternatively, Anchor block requirement shall

be evaluated and provided as and when required.

- Stress analysis of pipeline at station approach and at above ground station.

Road, rail and water crossings are designed to withstand superimposed loads by using heavy wall pipe,

concrete coating, additional cover, or by using other measures to ensure adequate distribution of all

superimposed loads.

6.6. Stress Analysis

Stress Analysis shall be carried out for the Pipeline and station facilities as per the criteria mentioned

below :

Various loadings significantly affecting piping stresses shall be considered in accordance with ASME B

31.8 and shall include the following at minimum :

• Load of bare pipe+ fluid+ insulation (if any),

• Weight effects (live and dead),

• Ambient effects,

• Thermal expansion effect,

• Seismic load ( earthquake),

• Load of valves,

• Online equipment and instruments,

• Loads due to internal pressure,

• Any external loads/concentrated load etc.

Stress analysis shall be carried out for stations considering the above ground piping at stations along with

the buried pipeline up to the distance of Virtual Anchor Length.

The supports shall be designed as per the loads & recommendations from Stress analysis.

6.7. Pipe Wall Thickness Pipe wall thickness calculations has been carried out in compliance with ASME B 31.8 and with a

corrosion allowance of ‘2.0’ mm for 12” mainline pipe, and for Station Piping (10” & below). All Wall

thicknesses used in this project, for both station Piping as well as for the Main 12” Pipeline, shall be as per

this document.

The same is summarized in Section 6.7.1 to 6.7.3 below, for ready reference.

6.7.1. Material

Line pipe material shall be API 5L Grade X 70, PSL2 for 12” main pipeline.

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HFERW/Seamless line pipe shall be used for 12” mainline for all the stretches. However, only Seamless

pipes shall be used for fabrication of Hot Induction Bends.

For Station Piping the material shall be API 5L Grade X 70, PSL2 for 12” mainline. All other station

pipes (size 10” and below) shall be LTCS Seamless pipe of material ASTM A 333 Gr. 6. (Refer P & I

diagrams & piping material specification, wherein demarcation of materials are provided).

In addition, the following is considered, for arriving at Pipe Wall Thickness for all Pipes :

• Manufacturing Tolerance for Wall : ‘Zero’ Negative tolerance for 12” Pipes

Thickness (API 5L Grade X 70 Pipes)

: (+/-) 12.5% for ASTM A 333 , Grade 6 Piping


6.7.2. Main Line Pipe :

Based on Wall Thickness Calculations, following is the Material & Thickness Summary of Mainline pipe

and Station Piping :

• Material for 12” Main Line Pipe : API 5L X70, PSL 2

• Selected Wall Thickness for 12” Line Pipe :

Location Class of

Pipeline Route

Selected

Wall Thickness

Location Class 1 6.4 mm




Please note that the selected thicknesses are the next available standard thickness, as per ASME B 16.10.

Considering small length of the pipeline, the pipe may be procured from available stocks of suppliers, and

hence only standard pipe thicknesses have been considered.

It is to be noted that entire Pipeline Route falls in Location Class 1, 2 and 3 only. Location Class 3 shall

also be considered for all Station Piping and certain crossings in Location Class 2 which require Factor of

safety of 0.5, as per PNGRB (See Table below for Details).

Location Class 4 is not encountered along the Pipeline route. However as per requirement of Railway

Regulations (Notification BS-105, and Addendum-4), entire railway crossing including pipeline falling in

risk radius, shall be considered as Location Class 4.

• For details of Railway & State Highway Crossings, refer Section 6.12.

• For details of River / Canal Crossing, refer Section 6.13.

• Further, for Pipe thickness to be used at all crossings, along the proposed 12” Pipeline Route, see

Table given in Section 6.9

6.7.3. Hot Induction bends :

For fabrication of Hot Induction bends for any location class, pipe of one class higher thickness shall be

used. This is to ensure that even after bending, the thickness of Pipe remains above the minimum required

thickness for any location class,

In this project, the entire Pipeline route falls in Location Class 1, Class-2 and Class-3. Further entire

Pipeline route falling within Railway ‘risk radius’ shall be considered as location Class-4. Wherever Hot

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Induction bend is required in Mainline Pipe laying at any location, due to space constraint or site

requirements, the following thickness shall be used for fabrication of Hot Induction bends,:

• For Location Class-1 : Thickness to be used for fabrication of Hot Bend – 7.1 mm




Further, all station piping is considered as Location Class-3. Accordingly, for Hot Induction Bends to be

installed at all station locations, the thickness of Pipe used shall be as as below :

• For Location Class-3 (Station piping) : Thickness to be used for fabrication of Hot Bend – 8.4 mm

Hence, for pipeline laying in any location class, and for Station piping, the thickness of pipe to be used for

fabricating Hot Induction bends, shall be as below :

Pipe Thickness required for fabricating Hot Induction Bends – 12” Mainline

Location of Bend Location Class of

Pipeline Route

Pipe Wall Thickness to be used,

for fabricating Hot Induction

bends

Along Pipeline route :

12”NB Main line Location Class-1 & 2 7.1 mm (Class-3 thickness)

12”NB Main line Location Class-3 8.4 mm (Class-4 thickness)

12”NB Main line Location Class-4

(within Railway ‘risk radius’) 9.5 mm

At Station Locations :

12” NB Hot Induction

Bends at Stations

All Stations considered as

Location Class-3 8.4 mm (Class-4 thickness)

The pipes used for manufacturing Hot Induction Bends will be bare pipes (Not Coated), and shall be

coated with wrap around sleeves at site, as per project specifications. Further, only seamless pipes shall be

used for fabrication of Hot Induction Bends.

6.7.4. Wall Thickness for Station Piping :

A. 12” NB Mainline Piping at Stations :

The material considered for 12” NB Station Piping is API 5L, Gr. X-70; PSL-2. Further, the thickness of

12” Station Pipe has been calculated considering Location Class-3, to facilitate welding of the Pipe with

the Fittings, which shall have a higher wall thickness.

Additionally, the Hot Induction Bends to be used at Stations shall have thickness as per Location Class-4,

to ensure that even after bending, the Thickness does not fall below Class-3 requirement. Hence, Mainline

Station Piping shall be as below :

Based on the Wall Thickness Calculations,, the Wall thicknesses to be used in Station Facilities, for

various Pipe Sizes, shall be as summarized below:

• 12” Mainline at Stations : API 5L X 70, PSL 2 - (7.1 mm WT)

• 12” Hot Induction bends at Stations : API 5L X 70, PSL 2 - (8.4 mm WT)

B. All Station Piping 10” NB and below :

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The pipes for all other station piping of size 10” and below, shall be LTCS Seamless pipes of material

ASTM A 333 Gr. 6. All LTCS Pipes shall be Charpy Impact tested at (-45 °C).

The wall Thickness for all Station Piping (10” and below) shall be as summarized below :

• Material for Station pipes (10” & below) : ASTM A333, Grade 6.

• Wall Thickness for Station pipes (10” & below) :

o Pipe sizes ½” to 2” NB Pipe - Schedule 160

o Pipe Sizes 3” to 10” NB - Schedule 80

The following Table summarizes the Wall Thickness and Material requirements for all Station Piping :

Thickness Summary for Station Piping

Station Pipe Detail

Location

Class

considered

for WT

Material for Station

Piping

Wall

Thickness

Selected

12” NB - Mainline Pipe at Stations Class-3 API 5L, Grade X-70, PSL-2 7.1 mm

12” NB - Hot Induction Bends at

Stations Class-4 API 5L, Grade X-70, PSL-2 8.4 mm

Station Piping - 3” NB to 10” NB Class-3 ASTM A 333, Grade 6 Sch. 80

Station Piping - 1/2” NB to 2” NB Class-3 ASTM A 333, Grade 6 Sch. 160

For details of Wall thickness Calculations, Please refer ‘Wall thickness Calculations’, Doc No :P.011947

M 05 0001 (latest revision).

6.8. Line Pipe Coating

Line pipe shall have 3LPE external coating as per ISO 21809-1, and coating thickness shall be 2.2 mm, as

per the requirements of DIN 30670. Type of external coating shall be ‘N-n’ type as per DIN 30670.

Heat Shrink sleeves of minimum 2.2mm thickness shall be used for field joint coating on pipeline girth

welds. The minimum thickness on welds shall be 1.8 mm. Field joint coating system shall comply with EN

12068. Coating material shall be EN 12068-C HT 60UV for C–60 Class.

For all Line Pipes used for HDD, the coating shall be 3LPP external coating as per ISO 21809-1. For HDD

joint coating, fiber glass reinforced heat shrinkable sleeve certified to Stress class C-60 type compatible

with 3LPP or SEAL for Life Industries (Part of Berry Plastics-USA)/ Canusa or DIRAX-PP shall be used.

For the buried valve at stations (molded piece, valves, elbows etc) Thermoset plastic coatings may be used.

Thermoset plastic coating shall be of Type 3 DIN EN 10289.

Internal coating shall be considered for 12” Mainline Pipes. Internal epoxy coating shall be as per ISO

15741.

Max design temperature for coating to be considered is +60ºC.

6.9. Crossings

All major crossings like State Highways, Railways, Lined Canals etc. shall be laid by Boring or whenever

imposed by concerned authority. Cased crossing is mandatory for Lined canals, State Highways &

Railroad crossing. For National Highway Crossing see Section 6.11.

At all crossings where Carrier / Casing pipe is installed by using Boring & Jacking method, and for all

HDD crossings, a separate 6” Casing Pipe (API 5L Grade-B, 6.4 mm thk, external epoxy coated, 500

micron thick) shall be installed, with 2 nos. 50 mm HDPE ducts laid inside the casing, 1 housing the main

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OFC cable inside it, and the other spare, for future OFC blowing. The 6” Casing pipe shall be installed

through separate boring as shown in the standard drawings.

The Wall Thickness of Pipes to be used at all the crossings shall be as per the design factors recommended

in PNGRB regulatios, Table-1.

All the crossings mentioned in detailed route survey shall be classified as per PNGRB, as shown in the

table below :

Type of Crossing as per Detailed

Survey Report Crossing Classification -

as per PNGRB Regulation ‘Table-1’ S.No

Crossin

g Code

Crossing

Description

Uncased Crossing (Open Cut)

1 AR Asphalted Road Uncased - Road, Highway, Public Street with Hard Surface

2 MR Metalled Road Uncased - Road, Highway, Public Street with Hard Surface

3 ODR Other District Road Uncased - Road, Highway, Public Street with Hard Surface

4 MDR Major District Road Uncased - Road, Highway, Public Street with Hard Surface

5 MUR Mud Road Uncased - Un-improved Public Roads or Private Roads

Cased Crossing (Boring + Casing)

6 SH State Highway Cased - Road, Highway, Public Street with Hard Surface

7 Ry Railway Cased - Railway Crossing – considering Location Class-4

(As Per Railway requirement)

8 LC Lined Canal Cased Crossing

9 RCC RCC Road Cased - Road, Highway, Public Street with Hard Surface

Open Cut/HDD

10 NH National Highway HDD

11 NL Nala River Crossing -Open Cut

12 DR Drain Uncased Crossing - Open Cut

13 Rl River River Crossing -Open Cut /HDD (depending on site

conditions)

For conservative design, all Mud Road / Cart Tracks shall be considered as Uncased ‘Public Road’, and

design factor shall be considered accordingly.

Applicable Design factor for each type of crossing listed above, shall be as given in PNGRB Table-1.

However for Railway Crossings ‘Location Class-4’ shall be considered, as per Requirement of Railway

Circular BS-105, and its Addendum-4 dated April 2014.

Further, for all crossings done by HDD, Pipe Thickness as per Location Class-3 shall be considered.

Hence, In line with requirements of PNGRB Regulations, Railway Regulation and Project Specifications,

the Wall Thickness of Pipes to be used at all crossings, along the proposed 12” Pipeline Route, shall be as

summarized in table below :

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‘Pipe Wall Thickness’ to be used at various Crossings,

along 12” Bantumilli-Ullamparru Pipeline Route :

(All wall thickness mentioned in the Table below, are in ‘mm’)

Facility

Pipe Wall Thickness to be used,

for each Location Class (in mm)

1 2 3 4

Pipeline 6.4 6.4 7.1 8.4

Crossings of roads, without casing:

(a) Private roads 6.4 6.4 7.1 8.4

(a) Unimproved public roads 6.4 6.4 7.1 8.4

(b) Roads, highways, or public streets, with hard

surface 6.4 7.1 7.1 8.4

Crossings of roads, with casing:

(a) Private roads 6.4 6.4 7.1 8.4

(b) Unimproved public roads 6.4 6.4 7.1 8.4

(c) Roads, highways, or public streets, with hard

surface and Railway crossings 6.4 6.4 7.1 8.4

Parallel Encroachment of pipeline on roads and

railways

(a) Private roads 6.4 6.4 7.1 8.4

(b) Unimproved public roads 6.4 6.4 7.1 8.4

(c) Roads, highways, or public streets, with hard

surface and Railway crossings 6.4 6.4 7.1 8.4

All Railway Crossings 8.4 8.4 8.4 8.4

Pipeline laid in area within 'Risk Radius' (150 m, on

both sides) of Railway Crossings 8.4 8.4 8.4 8.4

River Crossing- open cut 6.4 6.4 7.1 8.4

Horizontal Direction Drilling (HDD) 7.1 7.1 7.1 N/A

Fabricated assemblies (scraper traps, SV stations,

pressure/flow control and metering facilities, etc.) 7.1 7.1 7.1 N/A

Near concentration of people in Location Classes 1

and 2 7.1 7.1 7.1 N/A

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6.10. HDD for initial 6.6 kms Length of proposed Pipeline Route

The initial 6.6 kms length (approx..) of proposed pipeline route, starting from TP-07 near ONGC

Bantumilli (chainage – 0.424 km), and upto TP-50 (chainage : 7.0463 km) has a very restricted width of

ROU available. This section of pipe route runs adjacent to existing road and State Highway-113. The

following are the major observations for this section of the Pipeline Route :

• The proposed route runs adjacent to existing road from TP-07 to TP-19, and then adjacent to existing

SH-113 upto TP-50. The available width for construction of pipeline is very limited, at some locations

3 to 4 meters wide, and at various locations, existing constructions /structures are present.

• A water Channel (drain) runs on the other side of the proposed route, throughout the length of the

above section. (from TP-07 to TP-50). The width of the channel varies from a few meters to

approximately 10 meters, at various locations.

• The proposed route of the pipeline lies between road/SH-113 on one side and the water Channel

(drain) on the other side. The pipe shall be required to be installed in the restricted space available

between the road/SH-133 on one side and the channel (drain) on the other side.

• The channel/drain is lined at a few locations and unlined at many locations. Accordingly, seepage of

water and collapse of soil are highly likely during trench excavation and pipeline construction /

installation activity.

• In addition, a large no. of Fisheries / fish ponds are present on both sides of the proposed route, along

the entire length of the above section. Also, there is another Major Channel (Enamadurru Drain) on

further west of the proposed route.

• Due to presence of these water bodies surrounding the route, the soil is expected to be waterlogged,

and seepage is likely in the pipe trench. In view of the above, anti-buoyancy measures like concrete-

coating and / or saddle bags etc. will be required for the pipeline.

• Due to proposed route lying next to the road / SH-113, vehicular movement is likely on the pipeline

ROU, and accordingly extra protection shall be required for the pipeline against possible vehicular /

earth loads.

Considering the above observations, it is recommended that the above section of the pipeline be laid by

HDD Method. Laying by HDD will take care of possible constraints during pipeline construction, due to

restricted route width, and will also safeguard the pipeline from possible seepage, water logging and

vehicular loads expected during normal laying.

Since the length of the pipeline section is large, (approx.. 6.6 kms), the pipeline laying shall be done using

multiple HDDs. The depth of HDD shall be kept adequate to safeguard the pipeline from effects of

seepage, waterlogging and earth loads. The following shall be considered :

a. The exact location, length and starting & end points of the HDD crossings shall be determined based

on actual site conditions, and availability of space and permissions for carrying out HDD operation,

and ease of installation and movement of required equipment.

b. To the extent possible, most of the portions of the above section shall be preferably installed by HDD

Method. The sections where major construction constraints are likely shall be included in crossings by

HDD.

c. The no. and locations of HDD sections shall be decided based on site conditions and requirements,

availability of adequate space for carrying out the operation, movement and installation of equipment,

and ease of hooking up of different HDD sections.

d. The depth, routing and exact profile of the HDD shall be finalized based on site conditions and actual

site requirements.

e. The sections where it is possible to lay the pipeline by trenching, shall be carefully evaluated and

agreed by the client / site engineer. All such sections shall be hooked-up with adjacent HDD sections,

ensuring a smooth pipeline profile for ensuring that all pipeline stresses are within design limits.

f. Adequate protection against earth/vehicular loads in form of concrete slabs etc. and adequate anti-

buoyancy measures like concrete-coating, saddle bags or pre-cast concrete weight blocks etc. shall be

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provided, as per site requirements, for pipeline sections which are executed by normal trenching

method.

g. The pipeline laying in this entire section, including all HDDs shall be planned and designed very

carefully, considering site conditions, existing constraints, presence of large water bodies and a

running state highway adjacent to the route with traffic. The planning and design shall ensure safe

operation, construction and installation of pipeline, without affecting the highway traffic and in view

of the safety of public, adjacent structures and installations and water bodies.

h. In view of the above, the entire HDD operation, including design, engineering, execution and testing

shall be performed by a specialist HDD Contractor, with adequate experience and proven track record

of similar operations.

i. Design and engineering of HDD operation shall also ensure that no seepage of bentonite takes place

from the HDD into the adjoining soil / fields / fisheries / ponds etc. In case, any seepage happens, the

compensation for the same shall be done by the contractor.

The Design of all Hot HDD operations, including design of all materials, all engineering calculations,

execution, installation and testing etc. shall be carried out in full compliance to all applicable codes and

standards, statutory requirements and in line with project specifications and requirements. Best practices

from the industry shall be considered and followed where deemed suitable.

In view of the above suggestion, thickness for entire pipeline length from ONGC Bantumilli (Chainge -

0.0) to TP-50 (Chainage – 7.0463 km) has been considered as per location class-3, in view of possible

laying by HDD. (Most of this section already falls in location class-3. However, a small section from

chainage 0.750 km to 2.000 km, was falling under location class-1. The thickness for the same has been

considered as per location class-3, in view of possible HDD).

6.11. National Highway (NH-65) Crossing

The proposed pipeline shall cross National Highway (NH-65) at chainage 18.085 kms. The National

highway at this location lies in a congested stretch, surrounded by buildings and residential constructions.

The crossing location is very restricted and channel / drain is running adjacent to the proposed route of the

Pipeline along the crossing.

Due to presence of existing buildings, residential area in the surroundings and channel / drain running

adjacent to the proposed route, it is not feasible to carry out the crossing by Boring & Casing method. The

space available is not adequate for the operation.

Accordingly, it is suggested to carry out this crossing by HDD method. The HDD shall be planned in the

space available between TP-74 on the eastern side, and TP-70 on the western side, of the proposed

crossing. The exact starting point, end point, length, depth and exact profile of the HDD shall be finalized

based on detailed site study, and as per actual site requirements.

Design of HDD shall ensure safe operation, construction and installation of pipeline, without affecting

existing buildings and installations and ensuring safety of public. The HDD shall be planned and designed

carefully, considering site conditions, existing buildings and residential areas, presence of channel drain

adjacent to proposed route and a running national highway with traffic.

Hot Tap operation, including design, engineering, execution and testing shall be performed by a specialist

Hot Tap Contractor, with adequate experience and proven track record of similar operations. The Design

of Hot Tap operation shall comply to all applicable codes and standards, statutory requirements and in line

with project specifications and requirements. Best practices from the industry shall be considered and

followed where deemed suitable.

6.12. Railway & State Highway Crossings

Railway crossing shall comply with the requirements of API RP 1102 and Indian Railway Authorities

recommended guidelines (Report No. BS-105 and Addendum Slip-4 dated 08.04.2014). Pipeline at rail

crossings shall be provided with casing pipe, which shall extend min. 1500 mm on either side of railway

ROW unless specified otherwise by Railway Authorities. The length of Casing Pipe for Railway

Crossings, shall be as per site requirements. The casing pipe shall be installed by boring/jacking method.

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Carrier pipe shall be electrically insulated from the casing pipe and casing ends shall be sealed using

durable, electrically non-conducting materials. Suitable measures (epoxy coating, 500 micron) shall be

taken for anti-corrosive coating/painting of Casing pipes and/or as directed by concerned authorities.

Annular space between casing and carrier pipe shall be filled with bentonite.

For the purpose of determining Pipe Wall Thickness, all Railway Crossings, and the area falling under

Risk Radius (calculated as per clause 3.2 of ASME B 31.8S), on both sides of Railway ROU, shall be

considered as Location Class-4. Pipe with wall thicknesses as per Location Class-4, shall be used for this

entire stretch, for Pipeline Crossing and Laying, including the area falling under calculated Risk Radius,

on both sides of Railway ROU. For this project, the calculated Risk Radius, as per ASME B 31.8 S, is 90

meters, on either side of Railway ROU.

Casing pipe size for 12” Mainline shall be 18” NB. However, Final size and Thickness of the Casing Pipe

shall be determined during detail engineering, based on requirements of Statutory Authorities. All

applicable Statutory Authorities’ codes and requirements shall be complied.

Road crossing shall comply with the requirements of API RP 1102 and the requirements of the concerned

road authorities. In general for major road crossing, crossing shall be done by boring & casing method.

Pipeline at State Highway road crossings shall be provided with casing pipe, which shall extend min. 1500

mm beyond the drainage ditch on either side of road/ROW, unless specified otherwise by concerned

authorities.

The casing pipe shall be installed by boring/jacking. Suitable measures (epoxy coating, 500 micron) shall

be taken for anti-corrosive coating/painting of Casing pipes and/or as directed by concerned authorities.

Annular space between casing and carrier pipe shall be filled with bentonite.

Casing pipe size for 12”NB (Main Line) shall be 18 ”NB. However, Final size and Thickness of the

Casing Pipe shall be determined during detail engineering, based on requirements of Statutory Authorities.

All applicable Statutory Authorities’ codes and requirements shall be complied.

Provisions shall be kept for additional length/ increased width of crossing lengths of HDD crossings/

jacking + boring lengths to take care of restricted ROU’s or land issues.

Based on Casing Thickness Calculations carried out for the proposed 12” NB x 38.0 km Pipeline from

Bantumilli to Ullamparru, the Material and Wall Thickness to be used for Casing Pipe, for housing 12” NB

Carrier shall be as summarized below :

However, Final size and Thickness of the Casing Pipe shall be determined during detail engineering.

6.13. River / Canal Crossings

Minor water crossings and unlined canals shall be installed by open cut method. All lined Canals shall be

crossed by Boring & Casing method. Major water crossings like river or major canals shall be installed by

open cut/Horizontal Directional Drilling (HDD) method. The banks shall be protected by using gravel and

boulders filled embankment mattresses of galvanized iron wire to be laid over the backfilled, compacted

and graded banks.

Crossing Type

Details of Casing Pipe to be Used

Casing Pipe

Size

(inch NB)

Casing Pipe Material

Casing Pipe

Wall Thickness

(mm)

Railway Crossing 18” API 5L, Grade B 7.0

Highway Crossing 18” API 5L, Grade B 7.0

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The protection of the banks shall be carried out across the ROU width plus three meters on either side of

ROU or actual distributed bank during construction whichever is higher. All lined canal/drains/nala will

be restored to the original condition.

Based on the above points, and in addition, the information received during site visit, the following

methods are suggested for major crossings along the route of proposed 12” Bantumilli-Ullamparru

Pipeline :

Sr.

No. Crossing Detail

Location

Class

Center

line

Chainage

in (M)

Design

Cumulative

Chainage

(M)

Method

of

Crossing

Width

of

Crossing

/ HDD

(M)

ROU

Detail

1 Kommatippa Branch Channel 3 2,896.92 2,896.92 B+C 32.01 New

2 Enamadurru Channel 3 6,790.22 6,790.22 B+C 27.74 New

3 State HiHhway-113 ( From

Kalipatnam - To Bhimavaram ) 3 7,008.66 7,008.66 B+C 14.67 New

4 Uppukodu Drain 3 7,327.93 7,327.93 OC 75.32 New

5 Hunupudi Drain 2 10,792.05 10,792.05 OC 51.52 New

6 Vissakoderu Channel 1 14,333.74 14,333.74 B+C 54.16 New

7

South Central Railway (From

Bhimavaram RS - To

Pennadapalem RS)

4 16,921.24 16,921.24 B+C 43.49 New

8

National Highway-65 ( From

Bhimavaram - To Viravasaram

)

3 18,085.64 18,085.64 HDD 160* New

9 Basavarajukodu Drain 1 10,588.26 26,995.78 HDD 410* Existing

10 Gonteru Drain 1 9,793.90 27,790.14 HDD 200* Existing

11 Baggeswaram Drain 2 4,158.91 33,425.13 HDD 180* Existing

12 Narsapur Canal & SH-41 3 689.73 36,894.31 HDD 200* Existing

HDD : Horizontal Directional Drilling;

B+C : Boring and casing

OC+CC : Open Cut + Concrete CoatingT

Notes :

1. *The length mentioned for HDD crossings are tentative only, and shall be finalized based on actual site

requirements.

2. The Chainage given are as per Alignment sheets for New and Existing ROU.

3. The Chainages for new ROU are measured from Bantumilli, and increases towards DMPL

4. The Chainages for existing ROU are measured from Ullamparru, and increases towards DMPL

5. The Design Cumulative chainage are given for cross checking, and are measured from Bantumilli

towards Ulamparru.

The above methods proposed for the crossings are tentative, and are proposed based on information

available, and collected during site visit. However, the actual method of crossing shall be finalized based

on actual site requirements.

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6.14. Anti-Buoyancy requirements Anti-buoyancy measures shall be provided, over and above Pipe External Coating, in marshy lands, areas

prone to flooding or waterlogging, at water body crossings and other areas requiring anti-buoyancy

measures.

Anti-Buoyancy shall be provided by means of continuous Concrete Coating, use of Saddle Bags or pre-

cast concrete weight blocks. The preferred method for providing anti-buoyancy is by use of saddle bags

and or concrete blocks. Use of concrete coating shall be avoided and shall be followed only where use of

saddle bags or concrete blocks is difficult or not possible, due to restricted space, small ROU width or

other limitations.

For Rocky River (if any) anti-buoyancy measures shall be provided with gabion arrangement.

The size & spacing of saddle bags and concrete blocks shall be determined during detail engineering. The

thickness of concrete coating required for each location class, is tabulated below. The size, weight and

spacing of saddle bags or concrete blocks shall be such that it provides equivalent weight and anti-

buoyancy effect as provided by concrete coating thickness (for each location class) mentioned below :

Based on Buoyancy calculations carried out for the Pipeline, the Concrete Coating thicknesses, to be used

for 12” NB x 38.0 km long Main Pipe Line, from Bantumilli to Ullamparru, shall be as below :

Concrete Coating Thickness for 12” Line Pipe (API 5L, Grade – X 70, PSL 2)

Crossing Location Class Wall Thickness of

Pipeline to be used

Thickness of Concrete

Coating Required

Location Class 1 & 2 6.4 mm 40 mm

Location Class 3 7.1 mm 35 mm

Location Class 4

(pipeline laid within Railway ‘risk radius’) 8.4 mm 30 mm

However, final Thickness of Concrete Coating / size, weight and spacing of saddle bags / concrete blocks

shall be finalized, during detail engineering, based on requirements at site.

6.15. Other Crossings

Foreign Pipeline Crossing

In case any existing pipeline needs to be crossed, the new pipeline shall be laid at least 500 mm below

such existing pipeline, and a physical barrier in the form of 75 mm thick concrete slab shall be provided.

The existing pipeline shall be properly supported during and after the construction.

Over Head Power Transmission Line Crossing

Where overhead Power Transmission line equal to and above 11KV and less than 66KV needs to be

crossed, plastic grating of minimum 8 mm thickness shall be provided. For 66 KV and above power line

crossings, concrete slab of thickness 75 mm shall be provided over pipe trench.

6.16. Pipeline Burial

The minimum ROW requirement for laying of pipeline shall be of 20 M width.

Pipeline burial depth shall be appropriate for the route, surface, and use of land, terrain features and

external loads imposed. In areas likely to have an increased risk of impact damage or third party

interference, the pipeline shall be buried with a minimum depth of cover as given below:-

Location Minimum Cover (m)

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a) Normal terrain 1.2

b) Industrial, Commercial and Residential areas 1.2

c) Rocky terrain 1.2

d) Minor stream crossing/Canal (lined/unlined) 1.5

e) Drainage, ditches at roads/railway crossings 1.5

f) Uncased road crossings 1.2

g) Cased road crossings 1.5

h) Cased railway crossings 1.7

i) River Crossings (Below lowest scour depth) 2.5

j) HDD (Below lowest scour depth) (also see Note-ii) 2.5

k) Marshy and Creek Area 1.5

l) Terrain with Sandy clay (See Note vi) 1.2

m) Terrain with Sand Dunes (See Note vi) 1.5

n) Others 1.2

The minimum cover may further be increased based on the safety and risk assessment.

NOTES:

(i) Cover shall be measured from the top of coated pipe to the top of the undisturbed surface of

soil or the top of graded working strip, whichever is lower. The fill material in the working strip shall not

be considered in the depth of cover.

(ii) For river / watercourses that are prone to scour and / or erosion, the specified cover shall be measured

from the expected lowest bed profile after scouring / erosion. Where scour level is not known, the

scour depth shall be assumed atleast 5 meters below the existing bed of the river/water course, except in

case of Rocky bed. The cover, as mentioned in the Table above, shall be provided in addition to this, from

bottom of this assumed scour level.

(iii) Whenever the above provisions of cover cannot be provided due to site constraints, additional

protection in form of casing/ concreting, soil bags, etc. shall be provided.

(iv) When insisted by authorities, the depth shall be maintained as per the directions of the concern

authorities.

(v) For areas of brick kiln, the minimum cover of 1.5 m shall be measured from the current level or below

predicted excavation level, whichever is lower.

(vi) For terrain with sandy clay and / or with sand dunes, the minimum cover of 1.2 / 1.5 m shall be

measured from sound & compact ground level. The compact ground level shall be determined based on

site data and actual site conditions.

As per PNGRB requirements, when a cluster of buildings intended for human occupancy, indicates that a

basic mile (1600m) of pipeline should be identified as location class 2 or location class 3, the location class

2 or location class 3 may be terminated 200 m from the nearest building in the cluster on either side (i.e. at

start of cluster and at end of cluster). The boundary between location class 1 and location class 2 or

location class 3 shall be at least 200m away from the building closest to the boundary.

In case, any private dwelling, industrial building or place of public assembly falls within 15 M of pipeline,

additional cover of minimum 300 mm shall be provided over and above the cover indicated in the Table

above, up to a distance of 15 M from last building on either side

Where buried pipes come above ground, the anti-corrosion coating on the buried pipe will continue for a

length of at least 300 mm above ground.

6.17. Backfilling

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In cross-country areas, the pipeline trench shall be backfilled with excavated soil as per project

specifications, and extra top soil (black cotton soil) as per client’s requirement, unless warranted by

seismic analysis, wherein the backfill material shall be as per the recommendation of such analysis. Select

backfill/slope breakers shall be provided in the trench instep areas to prevent washout of trench backfill.

In case of rivers/water bodies, which are prone to scour and erosion, the safety cover shall be provided

below the predicted scour level. In addition to the cover, anti buoyancy measure shall be provided on river

crossings.

In rocky areas, the trench bottom shall have a sand/clean graded earth padding of 200 mm. After

installation of pipeline, sand padding shall be placed around and on top of the pipe so that thickness of

compacted padding on top of pipe corrosion coating shall be at least 200 mm. Rock shields are to be used

for backfilling in rocky areas.

6.18. Pipeline Valves Ball valves & Check valves shall meet the requirement of API 6D and API 6FA/API 607 for fire safe

design. Globe valves shall meet design requirement of BS 1873. Pressure temperature rating of valve shall

be as per ASME B 16.34.

Ball valves shall be either Manually operated type, Hydraulically Actuated or Gas-Over-Oil-Actuated. All

Ball Valves of size 4” and below, shall be wrench operated. Ball Valves 6” and above shall be Gear

operated upto 12” Size. Manual Ball Valves above 12” size shall be hydraulically actuated.

All the main line valves shall be Full Bore Ball Valves with double block and bleed arrangement. Valves

shall be side entry type only. All main line valves shall be either Gas-Over-Oil-Actuated or Hydraulically

actuated, and shall be operated and controlled by the SCADA system.

Refer PIDs for details on individual valve type at each location.

The vent/ drain/ stem/ greasing points etc. of all the underground valves shall be extended above ground

along with isolation valves.

Fully welded body type valves shall be used for underground services. The first Isolation valve on the

mainline, at all stations, shall have welded end connections.

Valve stem height shall be decided during detail engineering stage, which shall be at normal operating

height up to chest level from Finish Ground Level. Above ground valves can be split body type. However,

all the first isolation valves, connected to the mainline, shall have welded ends (BW ends) only.

All vent isolation valves shall be equipped with spectacle blind at downstream of the valve.

All Ball valves used in this project, either in Mainline or in station facilities, shall be full bore type. Valve

bore should be such that it matches internal diameter of the connecting pipe.

Material of valve shall be as per valve data sheet.

All valves 4” and above shall be Trunnion mounted.

Stem sealing shall be provided. Size of drain, vent and sealant pipelines & valves, wherever provided shall

be indicated.

Butt weld end valves shall be provided with pup piece. Pup piece length shall be of at least 2.0 D for size

below 6” & 300 mm for 8” and above size valves. Since mainline valves are to be welded with connecting

pipe API 5L X 70, PSL2 (for 12” mainline) hence material and thickness chosen for pup piece should be

such that it matches with connecting pipe at the pipe end and with valve (full bore)at the valve end,

maintaining piggability of the pipeline. The thickness of Pup piece shall be determined by the Vendor as

per the code requirements.

7.0 STATION PIPING / FACILITIES DESIGN

Station piping provided at dispatch/receipt terminals, tap-off points and SV stations shall be designed with

a minimum design factor as per ASME B31.8. Utility piping to be provided at these locations shall be

designed in accordance with the provisions of ASME B31.3.

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All piping shall be designed for combined effect of pressure with temperature during operating conditions

without over stressing the piping, valves or equipment. All piping shall be adequately supported, guided

or anchored so as to prevent undue vibration, deflection or loads on connected equipment.

Piping stress analysis shall be carried out to determine allowable pipe movement and support requirements

at the following Stations:

1. Dispatch Station (Bantumilli)

2. Receiving Station (Ullamparru)

Stress analysis shall be carried out as outlined in Section 6.6. Provision for expansion shall normally be

made with bends, expansion loops and offsets. Platform and Crossovers shall be provided for ease of

access during operation and maintenance.

All above ground piping system except 12” mainline, shall be of low temperature seamless pipes of

equivalent grade to match with design pressure and temperature rating.

All 600# mainline tapping arrangement shall be as per P & I diagram.

7.1. Station Piping Painting and Colour Code

All above ground piping shall be painted to prevent atmospheric corrosion. Painting shall comply to ISO

12944 Part 5. The recommended painting system should be of Category C5 – I Very high (Industrial) as

specified in the Standard ISO 12944 Part 1 to 8.

The proposed Painting system shall conform to Table A 5 of ISO 12944 – 5 Standard, (Refer Annexure – I

provided at end of this document) suitable for highly corrosive environment service. Paint type, DFT &

total DFT shall be as per paint system no. chosen from stated table. Final shade shall be as the Clients

Color coding system.

Color Coding:

The Color Coding shall be decided by the PMC/ client, during detail engineering.

Notes :

1. All under Ground Valves (including pup piece) and piping shall have epoxy based coating (2- Layers

Polyurethane (DIN 30677/2 PUR 50) - 1000 microns) after surface finish of SA 2.5.

2. Valves and above ground pipes need to be properly blasted to achieve surface finish of SA 2.5 before

the application of paints.

7.2. Station Facilities Design

Pigging facilities shall be provided at Dispatch and Receipt Stations. All Scrapper Traps shall be suitable

for normal and intelligent pigging.

Centre line elevation of scrapper traps shall be minimum possible from grade level, but not more than 1.2

meters. Traps shall be accessible by walkway/road for movement of equipment.

Scrapper traps shall be provided with handling and lifting facilities to facilitate handling and lifting of

instrumented pigs, cleaning and displacement pigs.

Equipment/valves requiring periodical maintenance shall be supported in such a way that the valves and

equipment can be removed with a minimum temporary pipe supports.

Blow down facilities shall be provided at each station for any emergency evacuation of the pipeline. Vent

line shall be fitted with a flapper end closure, rated at the pipeline design pressure, to prevent gas leaking

through the valves and escaping to atmosphere during normal operation.

In case the pipeline movement is to be arrested, adequate length of trench in approaches to station shall be

provided with a select backfill.

7.3. Sectionalizing Valve Station and Tap offs

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SV Station shall be provided along the Pipeline as per the details provided in Section 5.0 - ‘Pipeline

system configuration’.

SV stations will be located at a readily accessible location near roads and shall be provided with an access

RCC road from the nearest all-weather asphalted road. Location shall be clear of overhead power lines.

Tap Off points of size 12” NB shall be provided, 1 at SV station and 2 nos. at Ullamparru (Receiving

Station), for future connection.

Pipeline sectionalizing valve shall be installed buried and provided with a stem extension. Valve body

vent/drain shall be extended and terminated above-ground.

7.4. Insulating Joints

Insulating joints shall be provided to electrically isolate the buried pipeline from aboveground pipeline.

Insulating joints shall be monolithic type and shall allow smooth passage of pigs. Insulating joint shall be

installed in aboveground portion of the pipeline, immediately after the buried/aboveground transition at the

scrapper stations. Design shall comply with ASME Section VIII Div.1.

Requirement of IJ’s at any other location to isolate electrically shall be in the scope of contractor.

7.5. Pig Signaler and Pig launcher/receiver

The Scrapper Traps shall be provided with pig signalers. All Pig signalers shall be non-intrusive type. One

pig signaler, shall be installed on the minor barrel and the other on the main line, as per the PID.

Pig signalers shall not be provided/ installed in underground piping. (No pig signalers shall be installed at

SV Stations).

Pig signaler shall have trigger mechanism, suitable for maintenance with pipeline under operating

pressure, thus to be provided online under pressure extraction system.

Mainline Dispatch/Receiving station shall have pig launcher/receiver etc facility capable of handling all

type of normal cleaning and intelligent pigs. Pig traps shall be provided with QOEC with pressure

relieving device designed in accordance with ASME Section VIII Div.1.

Pig traps shall be designed in accordance ASME Section VIII Div.1 with corrosion allowance of 3mm.

Material of QOEC shall be similar to that of major barrel. QOEC shall be band lock type having 'O' ring.

The barrel shall have ASME U stamp. The Scrapper Trap manufacturer shall have “U” stamping of

fabrication yard. Internal diameter of minor barrel should be perfectly matched with that of connecting

pipe.

Scrapper traps shall be provided with handling and lifting facilities to facilitate handling and lifting of

instrumented pigs, cleaning and displacement pigs. Reducer connecting barrel body to the neck shall be

eccentric type, for all Scrapper Traps.

7.6. Skids Proposed Along With The Pipelines

In addition to the station facilities and station piping, the following skids are proposed to be installed at

Dispatch and Receiving stations, on proposed 12” Pipeline :

7.6.1. At Bantumilli Dispatch Facility :

A combined skid, comprising of modular skid units, as described below, is proposed to be installed, at

Bantumilli Dispatch facility, on the upstream of the proposed 12” Pipeline :

The skid will have the following units : a ‘Knock out Drum’ and ‘Filtering unit’, for filtering the gas, and

removal of liquids, if any, a ‘Metering unit’ with ‘gas chromatograph’, for metering the flow of gas, and

for measuring gas quality, and a ‘Pressure Regulating unit’ with ‘Flow Control Valve’, for regulating the

pressure and flow of gas into the pipeline. The gas from downstream of this skid shall be fed into the

proposed 12” pipeline.

The skid will be installed, upstream of the proposed pipeline, at proposed Bantumilli dispatch facility, to

be developed in the plot /area provided by ONGC, within their premises.

PIPELINE & PIPING

DESIGN BASIS

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7.6.2. At Ullamparu Receiving facility :

A Check Metering skid for metering of flow of gas coming from the 12” Pipeline, is proposed at

Ullamparu. The skid will be installed on the downstream of the 12” Pipeline, before being fed into the

existing 18” Pipeline.

7.6.3. Design Basis and process parameters for the skids

The Design of Fileting, Metering, Pressure Regulating and Flow Control skid, proposed at Bantumilli

dispatch station, and check metering skid proposed at Ullamparru receiving station, shall be as per the

Design requirements and process conditions given in ‘Process Design Basis’ - Doc No : P.011947 M

11017 101.

7.7. Hook-up with existing 18” Pipeline of GAIL at Ullamparru Receiving Station

At proposed Ullamparru dispatch station, the check metering skid shall be installed downstream of pig

receiver of proposed 12” Pipeline. The piping from downstream of this Check metering skid, shall be

hooked up to existing 18” Pipeline of GAIL, which passes through the Ullamparu plot, for feeding the gas

in existing GAIL network.

This Hook-up shall be done with a barred tee, to ensure Piggability of the 18” pipeline. Required Shut-

down shall be planned, for excavating, exposing and carrying out hot work on the existing 18” Pipeline,

for installation of the Barred Tee. The piping coming from 12” Pipeline shall be hooked-up to the 18”

Mainline, through this Barred tee.

A 12” Tap-off shall also be provided at this hook-up point, for future interconnection with existing 12” and

8” GAIL Pipelines, which are running parallel to the 18” Pipeline, through the Ullamparru plot location.

The excavation and Hot Work on existing 18” Pipeline shall be planned carefully and all the details

pertaining to the operation shall be worked out as per site requirements and applicable codes and

standards.

The methodology & materials, including Barred Tee for hook-up, shall be selected to ensure the

Piggability of existing 18” pipeline after hook-up. All detail engineering for Hook-up shall be carried in

consideration of the same.

Adequate protection and support shall be provided for the existing as well as the new Piping, as required,

during and after the hook-up operation on the 18” Pipeline. All temporary / permanent supports required

for the existing and new piping, during and after the hook-up operation, shall be provided, as per site

requirements.

8.0 CATHODIC PROTECTION

Cathodic Protection shall be provided for the entire length of Pipeline which is buried. PCP shall be

designed and installed for the entire Pipeline. In addition, TCP shall be provided during the construction

phase of the Pipeline.

Cathodic Protection system shall be designed and installed as per the requirements of applicable codes and

standards. The design and installation of TCP as well as PCP, shall be strictly as per the requirements of

‘Design Basis – Cathodic Protection’, Doc. No. : P.011947 E 11017 102 (latest revision).

9.0 WELDING

Welding shall be carried out in accordance with API 1104 Latest edition and applicable specifications. All

butt welds shall be 100% radio graphed for main pipeline.

Welding and inspection of production welds to be followed by Contractor shall be as follows :

Pipeline Mainline Station Work

12” Mainline Manual Welding with 100 %

Radiography by X-ray/ gamma rays.

Manual Welding with X-ray/

Gamma ray and manual UT

(with recording system).

PIPELINE & PIPING

DESIGN BASIS

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All Station Piping

including Tie-ins


gamma rays and manual UT (with

recording system)


Gamma ray and manual UT

(with recording system)

10.0 TESTING

All testing of pipeline system and station piping, shall be in accordance with the requirements of ASME B

31.8 and project specifications.

After installation, the entire pipeline system, including station Piping, shall be Hydrostatically tested

(Resistance & leak test) as per the requirements of ASME B31.8 and project specifications. After

hydrostatic testing, the pipeline shall be dried and commissioned in accordance with the Project

specifications.

11.0 FIRE FIGHTING Fire Suppression system shall be provided at all station Facilities. The Fire Suppression system shall be

designed as per the requirements of code NFPA 12.

In addition to Fire extinguishers, the following shall be provided:

• Carbon dioxide flooding system shall be provided for unmanned stations.

• FM 200 suppression systems shall be provided for manned stations.

Provision for fire suppression equipment shall be kept at stations control room buildings.

ΣΣΣ

PIPELINE & PIPING

DESIGN BASIS

P.011947

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Annexure – I

ΣΣΣ

CONSTRUCTION OF

NATURAL GAS PIPELINE

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LAYING AND ASSOCIATED WORKS FOR ONGC

BANTUMILLI TO ULLAMPARU PIPELINE IN KG BASIN


PTS - CONSTRUCTION OF NATURAL GAS PIPELINE

DOC. NO. P.011974 D 11097 102

0 01.05.2018 Issued for Procurement BP PP SK

Rev. Date Subject of Revision Prepared By Checked By Approved By

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Rev. 0 ONGC Bantumilli To Ullamparu Pipeline Project Page 1 of 1

TABLE OF CONTENTS

1.0 DEFINITIONS AND INTERPRETATION ........................................................................... 1

2.0 LAWS – CODES – RULES & STANDARDS ........................................................................ 3

PART 1 – SITE OCCUPATION ......................................................................................................... 6

PART 2 - TOPOGRAPHICAL DATA AND PREPARATION OF THE CONSTRUCTION

SITE ................................................................................................................................ 6

PART 3 - CIVIL WORKS FOR STATIONS ........................................................................................ 9

PART 4 - DELIVERY AND HANDLING OF THE MATERIAL ............................................................ 10

PART 5 – CHANGES IN DIRECTION ............................................................................................. 11

PART 6 – WELDING ..................................................................................................................... 13

PART 7 – INSPECTION AND TESTING OF PRODUCTION WELDS ................................................ 16

PART 8 – MECHANICAL CONSTRUCTION OF INSTALLATIONS .................................................... 19

PART 9 – COATING ...................................................................................................................... 20

PART10 – EARTHWORKS .............................................................................................................. 21

PART 11 – LOWERING-IN AND BALLASTING ................................................................................. 25

PART 12 – TELETRANSMISSION .................................................................................................... 26

PART 13 – CATHODIC PROTECTION .............................................................................................. 28

PART 14 – TESTING, CLEANING AND DRYING ............................................................................. 28

PART 15 – SITE REINSTATEMENT AND MARKING OUT ................................................................. 42

PART 16 – PARTICULAR CONSTRUCTION TECHNIQUES ............................................................... 44

PART 17 – ELECTRICAL AND INSTRUMENTATION ........................................................................ 46

PART 18 – PAINT WORK ................................................................................................................ 46

AMMENDED CLAUSES OF GENERAL TECHNICAL SPECIFICATIONS 70000/740/GTS/0501 FORHDD .................................................................................................... 48

AMMENDED CLAUSES OF GENERAL TECHNICAL SPECIFICATIONS Z/02/0028 FOR CONTROLLED BLASTING ................................................................................................................ 50

BUILDING SITE REGULATIONS ...................................................................................................... 50

ANNEXURE – 1 VIDEO SURVEY ...................................................................................................... 51

ANNEXURE – 2: CROSSINGS .......................................................................................................... 52

ANNEXURE –3:PARTICULAR INSTRUCTIONS FOR PRE-COMMISSIONING AND COMMISSIONING ........................................................................................................................... 53

ANNEXURE – 4:STANDARD TABLE AND GRAPH FOR HYDROTEST EVALUATION .......................... 57

ANNEXURE-5 :FORMATS TO BE USED DURING MECHANICAL COMPLETION, PRE-

COMMISSIONING AND COMMISSIONING ..................................................................................... 61

ANNEXURE-6 :FORMATS FOR WELDING ....................................................................................... 66

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1.0 DEFINITIONS AND INTERPRETATION

1.1. Particular technical specification (PTS) shall be read in conjunction with the General Technical

Specifications (GTS) of work, drawings, schedule of rates (SOR), Instruction to Bidder (ITB) and

other documents including Project documents forming part of the contract, wherever the context so

requires.

1.2. Where any portion of the General Technical Specification is repugnant or variance with any

provisions of the particular technical specification, unless a different intention appears, the provision

(s) of Particular technical specification shall be deemed to govern the provision (s) of General

Technical Specification of contract. If there is no variance or repugnance between General Technical

and Particular Technical Specification, both clauses shall be applicable.

1.3. In case of conflict between the requirement of this specification and that of the referred codes,

standards and specifications, the requirements of this specification shall govern.

However, if any clause in this PTS is at variance with PTS’s prepared for specific item, than later shall

prevail.

1.4. Definition of Terms

The terms used in the technical document must be understood as follows:

� “Approval” : Means written approval.

� “Approved

Supervisory

Body” or

"Recognized

Inspection

Organization"

:

Is the Supervisory Body appointed by Owner which is qualified to enforce

the safety and security measures to be taken when establishing and

operating installations for the transport of gas by pipeline. Hereinafter

referred to as the Supervisory Body or Recognized Inspection

Organization or Third Party Inspection Agency.

� “Commissioning

”

: It includes final drying, filling the nitrogen (If required), and

commissioning with gas, testing of golden tie-ins welds at Gas MOP, gas-

in activity and final acceptance dossier. It also includes all works related

to Cathodic Protection, electrical, instrumentation, OFC and civil

activities.

� “Construction

Site/Building

Site”

: Is the area where the works are to be undertaken by the Contractor in

accordance with the Agreement

� “Defective Joint” : Is each weld that has been declared by the Approved Supervisory Body to

be unacceptable and has to be repaired by welding.

� “Equipment” : Means all apparatus, tools and appliances of any kind whatsoever that are

necessary for the construction, execution and maintenance of the Works

specified in the Agreement.

� "Owner’s

Representative"

: Designate the individual or legal entity to which the Owner has entrusted

various tasks in relations with the carrying-out of his project.

� “HDD” : Horizontal Directional Drilling

� “Line Work” : Is the delivery and execution of all Works for the construction of pipelines

that do not form part of a Special Point, Particular Section, Natural Gas

Station or a Particular Point, that are executed in accordance with normal

accepted laying methods, for which a separate Lump Sum per meter is

provided and that are described in the special execution conditions of the

Particular Technical Specification (PTS).

� “Material” : Means the materials or any other supplies that are intended to be part of or

integral to the Works.

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� Mechanical

Completion

(MC)

: Mechanical Completion shall mean Completion of all Pre-Commissioning

Activities and completion of all associated requirements, including closure

of all Engineering Audit requirements like RFSU, PHSER etc. It also

includes completion of all works related to electrical, instrumentation,

telecom, CP and civil activities deemed necessary for completion of Pre-

commissioning.

� Natural Gas

Stations”

: Is the whole formed by underground and/or surface equipment and

accessories located in a well-defined part of the Owner's natural gas

transport network. A natural gas station is in particular characterized by its

main function (e.g. pressure regulation, metering, Filtration, let down

skids, valve junction, etc.) and mostly located within a boundary wall

owned by the Owner and codified as such. A Natural Gas Station can also

be a tool junction (in-line valve, branch junction, etc.), the components of

which belong to the feeder main and thus part of a codified pipeline and

can also be located in a non-fenced lot which is not the property of the

Owner and thus falls within the code of the pipeline. They are generally

indicated as Stations.

� “Particular

Point”,

abbreviated as

P.P.

: Is a part of the line of the pipeline with accessories that is situated at the

same level as a particular civil engineering structure or a natural obstacle

(rivers, canals, etc.)? For such Exceptional Points, a separate Agreement

may be provided by the Owner. The scope includes all works and

accessories as per technical specifications, GTS and PTS.

� “Particular

Section”,

abbreviated as

P.S.

: Is part of the line of a pipeline with accessories that, due to the particular

configuration of underground or surface, requires special measures

concerning the method of laying The scope includes all work and

accessories as per Technical Specifications, GTS& PTS. Only the Owner

is authorized to determine whether a part of the line must be considered an

Exceptional Section.

� PHSER : Project Health Safety and Environment Review

� “Pre-

Commissioning” : It includes mechanical resistance test, tightness/leak test, cleaning

including magnetic cleaning, Electrical Geometrical Pigging survey,

dewatering, swabbing,, pre-drying activity, Golden-tie ins connecting the

stations, OFC testing and final acceptance dossier (As built document) and

all other related activities. It also includes completion of all works related

to electrical, instrumentation, OFC, CP and civil activities.

� “Right of Use”

abbreviate to

ROU

: ROU for pipeline laying is provided to contractor as specified elsewhere

in the tender document.

� RFSU : Ready For Start Up

� Special Point”,

abbreviate to S.P

or CROSSING.

: Is a part of the line of the pipeline and its accessories that is situated at

railway crossings, road junctions, water course intersections and/or the

crossing points of underground obstacles which, due to the special

configuration of surface and/or underground, requires special measures

with regard to the lowering-in method and The scope of work shall

include all supplies, works and accessories as per technical specifications,

GTS & PTS including rock blasting, concrete coating, restoration etc. and

no extra cost will be accepted by Owner. Only the Owner is authorized to

determine whether a part of the line is to be considered as a Special Point.

� “Works” : Are either the execution or having executed together with the design of

works that complies with the requirements specified by the Owner. The

work is the result of all the construction activities intended to have an

economic or a technical function as such.

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2.0 LAWS – CODES – RULES & STANDARDS

2.1 General

Basically, the following are applicable:

• PNGRB Notification – G.S.R. 808 (E), Nov’2009. : PNGRB (Technical Standards and

Specifications including Safety Standards for Natural Gas Pipelines) Regulations.

• P&MP Act, 1956 & 1962 and Land Acquisition Act,

• Water & Gas ROU (Acquisition) Act, 2000.

• Railways/Highways/Forest/Other Pipelines – Statutory Regulations, Terms & Conditions as

applicable.

• Petroleum Rules.

• Basic Laws – Codes – Rules & Standards, mandatory by law in India and in the state of Andhra

Pradesh.

• The complete set of Specifications and standards, which are part of the present technical volume.

• Particular Codes & Standards as per Section 2.2.

• In general the pipeline and stations have to be built in accordance with the best state of

engineering practice and commonly used by the worldwide gas industry.

In case of contradiction, the above shall prevail in descending order of precedence.

2.2 Particular Codes & Standards (latest edition)

S No Code No. Description

1 ASME B.31.8 “Gas Transmission and Distribution Piping Systems” –

and all Codes it refers to.

2 API 1104 “Welding of pipelines and related facilities”

3 API 1102 Recommended Practice for Steel Pipelines Crossing

Railroads and Highways.

4 API 1107 Recommended Pipeline Maintenance Welding Practices.

5 API- 5L Specification for Line pipe

6 API- 6D Pipeline Valves

7 API 500C Classification of Locations for Electrical Installations at

Pipeline Transportation Facilities.

8 ASME Section VIII

Boiler and Pressure Vessel Code

Division 1 Pressure Vessels

Division 2 Alternate Rules for Pressure Vessels

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9 ASME Section IX Welding Qualifications

10 NACE-RP-01-69 Recommended Practice Control of External Corrosion on

Underground or Submerged Metallic Piping Systems.

11 NACE-RP-01-75 Recommended Practice - Control of Internal Corrosion

in Steel Pipelines Systems.

12 NACE SP-0177 Mitigation of AC and lightening effects

13 IEC - 79 Electrical Apparatus for Explosive Gas Atmosphere

14 IEC - 529 Degree of protection Provided by Enclosures.

15 AS/NZS 2885.5 “Pipelines – Gas and liquid petroleum – Field Pressure

Testing”

16 ISO-8502-3

“Preparation of steel substrates before application of

paints and related products – Tests for the assessment of

surface cleanliness”.

17 ISO 9305

“Seamless steel tubes for pressure purposes full

peripheral ultrasonic testing for the detection of

transverse imperfections”.

18 ISO 10124

“Seamless & welded (except submerged arc welded)

steel tubes for pressure purposes. Ultrasonic testing for

the detection of laminar imperfections”.

19 ISO 12094

“Welded steel tubes for pressure purposes. Ultrasonic

testing for the detection of laminar imperfections in

strips/plates used in the manufacture of welded tubes”.

20 ISO 15741

“Paints and varnishes – friction – reduction coatings for

the interior of onshore and offshore steel pipelines for

non-corrosive gases.”

21 ISO 15590-1

“Petroleum and natural gas industries – Induction bends,

fittings and flanges for pipeline transportation systems –

Part 1: Induction bends”.

22 ISO 14313 Valves

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23 DIN 30670 “Polyethylene coating for steel pipes and fittings”.

24 DIN 30671 “Thermoset Plastic Coatings for buried steel pipes”.

25 DIN 30672

“Tape and shrinkable materials for the corrosion

protection of buried or underwater pipelines without

cathodic protection for use at operating temperatures up

to 50ºC.”

26 DIN 30673 “Bitumen coatings and linings for steel pipes, fittings

and vessels.”

27 DIN 30675-1 “External corrosion protection of buried pipes & range of

applications for steel pipes.”

28 DIN 30677 “Corrosion protection of buried valves coating for

normal requirement.”

29 EN 12062 “Nondestructive examination of welds – General rules

for metallic materials”.

30 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.”

31 IS 12944-5

“Paints and Varnishes – Corrosion Protection of Steel

Structures by protective paint system – Protective Paint

Systems.”

32 IS 8062 “Code of practice for Cathodic protection of steel

structures”

33 IS-5572 Electrical area classification of Installation for selection

of Electrical Equipment

34 IS - 5571 Guide for selection of Electrical Equipment for

Hazardous Area.

35 IS 3043 For earthing of all electrical equipment, systems,

structures and fencing, etc.

36 IS:2309 Lightening protection

37 OISD - 226 Natural Gas Transmission pipeline and City Gas

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Distribution Networks

And all other relevant codes/standards, etc.

AMMENDED CLAUSES OF GENERAL TECHNICAL SPECIFICATIONS

70000/740/GTS/0502 FOR CONSTRCUTION OF GAS PIPELINE AND ACCESSORIES

THE NUMBERING OF THE PARTS IN THE BELOW CORRESPONDS TO GTS: GENERAL

TECHNICAL SPECIFICATIONS: 70000/740/GTS/0502.

The present specification (PTS) can confirm, complete, modify or delete certain sections/paragraphs of

those clause numbers of 70000/740/GTS/0502 appearing below.

Contractor shall note that relevant clauses pertaining to item rate contract in GTS are not applicable.

The payment shall be made ONLY on the basis of Schedule of Rates (SOR) forming the part of bid

document.

The drawings, document review system as specified in the tender bid elsewhere.

The qualifying statements and conditions against GTS clauses are detailed as below.

PART 1 – SITE OCCUPATION

1.1 Occupation of the Site

Add:

Min. 300 mm Top-soil/arable soil (measured from top of initial site condition) removed during grading

shall be stored & preserved separately from sub-surface excavated material.

The Additional Land, if any, required on temporary basis for transit of Construction Equipment and in

the restricted row zones, shall be arranged by the Contractor at his own cost and initiative.

1.2 MARKING OUT AND PROVISIONAL FENCING:

Fencing of the terrain shall be at the discretion of Contractor. However, the contractor shall be fully

responsible for any damage, accidents etc. arising during construction work along the route and any

compensation thereof and shall suitably indemnify the Owner/Owner’s representative for any such

damage and accidents.

1.3 Equipping the Site Installation:

For Owner complete site installation comes under a single category and Contractor has to comply fully

with all the local rules of the building site regulations, statutory provisions and other requirements

mentioned elsewhere in the tender documents.

The tentative location of proposed office &camps will be as defined in tender elsewhere.

The Contractor shall arrange Camp location, stores, warehouse, pipe yards etc. as per site condition

and within 5kms of radius from spread office & pipeline route.

1.3.1 Site Installation

Not Applicable

1.4. Clearing of the Site Installation

All the clauses of this section are applicable for pipe laying contractor (s) site installation.

PART 2 - TOPOGRAPHICAL DATA AND PREPARATION OF THE CONSTRUCTION SITE

FOREWORD:

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Guideline for Work Front Opening:

For Main line construction, work fronts shall be opened and each work front will be allowed as per

project requirement. Contractor shall ensure that the gap between the two consecutive pipe laying

activities shall not exceed 5 Kms. Besides, mainline construction; multiple Crews for skip section/tie-

in/Crossings shall be deployed.

Prior to start of construction (before clearing & grading of ROU), Contractor shall proceed with a

video survey to capture the prevailing site conditions, surface features, site encroachments&

environmental status (flora/fauna etc)as per specification under Annexure –1. The videography details

captured during ROU survey & before clearing and grading will be utilized for the purpose of

certification of restoration and liasoning with land owners.

2.1 Topographical Data

2.1.1 Staking-out the axis

Use of Digital Theodolite or DGPS (see survey reports) is mandatory for all surveys (For establishment

of road profile and pipeline profile).

A soft copy (native file) of the survey report (TP, IP listing), Crossing drawings and alignment sheets

will be handed over (on request) to the successful bidder.

Installation of Temporary Markers for stacking-out

Contractor shall provide/install temporary markers for the following based on information given in

alignment drawings and the existing survey pillars provided by the Owner:

• Intersection points (P) and other survey monuments.

• Stake markers at the C/L of the pipeline at distance of100 meters for straight line sections and

maximum 10 meters for horizontal bends.

• Stake two ROW boundary markers at least at every 100 meters.

• Install distinct markers locating and indicating special points, such as Obstacle crossings, change

of wall thickness, end of chainage etc.

2.2 Preparation of the Construction Sites

2.2.1 Occupation of the building sites

2.2.1.2 Duration of Occupation per pipe route section

Replace first Para with following:

Duration of the works (i.e. the duration from the opening of the working area/ROU to complete

restoration of the site) shall be in-line with the schedule / GCC/ SCC mentioned elsewhere in

RFP document.

2.2.2 Working strip

2.2.2.1 Width of the working strip

Add

The proposed 12’ Pipeline will be laid partly in new ROU (21 Kms from Bantumilli to DPML,

Vendra) & balance in existing ROU of GAIL (20 kms approx.. from DPML to Ullamparu). 20 mtr

width of new ROU from ONGC Bantumilli to DPML, Vendra and 18 mtr width of existing ROU

wherein 4” & 18” existing pipeline is already laid from DPML to Ullamparu. Therefore, aadditional

ROU if required for working strip wherever shall be arrange by contractor without any implication to

Owner. For more details , refer alignments enclosed with the tender.

2.2.2.2 Reducing the working strip

Contractor shall refer Scope of work for Narrowed working strips for pipeline works

Contractor shall not be compensated for any reduction in the width of working strip or reversal in the

width of working strip.”

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2.2.2.3 Reverse of the working strip

No fencing of any kind along the pipe route is essential to be provided. However, it remains the

responsibility of the Contractor that no untoward accident takes place. Please refer 1.2 above.

Contractor shall not be paid any price supplement in any case due to reverse of the working strip.

2.2.2.4 Working strip at ditch crossing

Owner will not provide area for storage of any kind of top soil, materials ets. Contractor shall arrange

the storage area to store the top soil and materials etc.

2.2.3 Working site location, working strip marking, warning signs

2.2.3.3 Markings on the construction sites

(b) Numbering of the special points and special sections

� Numbering of Special Points (SP) Particular Section (PS) or Particular Point (PP) will be

decided by the Contractor in co-ordination with the Owner/Owner’s representative.

2.2.4 Longitudinal profile

2.2.4.2 Research and soundings

Prior to any clearing activities of ROU, the Contractor shall investigate and determine the top soil

characteristic alongside the pipeline route in farming areas. The Contractor will take all necessary

measures to store and protect from mixing the top soil and reinstate the ROU as before the construction

of pipeline and as per land Owner/concerned authorities satisfaction. If deemed necessary by

Owner/Owner’s representative, top soil will be investigated at Contractor’s cost after reinstatement and

eventually corrective measures will be taken by Contractor (at his own cost).

2.2.5 Improvement of the working area and the access roads to the working sites

Contractor shall improve &maintain the ROU in motorable condition until completion of the work.

The ROU damaged especially due to movement of crawler mounted heavy equipment shall be

regularly graded, leveled& sprinkled with water for dust suppression.

Access roads to the working sites and ROU

Contractor shall ensure that the working site and the ROU has proper motorable access, suitable for all

Equipment, Machinery, Transportation etc required for the completion of work. In case access is not

readily available, it will be Contractors responsibly to prepare and maintain proper access to working

site and ROU as per the above requirement. Contractor shall not be entitled to claim any extra time or

cost for building and maintaining this access to ROU/Working sites.

� PROVISION OF DETOURS :

CONTRACTOR shall do all necessary grading and bridging at road, water and other crossings and at

other locations wherever needed, to permit the passage of its men and equipment. It is understood that

the CONTRACTOR has recognized such restrictive features of the RoW and shall provide the

necessary detours and execute the works without any extra cost to OWNER. Public travel shall neither

be inconvenienced nor be wholly obstructed at any point, at any time. CONTRACTOR at his own cost

shall furnish and maintain watchman detours, lanterns, traffic lights, barricades, signs, wherever

necessary to fully protect the public, necessary ramps, bridging or access to fording or ditches and

small streams shall be constructed, so as not to interfere with the flow there in or damage unduly the

banks thereof. CONTRACTOR shall be responsible for moving its equipment and men across or

around watercourses and canals. This may require the construction of temporary bridges or culverts.

No public ditches or drains shall be filled or bridged for passage of equipment until CONTRACTOR

has secured written approval of the Authorities having jurisdiction over the same. CONTRACTOR

shall furnish a copy of such approval, to the OWNER.

2.2.5.6 Protection of the arable soil and subsoil

Contractor shall preserve top soil dug and restore to original condition on completion of the work. For

this purpose, a separate stock-pile of top-soil shall be maintained away from the subsurface stacking to

prevent mixing of both.

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2.2.5.9 Activities in Wooded/ Forest Area

If approved by Owner, in narrow / Forest ROU where circulation over existing pipes is unavoidable,

Contractor shall use wooden flat boards.No compensation shall be paid for reduction in working strip

to the Contractor.

PART 3 - CIVIL WORKS FOR STATIONS

Refer: Design basis - Civil / Structural / Architectural (P.011974 C 11017 101)of bid document for

scope and specifications for Station Civil works.

Mitigation measurement for seismic area and other geo hazard of bid document shall be considered as

below :

SEISMIC DESIGN CRITERIA

Contractor at its own cost shall carryout out "Seismic Hazard Assessment of buried pipeline. Institute

of Seismological Research in india can be source for obtaining the following information for carrying

out seismic Hazard Assessment.

i) Generation of Shear Wave Velocity

ii) Geological correlation with VS

iii) Preparation of Geological Map of study area/ Pipeline route

iv) Preparation of Seismotectonic map of the study area

v) Ground truth check

vi) Active Fault Mapping

vii) Soil Modeling

viii) Strong Motion estimation at Bed rock

ix) Strong Motion estimation at surface

x) Liquefaction Potential of the study area

Based on the Seismic Hazard Assessment, buried pipelines shall be designed as per “IITK-GSDMA

Guidelines for Seismic design of Buried Pipeline” of NICEE(National Information Center of

Earthquake Engineering)

Design Criteria for parallel Fault line or its Crossing

Fault is a crack of zone of crack between two blocks of rock. Faults allow the blocks to move relative

to each other. This movement may be due to sudden displacement or may be due to gradual

accumulation. The sudden fault movement is mostly associated with the seismic event.

Contractor needs to carry out detailing seismic analysis of pipeline mainly on following consideration:

• Determine the location and nature of faults in and around the area. This will be based on published

information like from Seismotectonic Atlas of India, Satellite imageries and a field visit.

• Liquefaction potential evaluation of the soil based on SPT or CPT data and make

recommendations on seismic analysis parameters.

• Carry out a deterministic seismic hazard analysis and provide recommendations on ground motion

to be considered for seismic studies.

Wherever the pipeline shall be passing through earthquake prone and fault line areas, it shall need to

be protected from varying soil strata to mitigate the seismic hazards. The pipeline shall be concrete

coated in areas where there can be occurrence of soil liquefaction. In clayey soil the pipeline shall be

protected by covering it all around with a 300 mm layer of cohesion-less soil or sand. In areas where a

fault line exists, the pipeline shall be laid as much away from the fault line as feasible, and protected

by reducing the bends / ensuring a minimum distance of 100 Mtr between bends, as also protection by

covering it all around with a 300 mm layer of cohesion-less soil or sand . The 300mm layer of sand

shall be applied along the entire length of pipeline, except where pipeline is passing through a terrain

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of continuous sand or cohesion less soil, low marshy land water course, where concrete coating may

be required. In case of concrete coating, sand or soft soil filling requirement shall be considered

jointly between EPC & Owner, at site level.

PART 4 - DELIVERY AND HANDLING OF THE MATERIAL

4.1 GENERAL

Contractor should refer scope of work for supply of free issue materials from owner as specify in

tender document elsewhere.

Receipt, Storage & preservation of free issued material (FIM):

The free supply material of the Owner will be transported from manufacturing plant directly to

Owner’s Warehouse / Store (Location shall be communicated to successful bidder)as specify in the

tender. The scope of Contractor shall cover receiving/taking over of material in presence of

Owner/Owner’s representative at store/warehouse. The scope also covers Loading, unloading, storage

in waterproof & covered area, preservation, watch & ward of FIM.

Any visible/apparent defect found before taking over of other FIM shall be reported to Owner. Any

apparent defect found in these items after taking over, shall be responsibility of Contractor and same

shall be rectified by them without any cost and time implication.

4.3 ACCEPTANCE PROCEDURES

FIM may also directly transported to Contractor’s store. The Owner/Owner’s representative will

communicate name, address and contact person for OTHER vendors (engaged by Owner) to whom

EPC Contractor may require to coordinate in due time.

4.3.1 Owner Depot or Store Site

The clause to be read as follows:

“For FIM, the material may also be directly transported to Contractor’s store. The Owner/Owner’s

representative will communicate name, address and contact person for OTHER vendors (engaged by

Owner) to whom EPC Contractor may require to coordinate in due time.”

4.3.3 Take over report

To be prepared for all free issue material by owner.

4.4 MATERIALTO BE SUPPLIEDBY THE CONTRACTOR

4.4.1 Supplies

All material supplied by Contractor shall be accompanied by requested certificate (as per PTS or

GTS). MTO shall be prepared by the contractor based on the tender drawing/document which shall be

finalized during detailed engineering or execution of pipeline work to be carried out by the contractor.

During finalization of MTO, the contractor should take into account some extra quantities that may be

required to take care of site circumstances like unexpected damage / theft during transportation /

storage etc. without any cost implication.

The required certificates (3.1 or 3.2) as per technical specification for all supply materials should be

delivered by qualified inspector of recognized international inspection agency. Only approved agency

(by Owner) may perform the inspection.

The Owner/Owner’s representative has the right to inspect (jointly with Contractor) quantitative and

qualitatively all material supplied by Contractor. Materials approved by Owner/ Owner’s

representative shall only be used for the entire work under the scope of Contractor.

The Contractor has to provide all services and supplies other than Owner’s supply of material for

completion of project as detailed in Scope of work. Please refer clause 4.0 of Scope of work

(Document No.: .011947 G 96 1002).

Other Supplies

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Consumables (including Electrodes, Joint Coating materials etc.) &utilities whatever are required for

complete execution, testing and completion of the project.

All civil, structural, steel material required to complete the buildings, roads, plumbing system etc.

All Nuts, Bolts including Foundation Bolts, Galvanized Bolts, Gaskets (as per specifications), Copper

jumpers etc.

Paint /coating for above ground and underground piping and steel structure.

4.4.2 Extra Supplies

Except for as noted above, the Contractor has to supply all other material for completeness of the

contract till pre-commissioning and commissioning.

4.6 STORAGE AND HANDLING OF MATERIALS

EPC contractor shall prepare transportation procedure of line pipe and others materials which shall be

issued as free from owner and submit to owner / owner’s representative for approval before start the

transportation of line pipe and other free issue materials of project.

4.8 RETURNING SURPLUS MATERIAL

The address of Owner depot for returning surplus material shall be communicated in due time to the

successful Contractor.

Return of surplus material shall be in line with Applicable clause of GCC and SCC of the Commercial

tender.

The reconciliation activity has to be done regularly on monthly basis, and the final reconciliation shall

be completed within max. 15 days after the commissioning of the pipeline.

4.9 USEFUL INFORMATION

4.9.1 Owner’s storage site, warehouse and workshops addresses

Owner’s storage site, warehouse and workshops Location as specify in the tender or will be

communicated to successful bidder. However, for returning of surplus FIM (if, any), the storage

location will be communicated to the successful bidder on his/her request.

PART 5 – CHANGES IN DIRECTION

5.1 GENERAL

Point 4 Factory made elbows are not permitted in pipeline.

5.3 FIELD COLD BENDING OF COATED PIPES

Point 4 Use of mandrel is mandatory for pipe size 12”.

Point 8 Before starting the production of cold bend, 1st test bend of 150 per thickness and per

diameter will be made. After bending if the necessary measurement cannot be

achieved satisfactorily from inside, the coating will be removed in order to control

the ovality, the wrinkles and the wall thickness. The checking will be made in the

presence of Owner’s representative. The bend pipe will then be recoated by the

Contractor, as per specification, without any time and cost implication. In case, the

test bend is not accepted a new test bend will be made by the Contractor.

Point 12 The Ovality after bending shall be 2% (maximum) of pipe O.D. The diameter of the

gauge plate shall be 97% (minimum) of calculated ID of bend pipe.

While designing the bends, due care shall be taken to avoid encroachment of bend

arc length beyond ROU of pipeline. This shall be examined and verified for each

bend, as applicable.

Cold Bending Procedure

Contractor shall, before the start of the work, submit and demonstrate to Owner/Owner’s

Representative a bending procedure which shall confirm with the recommendations of the

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manufacturer of the bending machine with this demonstration, maximum angle that can be bent shall

get qualified. The procedure shall include amongst other steps, lengths, maximum degree per pull out

method and accuracy of measurement during pulling of bend. This procedure and the equipment used

shall be subject to Owner’s approval. Horizontal deviations shall be achieved by joining more

adjacent bends, the bending of the pipe lengths shall be made by positioning the weld seam (for

LSAW / HSAW / ERW pipes) alternatively 75 mm above and below the plane passing through the

neutral axis in such a way that the bends are welded with the seam welds displaced by about 150 mm

and situated in upper quadrants. In case of vertical bends formed from a number of pipe lengths, the

seam welds shall be positioned on the plane passing through the neutral axis of the bend to the right

and left alternatively.

The pads, dies and rolls of the bending machine shall have soft surfaces to avoid damages to the pipe

coating. Fully retaining bending shoes and roller type bending machine are preferred. Gauging plate

of 97% of the nominal internal diameter of the pipe shall be passed through the bent pipe.

Corrosion coating on cold bent pipes shall be thoroughly checked by beating with wooden Mallet

along the outer radius to check disbondment from the pipe. Cold bends on site shall have the

corrosion coating carefully checked with the aid of a holiday detector for cracks and loss of adhesion

etc. in coating.

a. Check for pipe thinning shall be carried out by means of a “D” meter/UT meter during procedure

qualification and for random checks in field. The wall thickness of finished bends, taking into

account wall thinning at the outer radius, should not be less than the design thickness. An

indication of wall thinning as a percentage is given by the following empirical formula:

Wall Thinning = 50 n +l

Where `n' is the inner bend radius divided by pipe diameter.

Pipes with measured wall thickness greater than the nominal wall thickness (i.e. with +ve

tolerance) shall normally be used for making cold field bends.

Cold bend pipes on site shall have the corrosion coating carefully checked with the aid of a holiday

detector for cracks in the coating down to the pipe wall. It must also be checked whether the

coating has disbonded from the pipe wall during bending by beating with a wooden mallet along

the outer radius. Any defects or disbonding of the coating caused during bending (also forced

ridges in the coating) shall be repaired at the Contractor's expense in accordance with Company

approved procedures.

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

c. CONTRACTOR shall layout and measures the pipe so that the number of cut off pieces less than 2

(two) meters long are held to minimum.

d. The pipeline laying Contractor shall ensure that the bends are executed which not affects smooth

will passage of long pig (Tool) for instrumented Pig Survey.

5.4 FITTINGS

5.4.3 Hot Bends

• Refer PTS- Long Radius Bend (Document No.: P.011947 M 11097 116) for manufacturing.

• Fabrication and supply of induction bends is included in the scope of Contractor.

• Contractor shall determine the quantity and angle of the bend on the basis of detailed site survey

carried out by them prior to the construction work.

• Heat Shrink sleeves of minimum 2.2 mm thickness shall be used for coating of hot bends which is

similar to field joint coating on pipeline girth welds. The minimum thickness on welds shall be 2.2

mm. Coating of hot bends / Field joint coating system shall comply with EN 12068. Coating

material shall be EN 12068-C HT 60UV for C –60 Class.

• All bends in the upstream and downstream of the Pig Launcher/Receiver should be hot/induction

bends.

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• All bends of pipeline entering/leaving the above ground Natural Gas stations shall be hot/induction

bends (sag-over and horizontal bends).

• All bends shall be transported with straight portions at the site.

• Except otherwise stated in detail drawings or PTS all hot/induction bends shall have minimum

bending radius of 6 x ND for ND 12”.

• An Inspection Test Plan (ITP) shall be submitted by the Contractor to Owner/Owner’s

representative for approval in line with PTS & QAP for Hot Induction Bend. Contractor must hire

his own (approved by Owner/Owner’s representative) third party inspection agency to control the

manufacturing of the Induction Bends. The TPIA must issue a 3.2 certificate as per code EN

10204. Owner/Owner’s representative will carry out the inspection before dispatch.

Owner at its option may authorize fabricated bends for installation at points where in owner’s

judgment the use of such bends is unavoidable. If due to local circumstances induced bends have to be

used in some places (not mentioned in detailed drawings); Contractor shall determine the deflection

angle, space and the numbers of induced bends. Contractor must take into account the location class

and the wall thinning when choosing bare pipe for induction bending. No compensation will be paid

to Contractor for induction bends deemed necessary during construction of entire concerned spread.

Over (upper) bend shall be made in such a manner that the center of the bend clears the high points of

the trench bottom. Sag (lower) bends shall fit the bottom of the trench and side bends shall conform

and leave specified clearance to the outside wall of the trench.

• The contractor has to decide over the degree of the bends as per the detail drawings.

• Each bend is to be carried out using full-length pipe.

• The requirement of test bend shall be in line with PTS – LR Bend (Document No.: P.011947 M

11097 116.)

• Contractor shall propose the reputed induction bend manufacturers from approved Vender list

attached elsewhere in the tender document.

• The contractor has to coat/paint the bends as per specification.

For fabrication of Hot Induction bends for any location class, pipe of one class higher thickness shall

be used. This is to ensure that even after bending, the thickness of Pipe remains above the minimum

required thickness for any location class,

The entire Pipeline route falls in Location Class 1, Location Class 2 and Location Class 3.Further

entire pipeline route falling within railway ‘risk radius’ shall be considered as location class -4

wherever hot induction bend is required in mainline pipe laying at any location, due to space

constraint or site requirements, the following thickness shall be used for fabrication of hot induction

bends :

• For Location Class – 1: Thickness to be used for fabrication of Hot bend – 7.1 mm




PART 6 – WELDING

ADDED :

The Contractor shall have capable to demonstrate the in-house capability or shall provide the list of

sub-contractor he intends to hire for welding of pipeline work. Contractor to ensure and submit the

Proposed welding procedure (PWPS) and minimum equipment (Refer to minimum equipment list for

the minimum acceptable quantity attached with the Commercial part of Tender under forms and

formats) to be deployed to achieve the work as per agreed schedule.

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WELDING AND METHOD OF INSPECTION FOR PRODUCTION WELDS TO BE FOLLOWED

BY CONTRACTOR AS MANDATORY:

Pipeline 12” Mainline Station Work

12” MAIN

LINE

Manual Welding with Internal clamp

and internal X-ray with crawler


Gamma ray and manual UT with

recording system

Tie-Ins

Manual Welding with External X-ray/

gamma rays and manual UT with recording

system

-

CROSSING

Manual Welding with External X-ray/

gamma rays and manual UT with

recording system

-

Notes:

• Welding specification chart shall be prepared by Contractor and approval on the same shall be

obtained from Owner before commencement of Welding activities.

For Mainline, first 100 number of girth weld joints performed by Manul welding to be examined by

Manual UT in addition to X-ray.

6 WELDING

Applicable Documents:

API 1104 Nineteenth Edition, Sep 1999 replaced by API 1104 Twenty First Edition, Sep 2013 with

Errata 1, April 2014, Errata 2, June 2014, Errata 3, July 2014, Errata 4, November 2015, Addendum 1,

July 2014, Addendum 2, May 2016.

6.1 QUALIFICATION OF WELDERS

Welders shall be qualified in accordance with the API 1104 and other applicable specifications

attached with tender document and as per approved WPS at Contractor expense.

The butt weld test pieces of the qualification test shall meet the requirements of visual inspection,

NDT (Non-Destructive Testing) and DT (Destructive Testing) requirements specified in API 1104,

GTS and present PTS.

A Welder who fails to complete successfully the qualification test session may be given a second

opportunity to qualify after mutual agreement between Owner / Contractor as per section 6.7 of API

1104 code. Contractor shall submit the Welder qualification test reports to Owner’s representative for

approval.

Welders shall always have in their possession the identification card (certified by Owner’s

Representative). No Welder shall be permitted to work without the possession of identity card.

Pre-Qualification of the welding

Prior to welding, Contractor under the supervision of the Welding Engineer shall conduct training

session for all Welders (Semi-Automatic& manual welding) based on approved WPS.

Contractor must qualify minimum numbers of Welders and must deploy minimum number of

equipment as specified in the tender documents elsewhere.

6.2 WELDING PROCEDURE QUALIFICATIONS (WPQ)

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The Welding Procedure Qualification Test shall be carried out in accordance with the API 1104 and

other applicable specifications attached in the tender document by the Contractor at his expense.

The butt weld test pieces of the Welding Procedure qualification shall meet the requirements of visual

inspection, NDT and DT test requirements specified in API 1104, GTS and present PTS.

6.2.1. General

Qualification of Welding Equipment and Operators.

Only the welding unit and operators qualified according to the requirements of Section 5 and 12 of

API 1104 will be accepted for semi-automatic or manual welding. Each Operator should have

received adequate training before the qualification tests.

All tests (destructive as well as non-destructive) will be done in an independent NABL accredited

Owner approved laboratory. In addition to the mechanical tests mentioned in API-1104, other tests

like macro/micro examination, hardness tests, dye penetration tests, Charpy V-notch (Impact test) etc.

shall be carried out on test specimens. All the above tests shall be carried in accordance with

specifications.

Essential variables for WPS of pipeline and station construction shall be in accordance with API 1104.

Welding Consumables shall confirm to the requirement of applicable standard “ASME Section 2 Part

C”.

The welding electrodes/filler wires supplied by the Contractor shall conform to the class specified in

the qualified welding specification.

Physical properties of the welds produced by electrodes recommended for the welding of a particular

base metal shall not be lower than the minimum values specified for the base metal. The choice of

electrode shall be the sole prerogative of the Owner/Owner’s Representative.

The Contractor shall submit batch test certificates from the welding consumable manufacturer giving

details of physical and chemical tests carried out for each batch of electrodes to be used. However,

welding consumable test also shall be conducted at project site and all tests shall be carried out in an

independent NABL accredited Owner approved laboratory which shall meet the requirement of

“ASME Section 2 Part C”.

All electrodes shall be preserved in good condition as recommended by manufacturer. Low-hydrogen

electrodes shall be kept in oven. The baking period shall be strictly as per manufacturer’s

recommendations. The electrodes used shall be free from rust, oil, grease, earth and other foreign

materials which affect the quality of welding.

All other consumables (like shielding gas) equipment and accessories shall be strictly as per

applicable standards, codes and instruction of Owner/Owner’s Representative.

Acceptance of welding process is in prerogative of Owner/Owner’s Representative.

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 bear the approval of the

Owner/Owner’s Representative.

Preheating temperature shall be maintained over the whole length of the joint during welding.

Temperature indicating crayons of other indicating devices shall be provided by the Contractor as per

instruction of Owner’s Representative.

Post weld heat treatment (PWHT), wherever required for joints between pipes and fittings, pipe body

and supports as necessitated by the provisions of code (ASME B 31.8) shall be carried out by the

Contractor at his own expense as per relevant specifications, applicable standards and the instructions

of the Owner/Owner’s Representative.

Preheating for API 5L Gr X70 material and above shall be minimum 80-100°C by induction heating

only. Interpass temperature for API 5L Gr X70 material shall be minimum 50°C and maximum

250°C.

6.2.2 Preliminary Welding Procedure Specifications (WPS)

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Point No 4: No separate payment will be made per WPQ. Bidder shall consider all applicable WPQ

cost in pipeline laying SOR / Package.

6.2.3 Additional essential variables

Add:

Contractor shall submit PTR of the welding consumables to be used for approval of Owner/Owner’s

representative.

6.2.4 Qualification tests. : Refer Welding Specification attached in the tender document.

6.2.4.1 Introduction

The pipes for qualification test shall be arranged by Contractor in place of Owner.

6.2.4.4 Destructive tests

1. Impact test

Point no.: 1 - Replaced

o 6 sets of 5 full size / sub size charpy V notch specimen must be taken in each procedure

qualification weld in transverse direction to the weld (One highest and one lowest energy value

out of 5 test specimens to be discarded. Finally 3 test specimens of impact test shall be

considered.)

� 4 set of specimen will be located in the middle of the weld thickness with notch located in the

weld center, Fusion Line (FL). FL+2, FL+5

� The other 2 sets of Charpy V notch Specimen will also be taken in the middle of the weld

thickness with the notch in the deposited weld material. These two must be taken at 1800 from

each other preferable 1 set at the top of the weld and the other set at the bottom of the weld.

6.6 ADD :

Following formats are enclosed with ANNEXURE-6 for compliance

i) Format -I : Electrode Qualification Test Record

ii) Format -II : Stress Relief Heat Treatment Procedure Specification

iii) Format -Iii : Welding Procedure Qualification Test Record

iv) Format –Iv : Example Of Record Form For Welder Approval Test

v) Format –V : Welders Identification Card

vi) Format –Vi : Radiographic Procedure For Pipe Welding

PART 7 – INSPECTION AND TESTING OF PRODUCTION WELDS

7.1 General

The following specifications shall apply in conjunction with the following (all latest editions) codes

and standards:

i) API 1104

ii) ASME B31.8

iii) ASTM E94

iv) ASTM E 142

v) ASNT, recommended practice no. SNT-TC-IA supplement A.

vi) ISO R 148

vii) ASTM A370

viii) ASME Sec. V

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ix) OISD - 226

Non-Destructive Tests (NDT)

The contractor shall appoint NDT agency from the vender list enclosed in the bid documents.

With each subcontractor, he must give a description of the NDT method (RT with Internal Crawler,

External RT,MUT, MPT etc.) and the minimum equipment to deploy to achieve the work as per agreed

schedule.

For NDT inspection of production welds, all operators must have the necessary qualifications and

training for interpretation of all NDT to be undertaken during the entire work.

NDT agencies for Testing of Production Welds with Semi-Automatic and Manual Welding shall be

from the Approved vendor list attached elsewhere in this tender document.

• The Contractor will use Radiography (X-Ray/Gamma)wherever possible even at tie-in

joint/crossings. If not feasible manual UT can be used. Proper recording of Manual UT shall be

done.

• The use of X-rays or gamma-rays will be restricted to safe location not accessible by unauthorized

persons.

• All inspection and testing of production welds are in the scope of the Contractor.

• All NDT activities will be supervised on site by the Owner/Owner’s representative. Contractor

must include in his QA/QC plan all procedures concerning the same.

7.2 TESTING OF WELDED JOINTS AND ACCEPTANCE CRITERIA

7.2.1.2 Radiographic Testing

All Radiographic films (100%) shall be submitted to Owner/Owner’s Representative for review and

further acceptance.

Contractor has to submit procedure for repair of Arc ignition points to Owner for approval. After

ground wall thickness of the pipe shall be within the tolerance specified in line pipe specifications.

Radiographic examination procedure to be demonstrated by Contractor and shall be submitted to

Owner’s Representative for approval. The procedure of radiographic examination to be followed as

below:

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

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

Densitometry shall be used to determine the film density. The transmitted film density shall be 1.8 to

3.5 throughout the weld. The unexposed base density of the film shall not exceed 0.3.

All parameters recorded during procedure qualification like SFD/ (Source to Film Distance), exposure

time, capacity of Radiography machine, type of film used, Image quality indicator, sensitivity and

density achieved etc.

The Radiography procedure shall be established for different techniques (like, SWSI DWSI, DWDI,

etc.).

When a complete weld is radiographed in a single exposure using a source inside the pipe, four

penetrometers approximately, equally spaced around the circumference shall be used. For radiographs

made with the source on the outside, a penetrometer shall be placed on each side of the film with

smaller one of the penetrometer tuned towards the end of the film itself.

Radiographic examinations shall be carried out using X-radiations only. Radiographic examination by

Gamma Ray may be allowed, at the discretion of the Owner’s Representative in case of inaccessible

joints.

Whenever possible, pipeline welds shall be radiographed by panoramic exposure (360°) method. If it is

impossible to place the radiation source inside the pipe, the weld will be inspected with the source on

the outside. An overlap of at least 40 mm at the ends of each film shall be required.

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The weld joints shall be re-radiographed in case of unsatisfactory quality of the radiography, at the

expense of the Contractor.

All the repaired joints shall be re-radiographed at no extra cost to the Owner. Repair welds shall be

indicated with ‘R’ to indicate repair. Total repaired joints shall be radiographed to compare with

original film in order to ensure the repair is correctly attended.

The final disposition of all unacceptable welds shall be decided by the Owner’s Representative.

Contractor shall be responsible for the protection and personnel monitoring of every man with or near

radiation sources. 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 (ies) of India. All safety equipment, manpower,

safety displays etc. shall be arranged by Contractor at his own cost.

All pipeline radiographers shall be qualified in accordance with the requirements of API 1104 and to

the satisfaction of Owner/Owner’s Representative. All documentary proof related to qualification of

all the radiographers shall be submitted to Owner/Owner’s Representative for approval. The

Contractor shall provide all the necessary facilities at site, such as a dark room with controlled

temperature, film viewer etc. to enable the Owner to examine the radiographs.

7.2.1.3 Ultrasonic Testing

Before execution of the work, Contractor shall submit the procedure which shall get qualified.

This procedure shall specify, but not limited to the following:

• Type of U.T. equipment used.

• Details for Calibration.

• Coupling medium.

• Frequency range.

• Inspection technique.

• Type and dimensions of transducers.

• Record details (With electronic output facility)

• Temperature range of the joints to be inspected.

The ultrasonic inspection procedure shall be approved by Owner/Owner’s Representative.

The Operator shall be fully qualified as per a recognized standard (ASME Sec. V or equivalent) and

they shall have as minimum level II.

In addition to GTS, UT shall be carried out for the following:

• All repaired positions of weld joints

• Weld joint between different thicknesses

• All Tie-in weld joints where gas-cutting & re-beveling is involved.

IMPORTANT REMARKS:

The inspection and testing of production welds will be executed as follow:

1. In case x-rays equipment cannot be used (tie-in joint) gamma-rays may be used (external testing)

subject to Owner/Owner’s representative approval. Use of low power source may be considered.

2. 100% (Manual UT) and 100% X-ray for HDD Crossing.

The Contractor will assure that all safety precautions to prevent public to X-rays or gamma-rays

exposure as per GTS/503, Indian Mandatory Regulation and Contractor SHE Plan.

The contractor will inform and get approval from relevant authorities before carrying on X-ray or

gamma rays testing.

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7.2.3 Destructive Test

At least one production weld (to be chosen by Owner) will be cut out during the first week of welding

production for each thickness and sent for destructive testing.

5 test specimens of impact test shall be carried out for production weld. One highest and one lowest

energy value out of 5 test specimens to be discarded. Finally 3 test specimens of impact test shall be

considered. In case of production weld failure, two (2) more additional joints has to be conducted for

same days, same welders and same thickness for which production joint failed.

Other production welds (cut out) to be sent for destructive testing shall be minimum one no. out of

every 1000 welding joints & any additional tests deemed necessary by Owner in view of inconsistent

quality of production welds, % of weld repair and performance track record of qualified welders. The

location of Production welds for carrying out Destructive Testing will be chosen by Owner/Owner’s

representative Contractor will not be entitled for any compensation for any destructive test deemed

necessary by Owner.

The destructive tests must be carried out in accordance with section 5.6 of API 1104. All tests will be

carried out in laboratory approved by Owner.

7.7 LOCAL REPAIRS AND CUT OUT OF DEFECTIVE WELDS

7.7.1 General

Bullet Point no 1 : Replace as the welds containing cracks including crater or star cracks regardless of

size or location, burn through, star cracks and incomplete fusion are unacceptable and shall be

considered as defect and welds having such defect shall be not be repaired by weld and shall be cut out

and re-weld.

Any indications that the pipe material next to the weld has been damaged in any way (e.g. arc burns,

mechanical damages, weld beads, defects in the weld seam of the line pipe) shall be reason to reject the

weld.

Suitable records shall be maintained by the Contractor on the day to day work done on welding

Radiography, Ultrasonic testing. The Contractor shall present the records to the Owner / Owner’s

representative on day-to-day basis and whenever demanded, for approval.

The Contractor shall maintain a welder performance record and submit it to the Owner / Owner’s

representative for review if required

7.8 SHARING OUT THE TEST COST

Not Applicable for this particular project.

PART 8 – MECHANICAL CONSTRUCTION OF INSTALLATIONS

The Contractor shall modify/revise the general arrangement layout of any of the natural gas station in

accordance with the size/shape of each allocated plot. Only the final design shall be submitted to

Owner/Owner’s representative for approval prior to start the work. Contractor will not be entitled to

any compensation in case final design differs from basic design.

• The Contractor must supply all material/equipment/workforce to achieve full completion of civil

work and architectural work in accordance with relevant GTS and PTS in due time (as per agreed

schedule).

• It will be the sole responsibility of the Contractor to assume the coordination with their Vendors

/sub-Contractors& specialized agencies like CP (Cathodic Protection), Electrical, Instrumentation

& Control and OFC in order to obtain all information regarding any provision or reservation for

cables, ducts, casing etc. to conceal or lay during civil work activities and interfacing.

• The Contractor will not be entitled to any compensation, if some provision or reservations have to

be added due to lack of coordination work.

• The Owner/Owner’s representative will communicate name, address and contact person for

OTHER vendors & Contractors (engaged by Owner) to whom EPC Contractor may require to

coordinate in due time to the successful bidder.

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Installation of Process and Utility Tie-ins with existing system

Contractor shall make all consideration for installation of Process tie-ins at hook-up stations ( Despatch

Terminal and Receiving Terminal). However, Contractor shall identify the exact location of tie-ins /

hook up including HOT tapping on existing pipe inline, obtain all necessary details (MOC: material of

construction, thickness, ratings, dimensions) and carry out detailed engineering for smooth

interfacing/adaptability with existing/proposed system.

The Owner will communicate the exact location of Process tie-ins / Hot tap (wherever applicable) at

Despatch and Receiving stations. Based on the location, Contractor shall carry out field measurements

and verify the As-built/proposed details of existing/Proposed system at Hook-up points. Contractor to

carry out Detailed Engineering and propose the methodology for Mechanical Construction at Tie-in /

Hook-up points.

All the required activities (but not limited to) such as identification/verification, design, engineering

&procurement for installation of Process and Utility tie-ins at each stations including necessary

modifications in existing system (if any) shall be covered in the scope of Contractor.

8.3 Installation of Equipment

The station mechanical work will comply strictly with the detail design and shop drawing duly

approved by Owner/Owner’s representative.

Detailed drawing like piping isometric drawings shall be prepared by the Contractor based on the plot

plan and the Piping GAD finalized by the Contractor. Any discrepancies between tender drawing and

detailed drawing will not be subject to cost implication.

Prior to start of any activities, the Contractor shall submit to Owner/Owner’s representative all design

and engineering work for approval.

The erection and associated piping for Metering Skid at Dispatch& Receiving Terminal shall be done

as per installation guidelines and detailed drawings provided by Skid Vendor (to be supplied by Owner

as Free Issue material).

The erection/installation and associated piping for Launcher and Receiver Barrels (Pig Traps) shall be

done as per the installation guidelines and detailed drawings provided by respective equipment vendor

(Equipment to be supplied by Contractor).

PART 9 – COATING

9.1 General

Please refer PTS-Field Joint Coating Doc no. P.011947 M 11097 112 for specifications.

9.1.1. Purpose of the coating

Maximum operating temperature to be considered is 600C, hence the design temperature for Field Joint

coating shall be considered as 600C.

Contractor to note that entire pipeline route is falling in Cultivate land and railway Therefore,

Contractor shall ensure that Coating application procedures must take into account such extreme

weather conditions (temperature/moisture/dust) to prevent disbandment/formation of air-pockets.

Line pipe shall have 3LPE external coating as per ISO 21809-1, and coating thickness shall be 2.2 mm,

as per the requirements of DIN 30670. Type of external coating shall be ‘N-n’ type as per DIN 30670.

Heat Shrink sleeves of minimum 2.2mm thickness shall be used for field joint coating on pipeline girth

welds. Field joint coating system shall comply with EN 12068. All the coating material for buried

pipeline section shall be C HT 60UV for C–60 Class as per EN 12068. For all Line Pipes used for

HDD, the coating shall be 3LPP external coating as per ISO 21809-1. For HDD joint coating, fiber

glass reinforced heat shrinkable sleeve certified to Stress class C-60 type compatible with 3LPP or

SEAL for Life Industries (Part of Berry Plastics-USA)/ Canusa or DIRAX-PP shall be used.

Add DIN EN 10289 for Thermosetting Plastic coating in place of DIN 30673.

All coating material shall be DIN – DVGW certified.

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9.1.2 Material to be coated

Line pipe shall be supplied with external (and internal) coating or bare.

External coating is as per Standard DIN 30670, ISO 21809-1 and relevant GTS/PTS.

Internal coating is as per Standard ISO 15741 and relevant GTS/PTS.

The coating cut back for Line Pipes shall be as per PTS -3LPE Coating Line Pipe or as specify in the

tender elsewhere.

For the buried valve station (moulded piece, valves, Fittings, flanges, elbows etc.) Thermoset plastic

coatings may be used. Thermoset plastic coating shall be of Type 3 DIN EN 10289.

Underground bare valves if any will be coated with above material.

9.1.5 Overview of the coating systems to be accepted by the Owner / Engineer.

The pipeline sections can be coated by means of

• Heat shrinkable sleeves

• Thermoset plastic coatings

9.1.6 Definition of the type of coating according to application

• Bare pipes and Hot / LR bends are coated with heat shrinkable Sleeves

• Weld joints can be coated with heat shrinkable Sleeves

• Moulded piece, valves, Fittings, flanges, elbows etc can be coated with thermoset plastic coating.

• For Horizontal Directional drilling, weld joints can be coated with Reinforced heat shrinkable

Sleeves only.

9.2 PREPARATION OF THE SURFACES TO BE COATED

Surface cleaning shall be as per SA 2½ (ISO 8502-3) for base items and will be achieved by shot or

Copper slag /Garnet blasting minimum roughness range to be between 50 and 100 um. The material

used for surface preparation such as Copper slag, Garnet or Sand shall be approved by Owner/Owner

representative prior to procedure qualification.

Following coating specification applicable for buried natural gas station is added:

DIN EN 10289 or DIN 30677 for Tar and Solvent free PUR (1000 microns) coating in two layers and

Epoxy RESIN (500 micron) or high build epoxy of 1000 microns.

9.5.1 Coating with plastic wrapping tape – Not applicable to this project

9.5.2 Coating with bituminous tapes – Not applicable to this project.

9.6 Repairing of the Coating

9.6.1 Repairing PE Coating

9.6.1.1 Repairing PE coating with Plastic wrapping tape - Not applicable to this project

9.6.1.2 Repairing PE coating with PE repair patch

The repair materials to be used for repair of 3LPE/joint coating shall be certified to Stress class C-60

as per EN 12068.

PART10 – EARTHWORKS

10.1 Excavations

The typical Trench sections for possible site conditions (Normal Soil & Rocky terrain are shown in

standard drawing number (GGNG-D-20707-002).

Contractor shall ensure that total length of open trenches (trench excavated but not backfilled) shall

NOT exceed 5 Kms. at any point of time during construction.

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10.1.2 Underground obstacles

In congested area or if deemed necessary by Owner/Owner’s representative or concerned authorities

where numerous utilities may be encountered, the Contractor should carry out the excavation normally

without entitlement of any compensation.

Replace the second last para as below:

• “Unless otherwise stated in particular cross section drawings, the clear vertical spacing between

the gas pipeline and utilities will be min. 0.50 meter at crossing point and will be min. 3.0 meter

horizontal, when the pipeline is running parallel to the utilities (As per PNGRB regulation).

Wherever it is possible, the minimum distance must be increased.”

10.1.4 Trenches depth

10.1.4.1 Minimum depth

Minimum cover depth of cross country pipeline is 1.2 meter.

Contractor shall not be entitled to any compensation for over cover depth of pipeline.

Second para last sentence deleted.

10.1.4.2 Depths greater than the minimum

Para 3rd, 4th and 5th – the minimum depth of pipe top below the water bed (rocky river bed) is 1.5meter

instead of 1.3 meter.

For river crossings the pipeline shall be 2.5 meter below the lowest scour level.

For Railway Crossing, the minimum cover of cased crossing shall be 1.7 Mtr.

In case of cased crossing, the depth of top of the casing pipe will be the same as noted above (for top

of the pipe) shall apply.

All crossings shall comply with authority requirements. No extra charge is admissible to comply with

authority requirements.

10.1.5 Trench Width

The width of trench shall be such that a minimum clearance distance of 200 mm for trench in normal

soil and 300 mm for trench in rock is maintained between edge of pipe and the trench wall at the

bottom of the trench.

10.1.5 Soring the trench and /or work pit

Para 2nd – contractor will not be paid any additional cost in any case.

10.1.8 Appearance of the Trench Bottom and Trench Walls

The trench shall 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. Owner reserves the right

to set the grade of the trench and locate the bends if so desired, in which case Contractor shall

excavate, at no extra cost, the trench and bend the pipe to such a grade. Owner desires to reduce to a

minimum the required number of cold field bends to lay the pipe to conform to the general contour of

the ground and maintain a normal cover. This can be accomplished by cutting the trench slightly

deeper at the crest of ridges and by gradually deepening the trench in approaches to crossings. Such

trenching work shall be done by Contractor at no extra cost to the Owner.

Contractor shall keep the trench in good condition until the pipe is laid, and no claim is to be made to

the Owner by reason of its caving either before or after pipe is laid. All lumber, sheet-piling jacks or

other materials 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 might be required to excavate the trench, install the pipe in it and backfill the trench as per

instruction of Owner’s Representative.

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Contractor shall excavate and maintain the pipeline trench on the staked center line of the pipeline

taking into account the curves of the pipeline. Contractor shall, by any method approved by Owner,

dig the pipeline trench on the cleared and graded Right-of-Way. In steep slope areas or on the hillside,

before commencing the works, proper barriers or other protection shall be provided to prevent the

removed materials from rolling downhill. In certain sloppy sections, before the trench cuts through the

water table, proper drainage shall be ensured both near the ditch and the Right-of Way in order to

guarantee soil stability.

In all cases where rock or gravel or Moorum or hard soil is encountered in the bottom of the trench,

trench padding / Rock Shield Materials and sand bags, approved by OWNER shall be provided to

safeguard the pipe coating. The extent of trench padding (length) shall be decided by OWNER. In

those areas that are to be padded, the trench shall be deeper by at least 200mm or the thickness of the

sand bags whichever more is. The trench shall be evenly and sufficiently padded to keep the pipe,

when in place, at least 200mm above the bottom of excavated trench. Supports shall be provided for

the pipeline by use of sand bags or intermittent transverse berms in the ditch bottom comprising rock-

free material, with a width of 15-20 cm and at an interval of approximately 7 metres. Acceptable

padding shall be placed under the pipeline before its installation and around it after installation, to

establish at both sides and on top of the pipe a permanent layer of padding. The thickness of

compacted padding shall be at least 200mm. Padding materials that are approved by the OWNER shall

be sand containing no gravel, rock, or lumps of hard soil. Sand used for padding shall pass through

sieve size ASTM C33 No. 16.

Contractor shall excavate and maintain the pipeline trench stable till pipeline is laid to the desired

depth in the sandy area at no extra cost to Owner.

10.1.10 Rocky Soil

10.1.10.1 General

Rock for some portion of the total length of the pipeline route is expected. Contractor must use suitable

stone crusher /screening equipment to generate back filling material.

10.2 Backfilling the Trench

10.2.1 General

Backfilling shall be done after ensuring that pipe have the proper fit and the pipe is following the

trench profile at the required depth that will provide the required cover and has a bed which is free of

extraneous material and which allows the pipe to rest smoothly and evenly. Before backfilling, it shall

be the responsibility of contractor to first get the approval of Owner/Owner’s Representative. If any

backfilling is done without Owner’s approval, Owner will have the right to require removal of the

backfill for examination, and the cost of such uncovering and refilling shall be borne by Contractor.

Backfilling of trench in water courses shall be carried out as per the relevant specifications.

Backfilling shall be carried out immediately after the pipeline has been laid in the trench, inspected and

approved by the Owner, thus avoiding long exposure of coating to high temperature, damaging actions

of adverse weather conditions, sliding down of trench sides and pipe movement in the trench. If

immediate back filling is not possible, a covering of at least 200mm of earth, free of rock and hard

lumps (Post-padding) shall be placed over and around the pipe and coating. On no account the top soil

from the ROW be used for this purpose. In general, the trench shall be dry during the backfilling.

Deviations thereof must have prior approval of the Owner. 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 crowned directly over the trench to such a height which

will, in Owner’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 backfill, Contractor shall be responsible for remedial work at no extra cost to Owner. Surplus

material, including rock, left from this operation shall be disposed of to the satisfaction of land Owner

or authority having jurisdiction at no extra cost to the Owner..

10.2.2 Survey To Be Carried Out Prior To Backfilling

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Bullet point no.: 3 – Northing and Easting co-ordinates shall be taken for each welds, concrete slabs,

change in direction of OFC / HDPE duct, anchoring, ballast underground pipelines, utilities & cables

and potential measuring points etc.

10.2.3 Working Method for Backfilling :

10.2.3.1 Lower Part

The trench shall be backfilled to 30 cm (instead of 10 cm) above the pipe with soft soil or sand.

The Contractor shall supply all necessary material and propose to Owner/Owner’s representative, the

method of backfilling he intends to use for the entire pipeline route. No additional charge will be

accepted for any particular precautions deemed necessary by Owner/Owner’s representative. In rocky

area wherever backfilling is found deemed necessary, the Contractor must submit the analysis of the

material intended to be used to Owner/Owner’s representative for approval.

Contractor will not be paid for purchase of free stone soil in replacement of non-suitable back filling

material or for evacuation of non-conformity material.

� Acceptable Backfilling Systems:

TYPE OF FILLING SOIL BACKFILLING SYSTEM

Good filing earth Backfill with excavated soil

Crushed rocky soil from the trencher or rock

crusher

Sand bed of 20 cm in the trench bottom and sand fill of 30 cm

above pipe.

Medium rocky soil (1) particles < 50 mm Sand bed of 20 cm in trench bottom (2). Sand bed of 30 cm

above pipe fill in with excavated soil max. 0/50

Rocky soil with (1) particles > 50 mm

Sand bed to 30 cm above and 20 cm under the pipe (2). Next 30

cm fill in with excavated soil max 0/50 complete the backfilling

with excavated soil max. 0/250.

(1) Filling method to be approved by Owner/Owner’s representative. Drop height of the filling

soil must be limited to the absolute minimum.

(2) Filling with sand-bed only applicable on flat terrain.

Slope Breakers

On sloping terrain, an alternative protection method (slope breakers may be used) shall be proposed

and used by contractor without any cost implication to Owner. Contractor shall furnish materials and

propose methodology to install breakers in the trench in steep areas (slope generally 10% and more)

for the purpose of preventing erosion of the backfill. Breakers shall be constructed of grout bags filled

with a mixture of 4:1 (Sand: Portland cement) at Owner’s direction. Contractor may propose other

methods such as foam dams etc. which shall be subject to approval by Owner. Such works shall be

done at no extra cost to Owner. Contractor shall pay attention to the direction of backfilling in such

steep areas.

Backfilling for Open-cut Road Crossings

During execution of the open cut road crossings or any other utility crossing the backfill material shall

be thoroughly compacted by special compaction methods, such as moistening or ramming of the

backfill in layers up to satisfaction of Owner/concerned authority. In these cases the surface of the

backfill be graveled with crushed rock or some other purchased materials and the road shall be

reinstated at no extra cost to Owner. Contractor shall follow the specific backfilling method as

imposed by Crossing Authority to his full satisfaction and without any cost implication to Owner.

10.2.4 Works during backfilling

10.2.4.1 Reinforced concrete slabs as mechanical protection for the pipe

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Reinforced Concrete slabs shall be laid on top of the pipeline for mechanical protection of the pipeline,

at all Road Crossings carried out by Open-Cut Method, as per drawing number- GGNG-D-20707-007.

In addition, Concrete slabs shall also be provided in all cart track Crossings along the Pipeline Route.

Wherever the pipeline is running parallel to public road in urban areas, a reinforced concrete slab will

be laid on top of the pipeline as per drawing no. - GGNG-D-20707-007.

Concrete slabs also to be provided in Particular Section (PS) as per instruction of Owner/Owner’s

representative.

If deemed necessary by Owner/Owner’s representative or due to site requirement contractor may be

instructed to supply and provide additional RCC slabs, without any cost and time implication

No additional compensation shall be paid separately for laying Reinforced concrete slabs as

mechanical protection.

10.2.4.1.1 HDPE Sheet as Insulation for the pipe at OHT Crossings.

Wherever the pipeline is running parallel to or crossing an overhead High Voltage Transmission Line

(above 11 KV & less than 66 KV), plastic grating of 8 mm thick shall be provided. For 66 KV & above

75 mm thick concrete slab shall be provided shall be laid on top of the pipeline as per relevant typical

drawing (GGNG-D-20707-007) and specification, in addition to appropriate CP protection, for

protecting the Pipeline. For details refer typical drawing (GGNG-D-20707-009) for OHT crossing

attached with the bid document.

10.2.4.2 Warning signs

10.2.4.2.2 Warning tape

Warning tape is required on the entire length of the pipeline. Warning tape shall comply PTS- Warning

tape requirements (Document No.; P.011947 D11097 104).

Note (Applicable for Part – 10):

The trench size shall be strictly maintained as per bid requirements and in case of lowering being

performed in adequate or smaller trench, Owner/Owner’s representative reserves the right to make

recovery from the Contractor for making smaller trench and less backfilling.

PART 11 – LOWERING-IN AND BALLASTING

11.1 Lowering-in

11.1.2 Conditions before Lowering

Contractor shall submit PIMS generated pipe book ( if applicable) up to Joint coating part to Owner’s

Representative. After certification of the pipe book only lowering - in can be started. Prior to

lowering - in; a complete check by a full circle holiday detector for pipe coating and field joint coating

in presence of Owner/ Owner’s Representative shall be carried out and all damages noted shall be

repaired at Contractor’s cost.

The pipeline shall be lifted and laid with all necessary suitable equipment’s of non-abrasive material

having adequate width for the fragility of the coating. Lowering in utilizing standard pipe cradles shall

be permitted if Contractor demonstrates that pipe coating is not damaged. No sling shall be put around

field joint coating and PE coated pipes as well.

The pipeline must be laid without interruption for the whole or the length of the section available. If

water is present, no lowering shall be carried out.

11.1.3 Precautions to be taken during lowering-in

A comprehensive report/method statement (along with S-curve calculations) on the laying operation

shall be submitted to the Owner for approval.

11.2 Ballasting of the Pipe (Concrete Weight Coating)

11.2.1 General :

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The Minimum Thickness of Ballasting/Concrete Weight Coating for 12” NB pipeline shall be as below

:

Crossing Location Class Wall Thickness of

Pipeline to be used

Thickness of Concrete

Coating Required

Location Class 1 & 2 6.4 mm 40 mm (Note – 1)

Location Class 3 7.1 mm 35 mm (Note – 1)

Location Class 4 8.4 mm 30 mm (Note – 1)

Note – 1 : Final Thickness of Concrete Coating or anti buoyancy weight for geo textile bags shall be

determined, during detail engineering, based on requirements at site.

For Rocky River / Fish pond area and any other area where anti buoyancy is required, concrete coating

or geo textile bags shall be provided as instructed by EIC.

The Contractor shall provide calculation for ballasting requirement in water logged areas and required

ballasting to be carried out as per agreed procedure and design. Contractor to carry out detailed

calculation / engineering and take the findings of Seismic analysis into considerations before

finalization of ballasting requirements.

11.2.2 Nature of the ballast:

The Pipe shall be continuously coated only with reinforced concrete Coating for River Crossings and

other waterway, and the cost for the same shall be included in the quoted prices.

PART 12 – TELETRANSMISSION

12.1 General

The scope of the pipe-laying Contractor includes Supply, installation, Testing of OFC all along the

pipeline route. Refer PTS- Optical fiber cable (P.011947 I 11097 104), PTS- HDPE duct – (P.011947 I

11097 105), PTS – Telecommunication System (P.011947 I 11097 103) & Control and

Instrumentation scope of work (P.011947 I 10775 101).

• The Pre-cast OFC jointing Pit /inspection chamber (Refer Drawing No. GGNG-D-20707-051)

shall be located at maximum distance of 4 Km and blowing pit shall be located at every 1 Km.

• The arrangement of OFC, 6” Casing Pipe, 2” HDPE Duct and Spare 2" HDPE duct & OFC in

NORMAL & CROSSING sections shall be as per standard drawing (GGNG-D-20707-002)

enclosed with tender document.

a) Crossings by boring.

• For pipeline crossings executed by boring / jacking method (for both cased and uncased

pipeline crossings) the OFC laid in permanently lubricated HDPE conduit shall be sub-ducted

in a separate CS casing conduit as per drawing (GGNG-D-20707-006 and GGNG-D-20707-

012) enclosed with tender document

• Easy-to-install OFC sealing plug shall be used to seal the ends of the conduit to prevent the

ingress of water, dirt and rodents, which may damage the OFC. The two ends of each conduit

shall be sealed immediately after installation and re-sealed when the OFC has been installed

inside the conduit.

b) Open Cut crossings:

• For all water crossings, the OFC laid in permanently lubricated HDPE conduit shall be further

sub ducted in CS conduits (specification of Casing conduit, installation of casing conduit with

pipeline, etc shall be as per specification).

c) Crossings by Horizontal Directional Drilling (HDD)

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• For crossings to be done through HDD, the OFC laid in permanently lubricated HDPE

conduit shall be sub-ducted in a CS casing conduit (specification of Casing conduit,

installation of casing conduit with pipeline, etc shall be as per specification).

12.2 Tele-transmission cable

• In case of river or water body or any other crossings by HDD, the armoured Optical Fiber Cable

and 2 nos. 2” HDPE Duct will be laid through approved 6” Casing pipe (API 5L Grade-.B, 6.4

mm thick, externally epoxy coated 500 micron thick) as per standard drawings (GGNG-D-20707-

013). The 6” Casing pipe shall be installed through separate boring.

• In case of Railway Crossing by Boring & Casing Method , the armoured Optical Fiber Cable and 2

nos. 2” HDPE Duct will be laid through approved 6” Casing pipe (API 5L Grade-.B, 6.4 mm

thick, externally epoxy coated 500 micron thick) as per standard drawings (GGNG-D-20707-

012).The 6” Casing pipe shall be installed through separate boring.

12.2.2 Applicable only in case of Owner supply free issue material.

12.2.3 Lowering-in the Cable

12.2.3.1 Para 2nd – Bending radius of cable shall be as prescribed by the manufacture.

Para 4th – The end of two successive cable section must be overlap by 15 M to facilitate subsequent

connection.

12.2.3.2 Position of the cable relative to the pipe

The cable will be laid on the right side of the pipe looking towards the final point of the pipeline as

per standard drawings provided in the tender.

12.2.5 HDPE duct (inner diameter – Min 50 mm) in place of Min 50mm.

12.2.8 Cable tests after the work

The cable tests must be carried out by Contractor or contractor’s appointed specialized agency. If

damage found during cable tests, all tracking, repair and rectification work shall be borne / carried out

by contractor.

12.3 FIBRE OPTICAL CABLE IN HDPE ENCASEMENT

12.3.1 General Technical Characteristic of the HDPE encasement.

• The HDPE Duct and all accessories like coupling, connections, sealing caps, sealing, the

inspection chambers and related accessories will be supplied by Contractor. Accessories like

couplings, sealing caps will be of push-fit type.

• Fill foam shall be used for sealing of duct entry in OFC pits.

12.3.3. Precaution when crossing obstacles:

In case of use of steel protective sleeve, this sleeve shall be protected externally by epoxy coating.

12.3.5.2 Preparation

Electrofusion coupler may be used by contractor in place of mechanical coupler without any

implication to owner.

12.3.5.3 Procedure for welding the connection

Procedure must be approved by Owner or engineer.

12.3.6 Inspection Chamber

OFC BLOWING PIT

The cable-blowing pit is required for blowing cable and keeping extra cable for future use

(~15m). The blowing pit shall enclose HDPE section ends from both sides at every 1 Km nominal

distance and shall be as per the OFC Blowing pit shown in drawing no. GGNG-D-20707-051.The

cable-blowing pit shall be circular and made of reinforced concrete with lifting lugs cast into the lids

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during construction itself. The pit shall be provided with suitable arrangement for the entry of HDPE

conduit (50mm Outer diameter) from both sides so that HDPE pipes should enter the pit at a height of

300 mm above the bottom level of the pit and to prevent entry of mud, insects etc.

OFC JOINTING PIT

The cable blowing pit as described above will be used as Optical Fibre Cable jointing pit at every 4

Km nominal distance. At every 4 Km nominal distances this pit will be used to enclose the OFC

jointing enclosure. Contractor has to leave 15m coil of Optical Fibre cable from both sides in the

jointing pit i.e. total 30 m of OFC will be coiled in jointing pit. (The name jointing pit and blowing pit

has been used interchangeably in the bid document). Contractor shall submit detailed drawing for

Jointing & blowing pits and gets approval from ENGINEER-IN-CHARGE.

PART 13 – CATHODIC PROTECTION

Refer Design Basis and PTS: Cathodic Protection and detailed specifications on Temporary (TCP)

and Permanent (PCP) Cathodic Protection (P.011947 E 11017 102 and P.011947 E 11097 101)

PART 14 – TESTING, CLEANING AND DRYING

14.1 General :

ADD following specifications to GTS

Submission of Test Procedure

Contractor shall submit a test procedure for Owner’s approval. The procedure shall strictly comply

with the requirements of this specification and shall be submitted to Owner for approval well in

advance. The procedure manual shall include all temporary materials and equipment, but not be

limited to the following items:

1) Diagram indicating all fittings, vents, valves, test headers, temporary connections, relevant

elevations and ratings. The diagram shall also indicate injection location and intake and discharge

lines.

2) Cleaning, gauging, filling and flushing procedures, including a complete description of all

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

3) Estimated amount of test water, water sources, results of test sample, including required

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

concentration.

4) The type and sequence of pigs and the pig tracking system for cleaning and removal of air

pockets. Pig inspection procedures, including procedure to be followed in case the caliper pig

indicates damage.

5) Procedures for leveling and stabilization after filling and for pressurization and to allow for

temperature stabilization.

6) Pressure testing procedure including a complete description of all proposed equipment and

instruments (including spares), their location and set-up, and proposed system for observation and

recording of data during the pressure test. The Procedure shall also cover the detailed calculations

and evaluation methodsto meet acceptance criteria (as specified in this PTS).

7) Procedure for detection and location of leaks.

8) Procedure for dewatering the pipeline section 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.

9) Forms & formats for recording the test data.

Requirement of Equipment& Instruments for Hydro testing

The Contractor shall furnish all necessary equipment for performing the work as stated in cleaning,

flushing, filling, leveling, stabilizing, testing and dewatering procedures.

This shall include, but not be limited to, the following equipment and instruments:

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1) Pigs for filling, cleaning and gauging:

- Cleaning pigs with nylon/polyurethane brushes.

(i) Four cup batching pigs;

(ii) Brush Pig with PE/Nylon brushes

(iii) Gauge plate diameter equal to 95% of the nominal inner diameter of heavy wall

pipe / valves or any equipment usedin the pipe sections.

(iv) Caliper pigs

The Contractor shall provide a sufficient number of pigs, including spares.

2) Filling 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: minimum 200 m3/h

Maximum 400 m3/h

If a single pump is used, a standby unit must be available.

3) Variable speed positive displacement pumps equipped with a stroke counter to pressurize the

line with a known stroke and capable of exceeding the maximum test pressure by at least 20 bar.

4) Two positive displacement meters to measure the volume of water used for filling the line.

These meters shall be provided with a calibration certificate not older than one month.

5) Pressure gauges of suitable pressure range (1.5 x pressure to be measured) and

accuracy.Calibrated Pressure gauge along with calibration certificate not older than one month

6) Pressure recording charts.

7) 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.

8) Two number Temperature Recorders along with calibration certificate not older than one month

for fill water.

9) Thermocouples for measuring the pipe wall temperature along with calibration certificate not

older than one month.

10) Two laboratory thermometers 0°C to 60°C range, accuracy ± 0.1 degrees to be used in

thermowells along with calibration certificate not older than one month.

11) Water tanks during water filling.

12) Portable tanks of sufficient size to provide a continuous supply of water to the pump during

pressurizing.

13) Means to measure the volume of water necessary to drop the line pressure by 0.5 bar (container

on scales or graduated cylinder).

14) Injection facilities(Dozing pump) to inject additive for anti-corrosion into the test medium in the

required proportions.

15) The temporary scraper traps/ Headers shall be installed according to the testing sections fixed

in the test procedure manual. Proper piping and valve arrangements shall be available to allow

launching and receiving of each pig independently.

16) 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.

17) Thermocouples for measuring the temperature of the pipe wall shall be installed on the pipeline

to be tested:

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- 1 thermocouple at about 500m distance from the pumping head.

- 1 thermocouple every 2500 m of the pipe.

- 1 thermocouple at about 500 m distance from the terminal head.

In addition to above, Owner’s Representative may demand to install more thermocouples as per

site conditions.Thermocouples shall be attached on the external surface of the pipe after removal

of external coating and shall be adequately protected from Heat. Damage of external coating of

pipe shall be repaired as per approved repaired procedure of coating in presence of Owner or

engineer. Report for repair of external coating must be singed off by Owner or Engineer.

If the difference of minimum and maximum atmospheric temperature should cause thermal instability

on the pipe section directly exposed to atmospheric condition, the scraper traps / headers and above

ground pipeline shall be properly protected.

PARTICULAR INSTRUCTIONS ON HYDROTEST ACTVITIES:

The information given below will be guiding the Contractor to develop his methodology for entire

hydrotest schedule covering (but not limited to) the following hydro testing activities in sequential

manner. However, Contractor shall submit the method statement in line with applicable codes,

standards, present specifications and best engineering practice before start of work for approval of

Owner or engineer.

(1) Water Filling

Arrangement of test water to be used for hydro test shall be in the scope of Contractor.The test medium

shall be tested to confirm soft non-aggressive water. 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 Contractor shall furnish and install all temporary piping which may be necessary to

connect from source of water to its pumps and manifolds/tankages.

Before filling operation the Contractor shall clean the pipeline by air driven pigs to remove all mill

scale rust/sand from the internal of pipe sections. The finishing touch shall be executed with pigs

provided with air jet holes or nozzles to keep the internal dust in turbulence ahead of the pigs. The

number of pig runs is depending upon the cleaning results and shall be determined by the Owner at

site. P-V Graph shall be used for calculating air volume for air cleaning.

After completion of air cleaning, gauge plate (size of 95% of nominal internal dia of the heavy wall

thickness of line pipe/ valves or any equipment used in the pipe sections.) shall be passed through the

section to check the possibility of out-of-roundness along the pipeline.After receiving the gauge plate,

it shall be presented to the Owner’s Representative for approval.

After gauging pipeline will be flushed with minimum 1 Km of pipeline volume then water shall be

filled with corrosion inhibitor by propelling min 2 pigs with water column of Min. 100 mts.

(2) Thermal Stabilization

After a check has been made to confirm if the pressure has attained at least 1 bar (g) on the highest

section, the thermal stabilization can be started.

Thermal equilibrium between the pipeline and environment shall be checked through the

thermocouples installed on the pipeline.

Temperature readings shall be made at 2 hours-intervals. Thermal stabilization shall be considered to

have been achieved when a difference not higher than 1°C is attained between the average values of

the last two readings. Thermal stabilization completion shall be approved by Owner’s Representative.

(3) Pressurization

The pressurization rate shall not be more than 2 bar/min. Pressure shall be recorded in dead weight

tester and confirmation can be done with pressure gauge on the same header. Volume shall also be

recorded with respect to pressure as follows,

- Each 5 bar increments up to 80% of test pressure as recorded by the dead weight tester;

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- Each 2 bar increment between 80% to 90% of the test pressure full test pressure as recorded by the

dead weight tester.

- Each 0.5 bar increment between 90% of the test pressure to full test pressure shall be recorded by

the dead weight tester.

In case, during the hold pressure periods, decrease in pressure is observed, the above operations shall

not be repeated more than twice, after which the line shall not be considered capable of test, until the

CONTRACTOR has isolated and eliminated the cause for the lack of water tightness.

(4) Air Volume Ratio shall be calculated as per following:-

i) Pressurize to 50% of test pressure, hold pressure for 1 hour and collect water for air volume

calculations.

ii) Drop pressure to static head of test section at test head.

iii) Pressurize 75% of test pressure, hold pressure for 1 hour and collect water for air volume

calculation.

iv) Drop pressure to static head of test section at the test head.

v) 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.

(5) Air volume Calculation

In order to check the presence of air in the pipeline, two separate consecutive pressure lowering of 0.5

bar shall be carried out.

For calculation of air in the pipeline the second pressure lowering shall be used, and the relevant

drained water shall be accurately measured (V1). This amount measured shall be compared to the

theoretical amount (V2) corresponding to the pressure lowering that has been carried out, by using the

procedure outlined in the specification.

If no air is present in the length under test:

V1/ V2 = 1

In order that the above ratio is acceptable, it shall not differ from 1 by more than 2% (i.e. 1.02).If ratio

is found within limits, pressurization can continue. If not, water refilling shall be carried out by

passing of another pig.

(6) Testing (Strength Test and Leak Test)

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 testing all ball valves in position shall be in partially OPEN condition.

During the testing period the following measurements shall be recorded/reported:

- Every one hour pressure measurements from 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 pressure is not exceeded.

Bleed-off water shall be accurately measured and recorded.

Requirement of Pre & Post hydro testing for Crossings

- The Major River Crossings are defined in Tender Document.

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Pre-Hydro testing : All HDD, all major river crossings and Cased Crossings as defined in bid

document prior to pull back operation, lowering-in Insertion of carrier of pipe will undergo a

compulsory strengthtest. The minimum duration of the strength test shall be 6 hours.

Post-Hydro testing: All major cased and rivers will be also post tested after completion of backfilling

work. The test will be similar as pre-testing work except HDD which will be tested for 24 Hrs..

For any other crossings, Pre testing for carrier pipe to be done in case requested/imposed by

statutory/concerned authority/Owner/Owner’s representative without any additional cost to owner.

14.3 Mechanical Resistance Test

14.3.1 General

- Resistance test has the same meaning as strength test

- Table referring to:

“Overview table-Resistance test for pipelines and mains to operate at less than 30% of the specified

minimum yield strength of the pipe, but in excess of 100 PSI is not applicable.”

- Table on page 4 of 12 of GTS is applicable.

Consider the following changes:

- Line pipe to be tested hydrostatically for 24 hours after stabilization.

- Hydrotest pressure

• 1.25 times Design pressure for pipe location Class 1 and 2.

• 1.25 times Design pressure for pre and post hydro testing for crossings (including HDD) in

pipe locations Class 1 and 2.

• 1.5times Design pressure for pipe location Class 3 and 4.

• 1.5times Design pressure for pre and post hydro testing for crossings in pipe location class 3.

• Station piping to be tested hydrostatically for 6 hours at a pressure of 1.5 times Design

pressure .

Acceptance criteria for Strength Test:

If during the hold period, all pressure containing components in the test sections maintain their

integrity at the specified strength test pressure, the strength test performance shall be deemed

satisfactory. (Refer also to AS/NZS 2885.5)

The final report including all data available will be presented in a format to be agreed by

Owner/Owner’s representative.

Test Water: Evacuation/Dewatering

Evacuated water after hydro test shall be properly drained out to a safe location, with no harm to local

environment without interrupting normal construction operation and working methodology shall be

approved by Owner/Owner’s representative

14.3.2. Hydraulic resistance test

General

a) Pipeline Construction:

Specifications for Electronic Geometry Pig: EGP

The terms Electronic Caliper Surveyor / Electronic Geometry Pig: EGP / Geometry Electronic

Device (GED) have same meaning.

The pipeline section has to be pre-cleaned prior to sending the Electronic Caliper pig for

Electronic Caliper Surveys

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After testing and cleaning of the entire pipeline sections, the Contractor shall run the GED as per

approved methodology. No cleaning operations will take place after the natural gas stations have

been connected with pipeline sections.

Contractor shall take prior approval for supply of GED pig. The GED shall be duly calibrated by

Owner approved methodology. A general criteria for GEG calibration shall be as under:

A machined ring of appropriate size shall be slipped over the sensing fingers. To simulate a dent,

calibration blocks shall be placed under one sensing fingers in increments of 2.5 mm upto the

maximum of 100 mm. Ovalities shall be simulated by two opposite sensing fingers with

calibration blocks in increments of 5mm upto 100mm (200mm) are placed. Additionally for spider

calibration, all sensing fingers shall be calibrated individually using blocks of 20mm or 40mm

increments under each of the sensing fingers. The electronic components shall be checked both by

a system test and functional test Calibration procedure of the EGP tool shall be submitted by the

contractor for owner/consultant’s approval. Calibration test shall be witnessed and certified by the

third party inspection agency. The consultant/owner shall review the report of the calibration test

to ascertain the diagnostic capability. For each pipe size, separate calibration test shall be

conducted. Tools having valid calibration tags including date of calibration shall be deployed at

the site.

The GED must be able to identify and locate inspected faults or defects such as;

S. No. Type of defect Acceptance criteria

1 Dents/Flats Spots As per PTS Line Pipe

2 Wrinkles As per GTS 740/GTS/0502, Part 5 and present

PTS (max. 2% of pipe OD)

3 Out of Roundness As per PTS- Line Pipe

The data collected from on-board memory system must be available for immediate analysis after

surveyor is removed from the pipeline.

The GED will be equipped -

• In order to know the exact locations of any detected fault with an on-board odometer with distance

correction and adjustment.

• On-site data review shall be available.

Contractor shall submit total work procedure and operation manual for EGP activities for

owner/consultant approval before start of work. Contractor shall prepare and submit daily site report

after completion of each EGP activity. Contractor shall prepare and submit preliminary report based

on the result of the electronic geometry pigging identifying locations for dig verification. This report

shall be submitted at site within 48 hrs of retrieval of EGP from receiver to enable to proceed further

for verification process by owner/consultant.

DIG SITE VERIFICATION

The contractor shall supply all equipments /instruments, manpower required for the dig site

verification, rectification of the defects and restoration to its original condition after verification. Final

data analysis of the geometry inspection shall be at the agency's data analysis centre.

Preparation and submission of the final report for each segment within 4 weeks after completion of

field activities of the particular segment for approval/acceptance by the owner/consultant as per

technical specifications.

GENERAL REQUIREMENT OF EGP

I. Intent

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This requirement is not intended to be all inclusive and use of guidelines set forth does not relieve the

contractor of his responsibility of successfully carry out all activities and to obtain reliable and valid

data from the EGP tool about condition of the pipeline as defined in scope of work.

II. Propelling medium

Since pipeline is not commissioned, contractor shall use air as propelling medium for which single

oil-free compressor of minimum 900 cfm capacity shall be used. The compressor shall have the

capacity to develop pressure upto 10KG/CM2. Contractor shall also keep one compressor of the same

capacity mentioned above as stand by. However, contractor shall mobilize higher capacity

compressors in order to complete electronic geometry inspection to meet any contingency like stuck

up pig/ early completion of pigging work in view of commissioning schedule of pipeline. The air shall

be reasonably dry and free from oil and dust particles. Contractor has to arrange all the facilities

required for pressurizing air into the pipeline and running the pigs at required speed so that valid and

interpretable data by running electronic geometry pig is generated by using the above media.

III. Electronic geometry pig runs

The electronic geometry pig shall be capable of recording the entire length of each segment i.e. from

launcher to receiver in one single run and therefore its electronic recorder system shall have requisite

data storage capacity. Cups should have requisite resistance to wear and tear to maintain effective

sealing throughout the entire run time.

IV. XYZ mapping

XYZ mapping data acquisition shall be part of the tool specification. XYZ mapping measurement

shall cover the entire 360 degree of internal pipe circumference using properly oriented and by

sufficient quantity of sensors. The tool shall be capable to identify and locate the following features as

a minimum.

i) Individual Girth weld, weld joints

ii) Dent, ovality, dent with ovality, buckles, wrinkles/ripples or any other out of roundness, change in

pipeline I.D. and difference of thickness.

iii) Tap-off

iv) Valves or any partially closed valves.

V. Tool performance

Tool shall have capabilities as under.

i) Minimum detection level for dent( at the specified accuracy) : 2% of ID

ii) Measurement accuracy for dent: -25% of the value in mm measured by the tool

iii) Minimum detection level for Ovality: 1.5% of OD (for 36” line)(At the specified accuracy) 2% of

OD (for 18” line)3 mm (for 12” and 8” lines)

iv) Measurement Accuracy for Ovality: +/- 2% of ID

v) Location Accuracy Axial: +/- 1M from the reported anomaly chainage

vi) Circumferential location accuracy: +/- 15 degree

vii) The tool shall be capable of negotiating 6D bend at maximum thickness and 15%reduction in Pipe

ID. Any deformation existing on the weld (circumfential or longitudinal) to be reported.

VI. Pig tracking

The movement of any type of pig put into the pipeline during electronic geometry pigging shall be

required to be monitored along the entire pipeline length. Contractor shall detail out the complete

methodology of pig tracking proposed to be deployed including complete technical details of the

equipment and device proposed to be used for this purpose. Minimum parameters for tracking devices

e.g. alarm (sound), time of detection& location of detection shall be considered.

VII. Data analysis

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Specialized agency shall carry out the data analysis at his data analysis centre. The analysis shall

consist of minimum of following: -

a) Defect sizing (depth & length) for all significant anomalies.

b) Identification of all pipeline permanent features e.g. valves, tees etc.

c) Identification of potentially hazardous defects likely to affect structural integrity of the pipeline.

d) Transfer of all the agency’s processed data in a CD with the user-friendly software operation on a

compatible PC.

VIII. Final work report

The contractor shall include in his offer the most appropriate reporting procedure envisaged. However,

report shall include but not limited to the following:

a) Detailed report about running of the electronic geometry pig including but not limited to the

operational and functional details.

b) Details describing the type, size and location of individual mechanical defects. The location of

each defect shall be suitably listed with reference to permanent pipeline features, circumferential

location, girth weld no., relative and absolute distance.

c) A detailed report in respect of each defect for which sizing has to be done indicating its length,

depth and axial as well as circumferential location suitably referenced.

d) Preliminary site report for each pipe segment for each running of electronic geometry pig runs

stating comments/observations of each run, pig condition operating parameters, and total time

required.

e) Velocity plot of the electronic geometry pig along the length of the segment.

f) Photographs of defects along with captions as observed during verification.

g) All data to be given shall be in graphical and Microsoft Excel format also. All the formats /

software / software outputs to be in line with ‘PODS’ stipulations.

h) List of anomalies and the pipe tally shall be compatible with excel files. The format of the above

report shall be mutually agreed upon between the contractor and owner/consultant. The above

report shall be submitted in four copies of bound volume. All raw and final processed inspection

log along with the operating software necessary for review/analysis of the data shall also be

submitted in 4 nos. CDs(master copy including copies). This is required to facilitate selection of

significant defects, their chainage and sizing. The software should be user friendly.

IX. Defect verification & rectification

To judge the tool performance and accuracy, contractor shall identify at least two verification dig sites

for each segment jointly with owner from the recorded data and provide defect sheet indicating

distance from the nearest pipeline feature or reference marker to facilitate location of defect in the

field. In case no physical verifiable defect is reported, then EGP tool performance will be verified by

detection and locational accuracy of permanent installations on the pipeline. The contractor shall

depute his representative for verification at verification sites for proving that field log detected

anomalies conform to sizing, including linear positions. Any deformation (i.e. reduction in pipe ID

expressed as % ID reduction) caused by elastic deformation, after exposure of pipe due to removal of

compressive load at defect location, shall be duly taken into consideration, while comparing physically

measured % ID reduction with the value measured by the EGP tool and reported in preliminary report.

All anomalies found beyond acceptable limit shall be verified and rectified. After completion of

necessary fabrication/rectification, contractor shall carry out repeat run and submit results to

owner/consultant for acceptance

X. Action during abnormal situations

The objective of this section is to write down foreseeable abnormal circumstances for taking

appropriate measures, should such a condition arise during implementation of project.

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Owner/consultant has foreseen the following abnormal conditions. However, if the contractor foresees

any other abnormal condition, he is free to mention.

a) tool failure

It is required to get valid interpretable and verifiable data for each segment of the pipeline. In case,

tool fails to perform electronic geometry inspection to generate valid data for any of the pipeline

segment, extra runs shall be carried out to get valid and physically verifiable data without any

additional cost and time implication to the owner.

b) stuck-up tool

The contractor shall detail out a contingency plan as proposed by him in case any of the pigs gets

stuck up. The plan shall identify procedure for exactly locating the stuck up pig, detail procedure

for retrieval of pig, equipment, including support facilities required to retrieve the pig. If pig does

not move from stuck up location, by any of suggested measure, then the pipeline section shall have

to be cut for retrieval of the pig. Contractor shall carry out necessary fabrication and modification

of pipe with new tested pipe piece after retrieval of pig at no cost to the owner in the event of pig

stuck.

XI. Mismatch of inspection results with actual defects during site verification:

In case of variance between the results of physical defect verification and the results reported by the

contractor on the basis of electronic geometry survey (after considering the tolerance as provided in the

contract) segments, this shall be considered as a failed run and shall be dealt as per clause no. X.(i)

above. EGP run shall be considered successful/unsuccessful under the following conditions:

EGP run shall be considered successful provided at the end of the electronic geometry pigging run, the

contractor is able to deliver valid, interpretable and physically verifiable data and which after dig site

verification in the field is found in conformity with the clause no. V (Tool accuracy).

EGP run shall be considered not successful provided at the end of the electronic geometry pigging run,

the contractor is not able to deliver valid, interpretable and physically verifiable data and which after

dig site verification in the field is found inconformity with the clause no. V (Tool accuracy). Also refer

clause no. IX (Defect Verification), in case, no physical verifiable data are reported.

14.4 Tightness (Leak) Test

14.4.1 Pipelines and mains to operate at less than 6.9 bar (100 PSI)

Not applicable

14.4.2 Pipeline > 6.9 bar (maximum operating pressure)

The leak test will follow the strength test.

The residual air content of a test section should be measured or proved to be below 0.2% of volume

added for a rise in pressure of 100 bar, especially when the final test pressure is below 200 bar. The

measurement of residual air shall be carried out as per approved method or Australian Standard

AS/NZS 2885.5 latest edition.

The air volume checks to be carried out before strength test.

The test duration for aboveground station piping shall be minimum 6 hours.

In addition to above, all above ground/ underground piping of terminals (despatch/receipt),

Intermediate Pigging Stations (IPS) & SV station shall be pneumatically tested with nitrogen at 7 bar

(g). Functional test of valves shall also be carried out during pneumatic testing.

14.5 Cleaning and Drying

Magnetic cleaning pig shall be used for the entire pipeline section (except natural gas station) and the

magnetic cleaning shall be accepted if less than 3 kg/100 Km of ferrous material are collected in the

last magnetic pig run. Pigs provided with ONLY Nylon wire brush shall be used in order to protect the

internal coating of line pipes.

14.5.1 Pipe Construction

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- The dew point temperature for Pipe line drying shall be (-) 8oC.

- The dew point to be measured after every 2 hours.

- The pressure of dry air after drying shall be 0.5 bar.

14.5.2.3 Drying :

Pre-Drying

Contractor shall submit the complete methodology for pre-drying of entire pipeline section to

Owner/Owner’s representative approval including the equipment to deploy. The Pre-drying includes

runs of high density foam pigs (suitable for internally coated pipes) till water content is acceptable by


Final Drying

Final drying will be performed through introduction of dry air (at -400C dew point at atmospheric

pressure) or through vacuum drying process or combination of both (dry Air + Vacuum drying).

Contractor shall perform drying for entire pipeline section. The complete methodology shall be

submitted to Owner/Owner’s representative approval including the equipment to be deployed.

A) Specifications for final drying with Vacuum Drying process

The Contractor shall take into account the following:

Generalities:

During the vacuum drying method the residual water in the pipeline left after the swabbing operation

shall be removed by means of boiling the water below the water pressure of the water present in the

pipeline. The vapour shall be drawn from the pipeline until the specified dryness has been achieved.

The vacuum drying (final drying) operation being part of commissioning work shall commence

immediately after completion of pre-commissioning activities.

Before the vacuum drying operation may start, Contractor shall verify that all his equipment and

instruments have been connected correctly to Owner/Owner’s representative satisfaction and that all

valves are set in the correct position.

Operational Requirements:

a) During the vacuum drying operation four stages shall be passed i.e. evacuation stage, boiling

stage, air purge dryness test and the final reduction of line pressure. The requirements for these

stages are:

• Evacuation Stage

The evacuation stage is the initial stage, when the air originally present in the pipeline is

removed and the pressure is reduced to a level at which the total pressure is equal to the

vapour pressure. The evacuation stage shall not last longer than 24 hours.

• Boiling Stage

During the boiling stage the total pressure and the vapour pressure stay approximately the

same. During this period, the dew point shall be maintained well above +3oC to prevent

freezing of the residual water in the pipeline. Boiling has to be continued until a rapid

decrease of pressure is observed.

• Air Dryness Test

Upon successful completion and acceptance by Owner/Owner’s representative of the boiling

stage, Contractor shall perform an air purge dryness test. This test is to confirm that the

pipeline has achieved the required dryness as specified in the Scope of Work;

The test shall consist of introducing air at one end of the pipeline and pumping the same

amount of air out at the other end while the pressure is kept the same. At both ends of the

pipeline the pressures as well as the dew points and the volume of air let in and pumped out

shall be measured. The dryness of the air being introduced at one end and let out at the other

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end of the pipeline shall be the same as that of the pipeline wall, being the required dryness

level or better;

Contractor shall supply air of the required dryness at the purge pressure by means of an air

drier which can deliver at the same dryness level as specified in the GTS & PTS and keep the

dryness level of the air going into the pipeline as constant as possible over the whole purge

test period.

As the air purge test shall be performed at a low pressure, Contractor must be aware that due

to expansion of air from atmospheric to a vacuum pressure inside the pipe, the dew point level

will decrease.

The air purge test shall be continued over a period of 24 hours after the situation has been

stabilized. The time required for air to travel from one end to other end of the pipeline is not

included in the stabilization time and shall be calculated by the Contractor and submitted to


The amount of air being introduced and the amount of air being pumped out of the pipeline

shall be measured. The accuracy of this flow measurement shall be at least one percent;

The pressure during the air purge test shall be at least 5 kPa ;

The dew point measured at the suction end shall not deviate more than + 1oC higher than at

the inlet, the pipeline must still contain free water. The boiling stage shall then be repeated

followed by the air purge dryness test.

• Final Reduction of Line Pressure

After successful completion of air purge dryness test and its approval by Owner/Owner’s

representative, Contractor should proceed with gas filling activity as per approved

methodology. If deemed necessary by Owner/Owner’s representative some pipeline section

shall be kept idle under 500mbarg of nitrogen as per approved methodology before gas in

operation.

B) Specifications for final drying with introduction of Super Dry Air (Without Vacuum drying)

The final drying operation being part of commissioning work shall commence immediately after

completion of pre-commissioning activities. Contractor shall submit the complete methodology for

Drying & Nitrogen purging (including activity schedule, communication system, process calculations,

detailed time schedule and organization chart). Before the final drying operation may start, Contractor

shall verify that all his equipment and instruments have been connected correctly to Owner/Owner’s

representative satisfaction and that all valves are set in the correct position.

The residual water in the pipeline left after the swabbing operation shall be removed by means of dry

air. For this purpose, contractor shall introduce dry-air at around -400C dew point at atmospheric

pressure from one end of pipeline and shall carry out open venting from other. The process of running

pigs and dry air through pipeline section shall be continued until the desired dew point at the outlet is

met. Contractor shall also ensure that intermediate/lower elevation portion of pipeline sections are

dried-up by carrying out soak test.

A soak test shall be performed by shutting the pipeline for at least 24 hours and then dry air volume

equivalent to pipeline volume shall be passed through the pipeline section at the lowest possible

pressure, while monitoring the dew point at the discharge point. If the discharge point confirms the

dryness criteria, the pipeline section shall be left at 0.5 bar overpressure dry air or under nitrogen.

(c) Filling of Nitrogen for gas-in:

The Nitrogen shall be injected in the pipeline before filling the pipeline with gas (gas-in) to prevent

direct mixing of gas with air. Assuming that Nitrogen filling flow is 1000 Sm3/hr (without counter

pressure) and a pressure of 3 barg is maintained during gas filling, a buffer of minimum 2 KM of

Nitrogen shall be provided. Contractor shall submit the detailed methodology for Nitrogen Filling and

Gas-in covering all HSE aspects for approval of Owner/Owner’s representative.

Contractor shall arrange the Liquid N2 tanks typically with 95-97% purity typically with dew point of -

700C. Due to high ambient temperature conditions prevailing at project site, Contractor shall ensure the

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adequacy of temporary equipment (vaporizer etc.) provided for gasification of liquid Nitrogen to

prevent any entry of liquid Nitrogen inside the pipeline section.

Nitrogen with dryness corresponding to a water dew point of -400C or better shall be used. The

maximum allowable oxygen content shall be 2% by volume. The carbon dioxide content shall not

exceed 5% by volume. During nitrogen purging the temperature shall be monitored so that the

temperature of nitrogen and pipeline wall does not fall below -50C.

14.8 Acceptance

Acceptance of Pressure (Strength and Leak) Testing

The hydrostatic test shall be considered as positive if pressure has kept a constant value throughout the

test duration, except for change due to temperature effects. Such changes shall be evaluated as

described below.

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 hour by hour.

If test section doesn’t meet the above requirement, 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 those cases where leaks

occur in circumferential welds, the approval for method of repair shall be obtained from Owner,

however the responsibility is completely lying with the Contractor. Contractor shall comply with

instructions of the Owner’s Representative whether to replace a section of the line pipe that includes

the line leak or whether to repair the same. The repair shall be carried out as per specifications. Where

failures occur in pipeline field bends, bends shall be replaced with same degree of bends. After

completion of repairs, the hydrostatic test shall be repeated in full, as per this specification.

The cost of repairs or replacements, followed by refilling and repressurizing the line, shall be borne by

the Contractor. Contractor shall not be entitled for any time extension due to the same. Subsequent

operations such as installation of sectionalizing valves, caliper pigging, swabbing, pre-commissioning

checks, purging/ inertising and commissioning shall be carried out as per the relevant specifications.

All thermocouples installed in the pipeline shall be removed and damaged coating shall be repaired

using Owner approved materials and procedure.

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 deployed by the Contractor 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 Owner. Four cup pigs run shall be

made 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 colours/ 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 Owner.

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 the start of dewatering and disposal of hydro test water, a procedure for treatment of

inhibited water to prevent pollution shall be submitted by Contractor to Owner for review and

approval.

Upon completion of the testing and dewatering operation, any provisional traps/ headers 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.

Termination

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After the positive results of testing and all the data have been gathered, the test shall be terminated

upon written approval given by Owner.

The pipeline shall be slowly depressurized at a moderate and constant rate as instructed by Owner.

Calculations& evaluation technique for test acceptance

The theoretical water amount that is necessary for filling the section to be tested shall be obtained from

the geometrical volume of the section considering the pipe tolerances.

The theoretical water amount that is necessary for pressurizing the section shall be calculated by means

of the following formula:

Vp = (0.884 ri + 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 Annexure-5 for water compressibility factor vs. pressure and temperature chart).

K = a dimensionless coefficient that is equal to a value of 1.02 for longitudinally welded (LSAW)

pipes.

The pressure change due to a water temperature change shall be calculated through the following

formula:

∆ P = B ∆ T

0.884 ri + A

t

Where,

∆ P = Pressure change resulting from a temperature change (bar).

∆ T = Algebrical difference between water temperature at the beginning of the test and water

temperature as measured at the end of the test (oC).

B = Value of the difference between the thermal expansion of water at the pressure and

temperature as measured at the end of the test and that of steel (oC-1) x 106 (as per

standard graph)Refer Annexure-5 for Standard Graph.

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 Annexure-5 for water compressibility factor vs. pressure and temperature chart).

ri = nominal inner radius of the pipe (mm)

t = nominal pipe thickness (mm).

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:

Provision shall be made for the installation of no-admittance signs to unauthorised personnel from the

roads to the R.O.U.

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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.

Provisional scraper traps shall be installed in compliance with methods and suitable location so that

their rupture cannot cause any injuries to the personnel or third parties.

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.

Once dewatering is over the sectionalizing valves and other valve assemblies tested previously, shall

be installed at locations shown in the drawings and in accordance with the procedures contained in the

relevant specifications. All thermocouples installed in the pipeline shall be removed and damaged

corrosion coating shall be repaired using Owner/ Consultant approved materials and procedure.

The Contractor shall prepare an emergency plan which shall describe actions to be taken in case the

test section or test equipment leaks or bursts. The emergency plan should include, B but not be limited

to, the following:

− How to deal with washouts and other damage?

− Telephone numbers of standby crews.

− Telephone numbers of police, medical and other emergency services that may need to be

summoned.

− Telephone number of the Owner’s/ Consultant’s camp office which may be contacted.

− List of equipment and machines available or needed.

− List of personnel

− Location of medical and first aid facilities.

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 as per relevant

specification/ Contract. Contractor shall obtain necessary approval from the Owner of the procedure,

type and quality and quantity of inhibitors used before commencement of the works

Final dossier and Handing-over

Contractor shall hand over final dossierassuring that the pipeline has been constructed as per

agreed/approved specifications, tests and statutory requirements, giving due respects to codes and

standards. The pipeline, piping and other station works shall be ready prior to commissioning activity.

If any defects due to bad workmanship or any short comings to any statutory requirements or any

deviations to contract requirements are being noticed after handing over, the same shall be rectified as

per contract requirements without any cost implication to Owner. Individual spread laying contractor

shall arrange for equipment, manpower, spares and consumables for commissioning without any cost

as well as time implication.

The Contractor shall issue a statement stating that “the pipeline has been constructed as per

agreed/approved specification, test and statutory requirements giving due respect to codes &standards.

The pipeline, piping and other station works are ready for use and are being handed over to Owner for

use”. However, if any discrepancy is found by Owner, the same shall be rectified by Contractor

without any cost implication.

This report shall contain as a minimum:

− Water test certificate; Inhibitor test certificate;

− The cleaning, gauging, flushing, filling and testing procedures used; Schematic layout of

cleaning, filling and testing facilities;

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− Equipments and Instruments calibration certificate; A profile of the pipeline that shows the

test sites,

− All instrument and injection connections with rating certificates; 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;

− Temperature data along the pipeline;

− Dead weight tester logs and recordings; 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 photographs of all leaks, if applicable.

PART 15 – SITE REINSTATEMENT AND MARKING OUT

15.1 Site Reinstatement - General

Add at end of last paragraph:

In the city area final reinstatement of the roads are not permitted by agencies like PWD etc, where

Owner is required to deposit the charges in advance while applying for the permissions, the same shall

be borne by the Employer/Owner. However, the contractor shall be responsible for reinstating the dug

up trenches to the conditions that it becomes motorable immediately after pipe laying to the entire

satisfaction of concerned authorities as the final reinstatement by the concerned authorities is only

undertaken after handing over the ROU.

15.2 Reinstatement Work

Protection of Bank: Minimum width of protection of bank for waterways shall be as per relevant

drawing. The protection of bank shall be carried out as per approved methodology. Bank protection

shall be a part of crossing work, no separate payment for gabions shall be made.

The earthen reinstatement with compaction shall be in the scope of contractor without any extra cost.

SOIL SURPLUS

If on site, as a result of the work and after careful backfilling and compacting, a sub-soil surplus exists,

this shall be worked up by grading and compacting below the sub-soil top layer and as a rule this shall

be done in the same lot of land. It shall not be permitted to remove the surplus from the lot concerned,

unless it concerns rejected soil which has to be removed. Working up surplus soil or removal of

rejected soil shall be considered to pertain to the Work

To work a soil surplus into the ground CONTRACTOR shall remove an additional strip of top soil

beside the trench. Next, the upper layer of sub-soil shall also be removed. Both soil types shall be

stored separately across a width depending on the size of the soil surplus. The soil surplus shall then be

distributed across the trench thus widened, after which it shall be graded and compacted and

subsequently the top layer of sub-soil and the top-soil shall be replaced in the correct order, in

accordance with the Specifications

In case the OWNER has given prior permission for mixed excavation of the sub-soil as well as in cases

where the OWNER deems mixed excavation permissible, the above provision of separate storage of

the upper layer of subsoil shall not apply to the working up of the soil surplus.

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In cases where the soil surplus can be worked up in other lots where soil shortage have arisen due to

the Work, this shall only be done after prior permission by land owner, land-user and the OWNER.

SOIL SHORTAGES

If due to unforeseen circumstances during backfilling and compacting there should not be enough soil

to fill the trench properly, or to install the crown height as stipulated, CONTRACTOR shall supply the

necessary backfill material. Soil shortage shall be supplemented and applied before the top-soil is

replaced.

The soil to be supplied shall be worked up in those locations and into those layers where a soil shortage

has been established. The quality of the supplemented soil shall be equal to that of the shortage

Soil shortages outside the trench e.g. in the haul path and/or soil depot strip, shall be dealt with in the

same manner by CONTRACTOR. Making good of soil shortages pertains to the Work of

CONTRACTOR

In case land owner does not give NOC for restoration of his land, then subject to certification by

Owner/Owner’s representative, the restoration can be accepted. If the Owner/Owner’s representative is

satisfied that the restoration has been done as per contract requirement, the contractor may proceed &

job can be accepted.

15.5 Marking Out of the Pipeline

Marking out the entire pipeline route will include:

− Pipeline warning signs

− Right of way boundary markers

− Kilometer Posts

− Ariel markers

− Directional markers

− Navigation marker

Pipeline Warning Sign shall in general be installed at

- National and state highway crossing 2 Nos. min.

- Other road crossings 1 No. min.

- Railway crossings 2 Nos. min.

- Minor water crossings (less than 15 m width) 1 No. min.

- Minor water crossings (above 15 m width) 2 Nos. min.

- Valve station 1 No. min.

- River crossing 2 Nos. min

and everywhere deemed necessary by Owner/Owner’s representative. Special care shall be taken in

urban areas and wherever the pipeline is laid in public areas.

Right Of Way Boundary Markers shall be placed at regular distance every 250 m on both side of the

pipeline axis to mark out the width of the ROW.

Kilometer Post shall be placed as instructed by Owner/Owner’s representative. Kilometer Post shall

indicate cumulative distance in Km from the reference point as indicated by Owner. A kilometer post

is not required if the relative distance between its location and any pipeline warning sign is less than

200 m.

Aerial markers will be placed at least every 5 Km at places specified by Owner. The locations where

Aerial markers are located, the Kilometer post at that location will not be required.

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Directional Markers shall be placed at every change in direction, two more directional markers shall be

installed along the pipeline alignment, one on either side of the turning point at 200 meter from the

turning point of the pipeline route and wherever deemed necessary by Owner/Owner’s representative.

All markers will be located at suitable place preferably in public area and /or at property/plot limits

boundaries.

For further details of individual Markers, refer to typical Standard drawings (GGNG-D-20707-016,

GGNG-D-20707-017, GGNG-D-20707-018, GGNG-D-20707-019 and GGNG-D-20707-020)

enclosed in bid document.

Special Markers

As directed by Owner, special markers shall be installed at location where following changes take

place:

− Change in pipeline diameter and wall thickness.

The above data may be provided on other types of marker (except RoU boundary marker), if the

relative distance between the two does not exceed 100 m.

PART 16 – PARTICULAR CONSTRUCTION TECHNIQUES

Contractor shall take a note that any crossing, which is neither identified in the crossing list nor

appearing in the Alignment sheet; however made known to contractor during detailed route survey or

during pipeline construction shall be executed by him at no additional cost to the owner. Such

additional crossing may include any unidentified UG utilities or any new facility (road/canal)

constructed after the preliminary survey by owner. Contractor based on his detailed design/engineering

shall submit the proposed methodology for owner/owner’s representative and also carry out necessary

liaisoning/ follow-up for obtaining the permission of the concerned authority.

16.2 Trenchless Crossings

Add: General

Installation of casing pipe may be performed by any method viz. open cut, HDD, boring, jacking,

ramming etc. depending upon site conditions/permission from respective statutory authority with prior

approval from Owner/Owner’s representative.

16.2.1.3 Casings

ADD:

Casing pipes with Factory applied coating (coating with epoxy 500 microns thick) shall be supplied by

Contractor along with other material like casing end seals, Casing Insulators (50 mm thk.) etc.

Tentative Size, Material Grade and Thickness of Casing Pipes shall be as follows:

For railway Crossings:

Casing Pipe Size - 24” NB Dia, Material – API 5L, Grade B, Wall Thickness – 8.0 mm.

The work shall be carried out in accordance with the drawings approved by the OWNER and

specifications as directed by Owner and to the satisfaction of the OWNER and the authorities having

jurisdiction over the facility crossed. The work carried out for road & rail-road crossings shall meet the

minimum requirements of API RP 1102, latest edition

For all other Cased Crossings:

Casing Pipe Size - 24” NB Dia, Material – API 5L, Grade B, Wall Thickness – 6.0 mm

The length of the Casing Pipe shall be determined by the Contractor based on site requirements.

The details provided above are indicative only. The Contractor shall carry out all required Calculations

to determine and finalize the Size, Material Grade and Thickness of the Casing Pipe, as per the

requirements of relevant statutory authorities for all Cased Crossings.

16.2.1.8 Filling the casing with sand and sealing the extremities of the casing

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Annular gap between casing & carrier pipe shall be filled with Bentonite.

Both extremities of casing may be sealed in an appropriate manner (End Seals).

16.2.2 Ramming of product carrier pipe

Ramming of the product will not be accepted.

16.2.4 Horizontal Directional Drilling

Refer GTS/740/501.

16.3 OPEN TRENCH CROSSING/WATER LOGGED AREA

Wherever possible, pipe sack shall be used especially in water logged and soft soil areas. Scour level

should be determined during sounding as per relevant clauses of GTS and shall be approved by


16.3.1 Casing in open trench

16.3.1.1 Materials

ADD;

Coated (coating with epoxy 500 microns thick) Casing pipes (Size - 24” NB Dia, Material – API 5L,

Grade B, Wall Thickness – 8.0 mm for Railway Crossings or 24” NB Dia, Material – API 5L, Grade B,

Wall Thickness – 6.0 mm for other Cased Crossings) and all other material like casing end seals,

Insulators, etc shall be supplied by Contractor.

16.4.3. Anchoring, Ballasting, Mechanical Protection of Sinkers:

Material Specification for Concrete Ballasting:

Materials for concrete coating shall comply with following requirements:

A. Cement:

Portland cement (conforming to IS-269), or High Strength Ordinary Portland Cement (conforming

to IS-8112) shall be used. Super sulphated cement shall be (confirming to IS 6909) used wherever

the soil is corrosive. Cement which has hardened or partially set or which has become lumpy shall

not be used. In case concrete weight coating is to be provided at locations affected by seawater

tidal flats etc., Portland cement in accordance with ASTM C-150 Type III shall be used.

B. Aggregate

• Aggregates shall comply with the requirements of IS: 383 and shall be tested in accordance

with IS:2286.

• Fine Aggregates

o 'Fine Aggregates' shall mean any of the following, as defined in IS: 383:

� Natural sand;

� Crushed stone sand;

� Crushed gravel sand;

o Sand shall be well-graded from fine to course in accordance with Table 4 of IS: 383.

• Coarse Aggregates

o Use of coarse aggregates shall be subjected to Owner / Owner’s representative

approval.

• Aggregates shall be clean and free from injurious amounts of salt, alkali, deleterious

substances or organic impurities.

C. Water

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The water shall preferably be limpid, fresh and clean and shall be free from injurious amounts of

oils, acids, alkalis, salts, organic materials or other substances that may deterious to concrete or

steel. It shall not contain chlorides, sulphates, and magnesium salts.

D. Reinforcement

Concrete coating shall be reinforced by a layer or layers of steel reinforcement according to the

provisions hereinafter described.Reinforcement shall be Fe 415.

Reinforcement shall consist of welded steel wire fabric manufactured in flat sheets or in rolls

(ribbon mesh) and shall conform ASTM A-185. Wires shall conform to ASTM A-82.

Steel wire shall be galvanised at finished size. The diameter of the wire and spacing of wires

(mesh dimensions) shall be selected according to the following criteria.

Wire fabric manufactured in flat sheets shall be 2 x 4 inches max. Steel wire mesh, 14 gauges U.S.

steel wire (2.4 mm) min. each way.

Wire fabric manufactured in rolls (ribbon mesh) shall be 1 x 2.5 inches of 14 gauge U.S. Steel

Wires (2 mm wire). The above dimensions will be applied unless otherwise specified by designs.

As a rule wire fabric (sheets) shall be used when concrete coating is applied by casting method,

while ribbon mesh (rolls) shall be used when concrete coating is applied by impingement method.

E. Coating Requirements

Pipes shall be concrete coated as per PTS – Concrete coating (Doc no. P.011947 D 11097 102) to

a thickness as specified in the drawings and documents. The concrete unit weight shall be

minimum 2500 Kg/m3 and the compressive strength shall not be less than 250 kg/cm2 in 28 days

and 170 kg/cm2 in 7 days. Concrete coating shape shall be circular and concentric to pipe outside

diameter. Other concrete coating shapes are not acceptable.

PART 17 – ELECTRICAL AND INSTRUMENTATION

Electricity and Instrumentation are included in the scope.

Refer PTS: Electrical Package (P.011947 E 11097 102), PTS: Instrumentation Package (P.011947 I

10775 101),PTS- Optical fiber cable (P.011947 I 11097 104), PTS- HDPE duct – (P.011947 I 11097

105), PTS – Telecommunication System (P.011947 I 11097 103) and control & Instrumentation scope

of work (P.011947 I 10775 101) and others applicable documents attached with this tender.

PART 18 – PAINT WORK

18.1 General :

Please refer "Painting system & colour code for final layer, Doc number- P.011947 M 11097 111 and

Design basis Pipeline, Document No.: P.011947 D 11017 101”.

The paintwork system has to be taken as a strict guideline. Contractor may propose equivalent or

better paint product for Owner’s /Owner representative’s approval.

Underground piping shall be painted/coated as illustrated in PTS- Field Joint Coating. Contractor shall

obtain approval from Owner/Owner’s representative before commencement of painting/coating.

For station work (mechanical) all above ground pipes, valves, accessories, supports, etc. will be

painted strictly in compliance with approved paint system.

The recommended painting system should be of Category C5 – I Very high (Industrial) as specified in

the Standard ISO 12944 Part 1 to 8. The proposed Painting system shall conform to Table A 5 of ISO

12944 – 5 Standard. The table is herewith reproduced for reference only,

The colour codes for final layer of Station Pipe Work & Metering Shed shall be as per painting

specification attached in the tender document.

18.1.1.1 Products chosen by the Owner :

The paint system proposed under clause 18.8 has to be taken as information only.

Only approved by Owner/Owner’s representative, paint system will be applicable.

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Contractor must propose a system of coating equivalent or better in quality for Owner/Owner’s

representative approval from the approved vendor list attached elsewhere in this tender document.

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AMMENDED CLAUSES OF GENERAL TECHNICAL SPECIFICATIONS 70000/740/GTS/0501

FORHDD

The qualifying statements and conditions against GTS 740/0501 Horizontal Directional Drilling

(HDD) clauses are detailed as below

1. GLOSSARY

Refer to definition of terms of the GTS 740/0501.

2. GENERALITIES

If the Contractor wish to use HDD method for crossing other major obstacles than stated in

CROSSING LIST, he must get the approval of Owner/Owner’s representative. No extra cost will be

payable and accepted.

If as per Contractor’s methodology the 6” casing (For OFC and HDPE duct with spare segment of

OFC) has to be laid separately, it will be without any cost implication.

In any case the contractor (at his cost) must carry out all necessary soil investigation calculation and

Hydrological data collection etc. as per relevant GTS and get the approval of Owner/Owner’s

representative and relevant authorities prior to start of work.

Following survey / test shall be performed by contractor before detail engineering:

• Detailed soil investigations and Hydrological data collection in the proposed crossing locations

so as to obtain site-specific soil data.

• Boring/coring into all type of soil/rock shall be done in each of the river crossing locations.

• Conducting Standard penetration tests and collecting disturbed and undisturbed Soil samples

from boreholes.

• Collection of soil and ground water samples for chemical testing

• Record water table in the boreholes.

• Laboratory tests on soil/water samples collected from boreholes.

• HYDROLOGICAL DATA COLLECTION

� To collect and furnish authentic hydrological data available from the regulatory agencies

for each of the river crossings. The data shall include but not limited to the following:

� High Flood Level (HFL)

� Discharge at HFL

� Velocity of flow at HFL

� Other river details such as meandering etc

� Calculation of Scour Depth & Furnishing Scour Profile

� Flood data, bank erosion rate, sedimentary load etc. if required, for detail engineering.

� Existence of any bridge or barrage or any other hydraulic structures within ten kilometers

(10KM) upstream and downstream of the crossings for each river crossings site from the

local/regional agencies such as CWC, Department of Irrigation, Flood Control Authority,

PWD etc. The data shall be maximum of the recorded data in the last 25 years.

If due to unforeseen reasons or local circumstances or as per Authorities requirement and only if

technically feasible, the Contractor may be asked to use HDD method instead of open cut method for

major rivers or canals crossings (soft soil & rocky soil) without any cost implication to Owner.

Contractor may propose HDD method instead of open cut or cased crossing for some particular

crossing if approved by relevant authority and Owner/Owner’s representative without any cost

implication to Owner.

2.2 Scope of the Contractor

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The HDD work is under the scope of the Contractor. Contractor shall be solely responsible for quality,

progress and coordination work assigned to any subcontractor/specialized agency. Contractor shall

propose the subcontractor/specialized agency for carrying HDD works for approval of

Owner/Owner’s representative. The welding of the string will be made only using semi-automatic

process. Refer to GTS 740/0501.

2.3 Supplies

First bullet point shall be read as under.

Except Free issue material i.e Owner supplied as specified elsewhere in the tender documents, all

required materials to complete the HDD work shall be supplied by contractor.

2.4 Site location

As per crossing list/drawing attached in the tender document.

5. RIGHT OF WAY AND WORK SPACE

5.1 Work Space

Owner shall provide only ROU to the contractor. Any other temporary working space or temporary

access if required at all HDD crossing locations shall be arranged by the contractor at his risk and

cost. For the temporary working space, working strip and temporary access. The contractor will be

responsible to negotiate with the relevant Owner, tenant or authorities. Any deemed compensation

will be borne by the contractor.

9. DOCUMENTS TO BE SUPPLIED BY THE CONTRACTOR BEFORE AND DURING THE

EXECUTION OF THE HDD AND AFTER ITS COMPLETION

9.2 After the HDD execution

All alignment sheet, length profile, coordinates, welds numbers etc. will be recorded and integrated as

per other pipeline work under the general scope of the contractor.

10 CONTROLS

10.2 Weld examination

All welds (for HDD string) shall be tested non-destructivity

100% MUT

100% X-ray

10.3 COATING

Only approved field joint coating system will be accepted for HDD string. Refer to GTS 740/0501.

Coating integrity test shall be performed for all HDD works. This test has to be done before tie –in

with main line. The contractor shall carry out Cathodic Protection at either ends immediately after

pull-back operation.

10.5 Testing

10.5.1 General

After completion of HDD testing and cleaning operations the HDD section will be integrated in the

pipeline and final testing and cleaning will be undertaken by Contractor during testing and cleaning of

the entire pipeline section.

Pre-testing (Resistance test) will be performed prior to pull-back operation and post test (Resistance

tests) must be repeated after pull-back operation and backfilling.

11. Reinstatement

Refer to GTS/740/0501.

12. Acceptance

Refer GTS/740/0501.

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AMMENDED CLAUSES OF GENERAL TECHNICAL SPECIFICATIONS Z/02/0028 FOR

CONTROLLED BLASTING

The qualifying statements and conditions against GTS Z/02/0028 Controlled rock blasting clauses are

detailed as below:

3 GENERAL

Add at the end of clause 3.7:

Only control blasting Sub-Contractors/agencies which have conducted successfully similar work

during last seven (7) years reckoned from bid due date shall be proposed for approval of


Contractor shall also appoint experienced expert to establish safe blasting procedure to ensure

integrity of pipeline and safety.

The proposed agency should have executed minimum 10 works requiring controlled rock blasting

related to trenching in hard rock.

The agency should have all necessary equipment to conduct controlled rock blasting.

The agency should have a valid license to perform rock blasting.

The main Contractor shall submit all necessary PTR and related documents (PO/Completion

certificate/NOC etc.) for approval minimum one (1) month before conducting trial test.

Contractor shall submit the detail working methodology procedure for approval of Owner/Owner’s

representative.

11. VIBRATION RECORDING

Add a new Clause 11.6 as below:

The PPV (peak particle velocity) shall never exceed 25 mm/sec.

Trial shall be conducted for each type of rock with a mock pipeline and the particle velocity shall be

recorded at the mock pipeline. If the safety of the existing pipeline is not acceptable rock trenching

will be done by conventional method only. Contractor may also use a rock trenching machine.

The length of the section to be blasted shall be limited to maximum of 50 meter.

All rock blasting shall be done before stringing operation. Excavation work shall be done after the

welding/NDT/Coating work in any case.

Rock blasting shall not be done if the distance between existing pipelines and new pipeline is less than

7 meter.

BUILDING SITE REGULATIONS

Refer Safety, Health and Environment Bridging document- P.011974 G960012 & GTS

70000/740/GTS/0503. In case of conflict, Bridging document will supersede the GTS.

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ANNEXURE – 1 VIDEO SURVEY

1.0 INTRODUCTION

The purpose of video survey is to capture before starting construction activities the ground realities

along the pipeline route and to co-relate same with digitizedmaps of Survey of India. Moreover during

construction activities the Contractor shall video report at least once a week all site activities.

2.0 SCOPE OF WORK

Contractor or the agency approved by Owner/Owner’s representative shall carry out the videography

along the route of the pipeline.

The work will be subdivided in two phases:

Phase 1: Videography of the entire route prior to any construction activities.

A) The contractor shall capture the video for the following areas but not limited to:

1. Pipeline route

2. Major features such as water bodies, plantation, flora & fauna, forest,

3. Location of various Stations and Tap Off points

4. All Crossing like road, railways, river, canal, khadi etc.

5. The photographs of the major crossing like river, railways highways both upstream and

downstream of the pipeline. The photographs and video should cover the type of soil and terrain

condition, obstacles, rocks etc.

B) The identified locations on digitized map of Survey of India shall be interfaced with Videography

through software whereby one can access both simultaneously and match the two. The identified

locations like Crossings-National Highways, State Highways, Rivers, Major Canals, Hill, Major

Khadi ; Areas – Rocky, Marshy, Forest, Plantation.

The digitized map shall be procured from Survey of India by the Contractor. Digital Theodolite

shall be used for all surveys However, Owner will provide all possible help in collection of

required map, and Authorization letter required, if any to contractor.

C) There is no need to carry out videography of the route if there is no change in topographical

features. Such areas should highlight at end and starting point in videography.

Phase 2: Videography during Construction activities

During construction, the Contractor shall video survey all distinct/main activities under progress

alongside the entire pipeline routing.

The purpose of this survey is to get a complete videography of the construction site at different stage of

the construction.

This includes all main activities as per phased working procedure.

Each phase of the construction shall be at least survey at 5 different locations distributed equally along

the pipeline routing.

Each Natural Gas station will be also surveyed on the same way.

Contractor shall submit his planning and his methodology for approval of Owner/Owner’s

representative right after the placement of award.

2.1 The proper log of the location, landmark, crossings, town, districts and important comments will be

embedded.

2.2 The search will be text based and it will be retrieved the relevant video segment along with

textual/visual data for reference.

2.3 A special program will be written which will help create interface through which the video of

important landmarks can be searched / viewed.

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2.4 Narration in back side of video will be provided along the route.

2.5 The Contractor shall hand over

CDs : 3 Nos. Phase 1

CDs : 3 Nos. Phase 2

3.0 ASSISTANCE

The Contractor to indicate in detail the information and assistance as required from Owner to execute

the survey.

ANNEXURE – 2: CROSSINGS

IMPORTANT NOTES FOR CROSSINGS

The details shown in crossing list such as Chainage, Crossing type, methodology, Overall Crossing

length, quantity of special measures are indicative. However, contractor is required to carry out

detailed pre-construction survey, obtain local information, verify geotechnical/ hydrological

soundings and submit the working drawing based on detailed engineering before the start of crossing

execution.

Contractor shall also make the provision for execution of any additional /new Crossing identified

during detailed pre-construction survey and propose the suitable Crossing Methodology as a part of

detailed engineering.

Any variation in number of Crossings and/or methodology / length / quantity of special measures with

respect to the Crossing list due to Authority permissions or as a result of detailed engineering shall be

taken care by contractor without any time and cost implication to the Owner/Owner’s representative.

SUMMARY OF CROSSING

State No of crossings and Details

Railways *

National Highway *

State Highway *

Other Roads *

Canals *

Rivers *

Nala/Drain (Major) *

Other pipelines *

Water Pipelines *

OFC *

Car Track *

Nala/Drain/Stream (Minor) *

TOTAL *

* :For further details of individual crossing, refer Alignment sheets and crossing drawings details

enclosed in the tender document.

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ANNEXURE –3:PARTICULAR INSTRUCTIONS FOR PRE-COMMISSIONING AND

COMMISSIONING

Contractor shall be responsible for pre-commissioning and commissioning of awarded pipeline system.

A. MECHANICAL COMPLETION

Mechanical Completion of systems shall mean that all installation works of the facilities (or a specific

part thereof where specific parts are mentioned in the bidding document) have been completed and

hydro-tested in accordance with approved construction drawings, approved specification, applicable

codes as defined in the bid document, accepted international good engineering practices and all the

activities have been completed physically and structurally in a comprehensive manner and made fit for

use in all aspects as per the scope in bid document including safety and quality aspects by the

Contractor.

This shall include following as the minimum:

a. Pipeline has been installed, non-destructively tested and accepted, restoration of entire pipe line

including crossings, flushed clean, cleaned by Magnetic Pigging, hydrostatically tested,

dewatered, swabbed, successful completion and acceptance of Caliper run (EGP) and XYZ

mapping for entire section from launcher to Receiver including restoration of entire pipe line and

crossings.

b. Piping and Associated Facilities – piping systems including SVs, mechanical equipment and

their supporting structure are installed including non-destructively tested and accepted,

piping system to be cleaned internally including cardboard blasting, hydrostatically tested,

flushed clean including cardboard blasting (as applicable), dewatered, blown by compressed

air to remove residual water to the maximum possible extent.

c. Stations/ terminals are ready in all respect including first to final layers of painting and complete

painting below the supports, the entire piping systems including SVs are pneumatically

tested at 7 barg with Nitrogen. SOP be followed to ensure safety while pressurization.

d. Piping stress analysis completed & detailed engineering stage HAZOP recommendation

complied.

e. Completion of all golden joints including SV stations between Launcher to Receiver.

f. OFC blowing, installation, joints, splicing, installation of OFC pits and markers and testing to be

completed.

g. Calibration & installation of all field mounted instruments, local panel mounted receiver

instruments completed.

h. Calibration & testing of all the meters (i.e. ammeters, voltmeters etc,) installed on Electrical &

Instrumentation panels completed.

i. Installation of permanent cathodic protection systems for entire pipeline system is

completed.

j. Walk Patrolling Survey of the entire pipe line, OFC installation in all respect and testing to be

completed.

k. Installation of all facilities like pig launcher/ receiver, line connections, Spool pieces, Pigs and

requisite accessories, valves, instruments, manpower etc. as required during various operations.

l. Preparation of detailed procedures, activity schedules, bar charts, schemes etc. This shall include

preparation of detailed procedures for dewatering, swabbing, electronic geometric pigging and

shall address the sequence and methodology describing all operations, data on materials,

equipments, instruments, consumables (e.g. Pigs and associated items), detailed time schedule

and organization chart.

m. Availability and arrangement of temporary pigging facilities have to be done by EPC contractor

at site as per P&IDs.

EPC Contractor's competent representative (i.e. commissioning, operational & maintenance personnel)

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shall check the system/sub-system so that facilities/system/sub-system meets the process requirement

and is constructed as per the approved drawings. After liquidating the checklist EPC Contractor shall

submit certificate (with EPC‟s competent representative’,s checklist and it‟s liquidation report) as

per FORMAT-I (attached in Annexure-5). Checklist generated by EPC Contractor representative

and test certificates connected with the system/sub-system shall form a part of the FORMAT-I.

Certificates of various statutory bodies for relevant portion of the work completed shall be made

available by the EPC Contractor as part of mechanical completion. OWNER / PMC representative

shall check the system along with EPC Contractor’s representative and shall issue FORMAT-II (as per

format given in Annexure-5) which includes deficiencies / modifications required for the portion of the

work that is declared by the EPC Contractor as mechanically complete. All checklist raised by

PMC/OWNER are to be liquidated by EPC contractor and issue the FORMAT-III (as per format given

in Annexure-5) stating system/sub-system as mechanically completed. Any exceptions which will

not affect the pre-commissioning start-up activities and which is acceptable to OWNER/PMC

with a plan to completing the same to be recorded.

B. PRE-COMMISSIONING

Pre-commissioning shall mean the testing, checking and making the total system “Ready for

Commissioning”

Contractor shall perform Pre-commissioning activities for all the system which are required to be

performed after completion / installation, inspection, hydro-testing etc. Of equipment / system to

make it ready for commissioning.

Contractor shall start pre-commissioning activities after acceptance of FORMAT-III by OWNER

/ PMC. This shall include but shall not be limited to activities such as system checking as per

P&IDs/ drawings, site modifications, internal inspection of equipment/ vessels, flushing/ steam

blowing, air blowing of piping including gasket blowing, purging of system using inert gas, leak test, ,

checking of the electrical equipment for proper earthling, continuity, insulation resistance, conducting

operability test on individual equipment/ system, charging of lubes & other chemicals. Fabrication

and supply of temporary facilities, for example, temporary bypasses, spools, blinds, jump-over’s,

vents, strainers, screens etc. which shall be required to carry out pre-commissioning activities shall

be in the scope of the Contractor. It is the responsibility of the Contractor to call the vendor

representative whenever required for successful commissioning of the equipments. All the pre-

commissioning activities shall be carried out by Contractor. Before start-up of the pre-commissioning

activities, safety audit to be conducted by Contractor and OWNER / PMC for entire facility.

Checklist/ deficiency generated by safety audit team shall be corrected / rectified by Contractor at no

time & cost impact to Owner.

The Contractor shall submit the list of systems and prepare list of pre-commissioning activities to be

performed for all applicable disciplines against each system including flushing schemes for the piping

sub-systems. The above details shall be prepared and submitted to OWNER / PMC at least 60 days

before start of the pre-commissioning activities.

In order to execute and perform pre-commissioning activities, the Contractor shall be responsible

for (but not limited to) the following:

a) Carrying out pre-commissioning checks of the pipeline system including Scraper Launcher /

Scraper Receiver at Dispatch Station/ IP station/ Receipt Station, Sectionalizing Valve (SV)

stations and their associated facilities under the scope of work to ascertain that the project has been

mechanically completed in all respect

b) Preparation of detailed pre-commissioning procedures, activity schedules, bar charts, schemes etc.

This shall include preparation of detailed procedures for idle time preservation (if

applicable), removal of idle time preservers (if applicable), flushing/blowing, leak testing

and shall address the sequence and methodology describing all operations, data on materials,

equipments, instruments, consumables, communication systems, necessary calculations detailed

time schedule and organization chart.

c) Pipeline to be dried up to (-) 8 Deg.c( dew point) and declared ready for commissioning

d) Stations:

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i. Testing, Acceptance and Verification of all electrical facilities and their supporting structures

including checking for grounding, integrity, terminations, continuity, megger and testing etc.

� ii. Testing, Acceptance and Verification of all instrumentation and fire and gas detection

facilities and their supporting structures including checking for grounding, terminations,

continuity, loop checking, SAT, instrument control and interlocks, leak test of hydraulic/

pneumatic tubing, validation test for instruments, checking of valve operations – open- close/

local – remote etc, checking safety logics, other testing etc.

iii. Checking proper functioning of all utilities like, UPS, state grid/ DG Power, drainage

system, normal water and potable water system etc.

iv. Complete installation of all markers, station boards, safety boards, fire – extinguishers

at all stations etc. Final painting including marking line numbers, color coding etc.

v. Power availability at each station either from Grid or the Owner’s DG in functional stage.

e) Submit all as-built drawings/ documentation/ upload the same in PIMS, if applicable, and NOCs

of all major crossings etc.

f) Material re-conciliation

g) Supervision & Supply of manpower for pre-commissioning

h) Operation of machinery and equipment for pre-commissioning

i) Supply and use of materials / consumables as required for the Pre-commissioning

activities

j) Commissioning of Permanent Cathodic Protection system.

k) Building to be completed with furnishings and finishing items ready for occupancy. Submission

of BU permission for building.

l) All Electrical Inspector’s clearance certificates, Structural Stability certificate etc. Certificate of

various statutory bodies for relevant portion of the work completed shall be made available by

Contractor.

m) Emergency response plan and Disaster management plan to be in place.

n) Preparations of all punch points.

o) Submission and approval of commissioning procedure, including preparation of deviation

list, if any.

p) All necessary work to perform the job successfully including all modifications that would be

required at various stages.

The Contractor shall demonstrate to Owner/PMC (for approval) the successful completion of all of the

above-mentioned activities.

In the event of any detail, which is not fully addressed, the Contractor should warrant that work shall

be performed in accordance with the relevant Codes, Owner/ PMC specifications and the best

recognized engineering guidelines and practices being followed in the on-shore pipeline industry.

The Contractor shall be responsible for carrying out commissioning activities as per approved

procedure and as per instructions of owner/ consultant. Commissioning activities shall be carried out

by EPC contractor after completion of all the pre-commissioning activities and on acceptance of

Format-IV (format given in Annexure-5) by Owner/ Consultant.

C. COMMISSIONING

Commissioning shall mean carry out all check outs, ensure functional safety of equipments, start-up

and charging the entire pipeline system with natural gas and stabilization.

a. Commissioning checks including Safety Review prior to start of commissioning activities to

achieve „Ready for commissioning‟ status for pipeline.

b. Surveillance of pipeline and attending leaks and operation of SVs and GOVs/HOVs (at Dispatch

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Station/ IP Station/ Receipt station), whenever required.

c. Carrying out and meeting all the guarantee and operational acceptance conditions as mentioned in

the bid document

d. Supervision and supply of manpower for commissioning, manning of SV and IP stations/ Receipt

station for pig tracking, pig receiving and other activities.

e. Supply and operation of machinery and equipment for commissioning, if required.

f. Supply and use of materials/ consumables (including bi-directional pigs) as required for the

commissioning activities.

g. Erection and supply all temporary line connections, spool pieces, strainers, valves, instruments,

manpower etc. as required during various operations.

h. Ensuring all communication facilities are in place and in proper working condition prior to start of

commissioning activities of the pipeline system.

i. Completion of PCP including all surveys.

j. Start – up and charging the entire pipeline system with natural gas.

k. Stabilization and 72 hours run of the pipeline system.

l. All necessary work to perform the job successfully including all modifications that would be

required.

m. A safety review of the entire pipeline system to be carried out after gas charging.

n. Intimation to the local authorities before gas in.

o. MFL to be done after Operational Acceptance and during Gas-In stage.

In order to execute and perform commissioning related activities, the contractor shall be responsible

for providing all support/assistance required for commissioning under the overall guidance and

supervision of owner/PMC.

In the event of any detail, which is not fully addressed, Contractor should warrant that work should be

performed in accordance with the relevant codes, Owner/ PMC specifications and the best recognized

engineering guidelines and practices being followed in the on-shore pipeline industry.

On successful completion of all the aforesaid commissioning activities, contractor shall offer the

system to owner for acceptance/ taking over. The system will be considered as taken over by Owner

on successful completion of all the aforesaid commissioning activities and on fulfillment of

Scope of Work mentioned in tender and on acceptance by Owner .

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ANNEXURE – 4: STANDARD TABLE AND GRAPH FOR HYDROTEST EVALUATION

DIFFERENCE BETWEEN THE WATER THERMAL EXPANSION FACTOR AND THE STEEL

THERMAL EXPANSION FACTOR (OC-1)X10-6

oC

bar

1 2 3 4 5 6 7 8

.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 -43.27 -26.58 -10.46 +5.15 +20.23 +34.85

70 -75.30 -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 +79.41 +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 +72.08 +84.83 +96.38

oC

bar

9 10 11 12 13 14 15

.981 +34.82 +49.22 +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

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oC

bar

9 10 11 12 13 14 15

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 +117.87 +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 +8851 +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 +125.75 +136.24 +146.67 +156.84 +166.69

290 +105.50 +116.79 +127.75 +138.39 +148.73 +158.78 +168.57

300 +107.4 +119.13 +130.00 +140.54 +150.79 +160.75 +170.45

oC

bar 16 17 18 19 20 21 22 23

.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 +207.07

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 +169.29 +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 +172.64 +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 +225.58

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 +175.49 +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 +230.89 +239.01

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oC

bar 16 17 18 19 20 21 22 23

300 +179.90 +189.13 +198.13 +206.92 +215.51 +223.93 +223.18 +240.26

oC

bar 24 25 26 27 28 29 30

.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 +246.75 +255.18 +264.27 +273.18

30 +218.18 +227.88 +237.41 +246.75 +255.69 +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 +223.43 +232.77 +241.94 +250.93 +259.78 +268.47 +277.01

90 +224.48 +233.77 +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 +263.62 +272.16 +280.38

140 +229.92 +238.84 +247.59 +256.18 +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 +283.20

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

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WATER COMPRESSIBILITY FACTOR VS. PRESSURE AND TEMPERATURE

Pressure, bar g

Wate

r com

pre

ssib

ility

facto

r, b

ar

x 1

0-6

Tem

pera

ture

OC

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ANNEXURE-5 : FORMATS TO BE USED DURING MECHANICAL COMPLETION, PRE-

COMMISSIONING AND COMMISSIONING

F O R M A T - I

INTIMATION REGARDING SYSTEM COMPLETION

PROJECT: __________________ CUSTOMER: __________ UNIT: ________________

Following system/sub-system has been mechanically completed in all respects with exceptions noted

below. The system/sub-system can be taken up for checking and preparation of checklist.

SYSTEM NO:

SYSTEM DESCRIPTION:

EXCEPTIONS:

SIGNATURE DATE

CONTRACTOR‟S CONSTRUCTION:

CO-ORDINATOR:

----------------------------------------------------------------------------------------------------------------------

The system is ready/ not ready for Check listing.

OWNER/ PMC:

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F O R M A T - II

CHECKLIST

PROJECT: ______________ CUSTOMER: _____________ UNIT: _____________

SYSTEM/SUB-SYSTEM:__________________________________________________

CHECKLIST TYPE PRELIMINARY/FINAL

SL.NO. CHECKLIST ITEMS REMARKS

SIGNATURE DATE

PMC:

OWNER:

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F O R M A T - III

READY FOR PRE-COMMISSIONING CERTIFICATE

PROJECT: _______________ CUSTOMER: ______________ UNIT: ______________

SYSTEM/SUB-SYSTEM: ________________________________________________

This is to certify that the following Plant/system/sub- system as detailed below isCompletely installed

and all the Checklist points are carried out except for minor details as given in the attached list.

DESCRIPTION ON PLANT/SECTION/SUB-SECTION:________________________

____________________________________________________________________

SIGNATURE DATE

CONTRACTOR‟S CONSTRUCTION

CO-ORDINATOR:

CONTRACTOR‟S COMMISSIONING

CO-ORDINATOR:

The system is ready/ not ready for pre-commissioning.

SIGNATURE DATE

PMC:

OWNER:

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F O R M A T - IV

READY FOR COMMISSIONING CERTIFICATE

PROJECT: ________________CUSTOMER:_________________ UNIT: ___________

SYSTEM/SUB-SYSTEM: ________________________________________________

This is to certify that all the necessary pre-commissioning activities for the system/sub-system as

detailed below have been completed and the system/sub-system is ready for commissioning except for the

minor details as given below which will not affect the commissioning trial runs.

DESCRIPTION OF SYSTEM/SUB-SYSTEM: ______________________________

___________________________________________________________________

SIGNATUREDATE


CO-ORDINATOR:

___________________________________________________________________

SIGNATURE DATE

PMC:

OWNER:

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F O R M A T - V

COMPLETION OF COMMISSIONING CERTIFICATE

PROJECT: ___________ CUSTOMER: _____________ UNIT: __________________

SYSTEM/SUB-SYSTEM: _______________________________________________

This is to certify that the system/sub-system as detailed below has been successfully commissioned and is under

operational control of Client's Production department. The minor items, which will not affect the normal operation of

the system/sub-system, are given in the attached list.

DESCRIPTION OF SYSTEM/SUB-SYSTEM: ______________________________

___________________________________________________________________

SIGNATUREDATE


CO-ORDINATOR:

_________________________________________________________________

SIGNATUREDATE

PMC:

OWNER:

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ANNEXURE-6 :FORMATS FOR WELDING

FORMAT -I ELECTRODEQUALIFICATIONTESTRECORD

Date:

A. Tested at (Sitename) :

Manufacturer's Name :

Brand Name :

Batch Number & Size Tested :

Classification & Code :

Intended for Welding in Positions: :

In combination with( if any) :

Code of Reference (used for testing) :

Special requirements :

B. All Weld Tensile Test :

Base Material used :

Pre-heat Temperature :

Post Weld Heat Treatment Details :

Visual Examination :

Radiographic Examination Results :

Tensile Test Results

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

1

2

C. Impact Test Results :

Test Temperature :

Notch in :

Type of Specimens(Charpy) :

Size of Specimens :

Sr.No. Specimen No. Impact Valve Average

1

2

3

4

5

6

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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 : (i)

(ii)

(ii)

Micro Test results :

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

3. Any other Tests :

Conclusion:

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FORMAT -II STRESSRELIEFHEATTREATMENTPROCEDURESPECIFICATION

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(Tick mark) : Gas/Oil/Elec. Res./Induction

Capacity(Size) :

Maximum Temp.(°C) :

Method of Temp. Measurement :

Atmosphere Control :

3 Heat Treatment Cycle Details :

Changing Temp .°C :

Rate of Heating, °C/Hr. :

Soaking Temp. °C :

Soaking Time, Hrs. :

Rate of Cooling, °C/Hr. :

Mode of Cooling :

4 Other Details, if any. :

Notes:

Thefollowingdocumentsshallbefurnishedalongwiththesespecifications:

(i) Material Test Certificates

(ii) Assembly/Part Drawing.

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FORMAT -III WELDINGPROCEDUREQUALIFICATIONTESTRECORD

Example of record form for welding procedure approval test:

Project/Contract :

Contractor :

Pipe and Coating Material :

Process :

Outside Diameter :

Pipe Thickness :

Joint Design(Sketch Attached) :

Make and type of filler metal Diameter Current Volts

Root

Second Run

Other Runs

Other Electrical Characteristics :

a.c /d.c :

Electrode +ve / -ve :

Shielding Gas :

Type or mixture :

Flow :

Shielding Flux :

Position :

Direction of Welding :

Root : Vertical up/Vertical down

Second Run : Vertical up/Vertical down

Other Runs : Vertical up/Vertical down

Number of Welders :

Root :

Second Run :

Other Runs :

Time lapse between commencement of root and

commencement of second run

:

Time lapse between commencement of second

run and commencement of other run

:

Minimum number of runs before joint allowed

to cool

:

Maximum time between commencement and

completion of weld

:

Type of line-up clamp

Removal of clamp after run :

Lowering off after run :

Cleaning :

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Preheating :

Minimum temperature °C :

Ambient Temperature °C :

Type of heater to be used :

Inter-pass temperature :

Minimum °C :

Maximum °C :

Post weld heat treatment :

Speed of travel :

Test Results :

State acceptable /non-acceptable (with

reasons)or give numerical results

:

Non-destructive test :

Visual :

Radiograph :

Destructive Tests 1 2 3 4

Transverse tensile

Tensile strength(with units)

Fracture location

Test temperature

Macro-examination

Fillet weld fracture

Hardness Survey

Type Load Location of hardness measurement(Sketch)

Hardness range:

Parent metal

Heat affected zone

Weld

Charpy V-notch impact tests

Specimen location and size

Notch location

Test temperature

Results(with units)

Additionaltestandtestsandresultse.g.chemicalanalysis,micro-examination,CTODtests,bendtests etc.

Thestatementsinthisrecordarecorrect.Thetestjointswereprepared,welded and tested in accordance with the

requirements of this specification.

Inspector

Date

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FORMAT -IVEXAMPLEOFRECORDFORMFORWELDERAPPROVALTEST

Welder test certificate Test No.

Project/Contract Date

Inspector

Contractor

Welders Name

Address

Pipe Material

Pipe Thickness

Pipe Outside Diameter

Welding Process

Root Fill and Cap

Electrode/Wire

Root Current Voltage

Second run Current Voltage

Full and cap Current Voltage

Direction of travel

Root Vertical up/ Vertical

down

Fill and cap Vertical up/

Vertical down

Reason for failure

Visual

Non-destructive testing

Butt joint

Fillet weld

Number of attempts

Comments

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FORMAT -V WELDERSIDENTIFICATIONCARD

Name :

Photograph

Identification :

Date of Testing :

Valid Until :

Approval of Welding :

Welding Position :

Material :

Diameter :

Wall Thickness :

Type of Welding Consumables :

Approved by Employer's Signature with seal

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FORMAT -VI RADIOGRAPHICPROCEDUREFORPIPEWELDING

1 Location

2 Date of Testing

3 Name of Supervised Contractor

4 Material

5 Dia &Thickness

6 Type of Weld Joint

7 Radiation Source

8 Type of equipment(External/Internal)

9 Intensifying Screen sand Material

10 Filter Type and placement mask, Diaphragm

Lead Screen etc. Adjacent to Radiation Source or

Specimen.

11 Geometric Relationship

Source local spot size, max and min

source strength

Object to film distance

Radiation angle with respect to weld and film

12 Limit of film coverage

13 Film type and make

14 Exposure Time

15 Processing

Time for Development

Temperature For Development

Stop Bath or Rinse

Fixation

Washing

Drying Etc.

16 Density

17 Sensitivity

18 Type of penetrometer.

Approval of the COMPANY Signature of CONTRACTOR with Seal

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PTS - CONCRETE WEIGHT COATING

DOC. NO: P.011974 D 11097 103



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TABLE OF CONTENTS

1.0 SCOPE

................................

................................................................

................................................................

................................................................

................................................................

................................................................

...............................................................

..............................................................

...............................

1

11

1

2.0 REFERENCE DOCUMENTS

................................

................................................................

................................................................

................................................................

...............................................................

..............................................................

...............................

1

11

1

3.0 MATERIALS

................................

................................................................

................................................................

................................................................

................................................................

................................................................

......................................................

............................................

......................

1

11

1

4.0 COATING REQUIREMENTS

................................

................................................................

................................................................

................................................................

.............................................................

..........................................................

.............................

2

22

2

5.0 APPLICATION METHOD

................................

................................................................

................................................................

................................................................

................................................................

................................................................

..................................

....

..

2

22

2

6.0 EQUIPMENT

................................

................................................................

................................................................

................................................................

................................................................

................................................................

.....................................................

..........................................

.....................

3

33

3

7.0 MEASUREMENTS & LOGGING

................................

................................................................

................................................................

................................................................

........................................................

................................................

........................

3

33

3

8.0 PROCEDURE QUALIFICATION

................................

................................................................

................................................................

................................................................

.......................................................

..............................................

.......................

4

44

4

9.0 APPLICATION OF REINFORCEMENT AND CONCRETE COATING

...............................

..............................................................

...............................

4

44

4

10.0 TOLERANCES

................................

................................................................

................................................................

................................................................

................................................................

................................................................

...................................................

......................................

...................

6

66

6

11.0 WEIGHING

................................

................................................................

................................................................

................................................................

................................................................

................................................................

.......................................................

..............................................

.......................

6

66

6

12.0 INSPECTION AND TEST

................................

................................................................

................................................................

................................................................

................................................................

................................................................

..................................

....

..

6

66

6

13.0 COATING OF FIELD JOINTS

................................

................................................................

................................................................

................................................................

...........................................................

......................................................

...........................

6

66

6

14.0 REPAIRS

................................

................................................................

................................................................

................................................................

................................................................

................................................................

...........................................................

......................................................

...........................

7

77

7

15.0 MARKING

................................

................................................................

................................................................

................................................................

................................................................

................................................................

.........................................................

..................................................

.........................

7

77

7

16.0 UNLOADING, TRANSPORTATION, STORING AND HAULING

................................

................................................................

.....................................

..........

.....

8

88

8

∑ ∑ ∑

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1.0 SCOPE

1.1 This specification defines the minimum technical requirements for the materials, application, inspection,

handling and other activities for external concrete weight coating of pipeline.

2.0 REFERENCE DOCUMENTS

Reference has been made in this specification to the following codes and standards:

IS 4948 Welded steel wire fabric.

ASTM A 641 Specification for Zinc Coated (Galvanized) Carbon Steel Wire.

ASTM C-642 Test method for Specific gravity, absorption and voids in hardened concrete.

ASTM C-138 Test method for Unit weight, yield and air content of concrete.

ASTM C-309 Specification for Liquid membrane forming compounds for curing concrete.

ASTM A-185 Welded Steel wire fabric for concrete re-enforcement.

ASTM A-82 Specification for steel wire, plain, for concrete reinforcement.

ASTM C-39 Test method for Compressive strength of cylindrical concrete Specimens.

IS - 269 Indian Standard Specification for Ordinary and Low Heat

Portland cement. (1959; Reaffirmed1999)

IS – 456 Plain and Reinforced Concrete – Code of Practice (3rd Revision – 2000)

IS – 6909 Indian Standard Specification for Supersulphated Cement (1990)

IS-2386 (PARTI-VIII) Indian Standard Methods of test for aggregates for concrete.

IS-516 Method of test for strength of concrete.

3.0 MATERIALS

The Contractor shall supply all the materials necessary for the performance of the work. All materials

supplied by the Contractor, which in the opinion of Owner / Owner’s representative, do not comply with

the appropriate specifications shall be rejected and immediately removed from site by Contractor at his

own expense.

All materials for concrete coating shall comply with following requirements.

3.1 Cement

1.1.1. Portland cement (conforming to IS-12269: 53 Grade) or High Strength Ordinary Portland Cement

(conforming to IS-8112) shall be used.

1.1.2. Super sulphated Cement shall be (conforming to IS 6909) used wherever the soil is corrosive.

1.1.3. Cement which has hardened or partially set or which has become lumpy shall not be used.

1.1.4. Test Certificates from the cement Manufacturer shall be supplied to the Owner / Owner’s representative

for all batches of cement delivered to site.

1.1.5. Cement which is more than three months old shall not be acceptable.

1.1.6. In case concrete weight coating is to be provided at location affected by seawater tidal flats etc. Portland

cement in accordance with ASTM C-150 Type III shall be used.

3.2 Aggregates

1.1.7. Aggregate shall comply with the requirements of IS: 383 and shall be tested in accordance with IS: 2386.

1.1.8. Fine Aggregates

'Fine Aggregates' shall mean any of the following, as defined in IS: 383:

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I. Natural sand;

II. Crushed stone sand;

III. Crushed gravel sand;

Sand shall be well-graded from fine to course in accordance with Table 4 of IS: 383.

1.1.9. Coarse Aggregates

Use of coarse aggregates shall be subjected to Owner / Owner’s representative approval.

1.1.10. Aggregates shall be clean and free from injurious amounts of salt, alkali, deleterious substances or organic

impurities.

3.3 Water

The water shall be potable, fresh and clean and shall be free from injurious amounts of oils, acids, alkalis,

salts, sugar, organic materials or other substances that may be deleterious to concrete or steel. It shall not

contain chlorides, sulphates, and magnesium salts.

Water from each source shall be tested by the Contractor before use and the test reports shall be submitted

to the Owner / Owner’s representative for approval.

3.4 Reinforcement

Concrete coating shall be reinforced by a single layer or multiple layers of steel reinforcement according to

the provisions hereinafter described. Reinforcement shall be Fe 415.

Reinforcement shall consist of welded steel wire fabric manufactured in rolls (ribbon mesh) or in flat sheets

and shall conform ASTM A-185. Steel wires in the ribbon mesh shall conform to ASTM A-82.

Steel wires shall be galvanized at finished size as per ASTM A -641. The diameter of the wire and wire

spacing (mesh) dimensions shall be selected according to the following criteria.

Wire fabric manufactured in flat sheets shall be 2x4inches max. Steel wires mesh, 13 Guage U.S steel wire

(2.4mm) min each way

Wire fabric manufactured in rolls (ribbon mesh) shall be 1 x 2.5 inches of 14 gauge U.S. steel wires (2mm

wire). The above dimensions will be applied unless otherwise specified by Owner / Owner’s representative.

As a rule wire fabrics (sheets) shall be used when concrete coating is applied by casting method, while

ribbon mesh (rolls) shall be used when concrete coating is applied by impingement method.

4.0 COATING REQUIREMENTS

Pipes shall be concrete coated to a thickness as specified in the relevant drawings and as per the design

documents.

Concrete shall conform to the following:

Property

Minimum Acceptable Value

Concrete Density : 2245 Kg/m3

Compressive Strength (After 7 Days) : 165 Kg/cm2

Compressive Strength (After 28 Days) : 250 Kg/cm2

Contractor shall be permitted to select any proportioning of materials to achieve the specified requirements

of concrete density and weight

5.0 APPLICATION METHOD

Concrete coating shall be applied by impingement method. The application method shall ensure the basic

characteristics of concrete coating in compliance with the minimum requirements of this specification.

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Contractor shall submit to the Owner / Owner’s representative, prior to commencement of work, the

procedure of concrete application for approval.

Wherever practical, the specified total thickness of concrete coating shall be applied in a single pass.

To avoid slippage between the concrete and the anti-corrosion coating, precaution shall be taken,

Contractorto submit the detailed procedure.

6.0 EQUIPMENT

The equipment used for performing the concrete coating shall be capable of doing so with a reasonable

degree of uniformity with respect to thickness, density and strength. The proportioning equipment and

procedure shall be of the type to ensure consistently proportioned materials by weight. Concrete shall be

mixed in a mechanical mixer, which shall ensure thorough mixing of all materials. Any equipment that

tends to separate the ingredients shall not be used. Equipment list to be added.

Ready mixed concrete supplied by ready-mixed concrete plant shall be preferred

7.0 MEASUREMENTS & LOGGING

Contractor shall submit detailed methodology in their procedure for measurement and logging.

AllMeasurements as mentioned below shall be taken during the work stages and clearly logged in a proper

logbook. A special logbook shall be used for recording tests and trial results. A logbook shall refer to pipe

lengths having the same nominal diameter, and wall thickness.

7.1 The logging methodology shall include minimum the following details:

7.1.1 Line pipe

I. Field identification number

II. Mill serial Number

III. Length (m)

IV. Weight (kg)

V. Average outside diameter (mm)

7.1.2 Corrosion Coating

I. Type of coating

II. Thickness of coating (mm)

III. Weight of coated pipe (kg)

IV. Date of corrosion coating application

7.1.3 Concrete Weight Coating

I. Batch identification number

II. Date of placing of concrete coating.

III. Average concrete coating thickness.

IV. Wet weight of coated pipe (weight and date of weighing)

V. "Dry weight" of concrete coated pipe(Weight and date of weighing or related weight 28 days after

placing of concrete and so identifiable).

VI. "Unit dry weight" of concrete coated pipe.

VII. "Negative buoyancy" (unit) of concrete coated pipe

7.2 No concrete placing shall be done before items 7.1.1 & 7.1.2 listed above have been logged. In addition,

each batch / shift shall be identified and logged against cube samples taken for compressive strength and

dry density.

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8.0 PROCEDURE QUALIFICATION

Before commencement of the work, Contractor shall perform all tests, either in the laboratory or in field to

properly select type of mixture, which meets the requirements of section 5.0 of this specification.

8.1 The type of mix, i.e., the correct combination of the cement, aggregates and water which results in the

desired properties of concrete shall be first determined. For each mix the following shall be accurately

checked and recorded:

I. Proportions and weights of the respective materials used

II. The water/cement ratio

III. The grading of the aggregates.

8.2 Samples shall be prepared and tested in accordance with ASTM C-642 to determine the dry specific gravity

of concrete. In parallel, test according to ASTM C-138 shall be performed so as to determine the expected

correlation between concrete weight after placing and dry specific gravity (28 days after placing). Test for

concrete specific gravity at Intermediate time (7 days after coating) shall be performed.

8.3 When the results of the above tests do not meet the requirements, the mix shall be modified and concrete

samples tested until a proper mix has been determined.

8.4 The design mix shall be used for sampling of concrete to be submitted for compressive strength tests as per

ASTM C39 / IS 516.

8.5 Frequency of sampling for tests for density and compressive strength of concrete shall be as follows:

Quantity of Concrete(m3)

Number* of Samples

Up to 25 3

26 to 50 4

51 and above 4 samples and one additional sample for each additional 50 m3 or part thereof.

* Quantity is the volume of concrete to be used for each qualified mix.

9.0 APPLICATION OF REINFORCEMENT AND CONCRETE COATING

9.1 Two test cubes each per day shall be obtained from batches and tested at site after the end of 7 days of

concrete coating, for compressive strength and specific gravity.

9.2 The moisture content of the aggregates used shall be such as to maintain a satisfactory control on the water

/ cement ratio of the concrete mix.

9.3 To maintain the water / cement ratio constant at its correct value, determination of moisture contents in

both fine aggregates and coarse aggregates (if used) shall be made as frequently as possible. Frequency for

a given job shall be determined by the Owner / Owner’s representative according to weather conditions.

9.4 Reinforcement application

9.4.1 Prior to placing of reinforcement, the protective coating of each pipe length shall be carefully inspected

visually and by holiday detectors. If damages are found, they shall be repaired before start of the work.

Foreign matters, if any, shall be removed from the surface of the protective anti-corrosion coating.

9.4.2 Reinforcement shall be placed around the pipe in such a way as to cover whole pipe length or sections to

be concrete coated. The reinforcement shall protrude a minimum 50 mm from the finished concrete

coating at the pipe ends.

9.4.3 Splices and attachments shall be done by binding with steel wire having 1.5mm diameter.

9.4.4 Circular and longitudinal joints of wire fabric in sheets shall be lapped at least for one mesh. The spiral

lap shall be one mesh while the spliced lap shall be three meshes.

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9.4.5 Reinforcement shall rest on synthetic resin spacers forming a "Crown" whose number shall be such as to

avoid contact of the steel reinforcement with the pipe's protective coating. Spacing between the two

consecutive 'crown' centers shall be 500 to 1000 mm.

9.4.6 One layer of reinforcement steel shall be provided for concrete thickness up to 50 mm. The reinforcement

steel shall be embedded approximately midway in the concrete coating thickness. For concrete thickness

above 50 mm two layers of reinforcing steel shall be provided. If application method requires more than

one pass of concrete, one reinforcement layer for each pass is to be applied irrespective of the concrete

coating thickness.

9.4.7 In case on one layer of reinforcement, it shall be located approximately in the middle of the concrete

thickness. In case of two layers of reinforcement, layers shall be located at 1/3rdand 2/3rdof the concrete

thickness. In case of three layers of reinforcement, layers shall be located at 1/4th, 1/2 and 3/4thof the

concrete thickness. Contractor shall demonstrate that the procedure used ensures no physical contact

between steel reinforcement and the pipe and the reinforcement is placed in position as mentioned above.

9.5 Concrete placing

9.5.1 Concrete shall be placed within a maximum of 30 minutes from the time of mixing (adding water to mix)

and shall be handled in such a way so as to prevent aggregate segregation and excessive moisture loss.

Concrete containers shall continuously be kept clean and free from hardened or partially hardened

concrete.

9.5.2 Placement of concrete shall be up to the specified thickness in one continuous course, allowance being

made for splices of reinforcement and providing reinforcement in the right location.

9.5.3 No passes shall be stopped for more than 30 minutes. Before placing fresh concrete against the joint, the

contact surfaces shall be carefully cleaned and wetted to obtain a good bond between the fresh material

and the previously placed material.

9.5.4 Suitable means shall be provided to ensure that the temperature of the concrete, when placed, does not

exceed 32 Deg. C.

9.5.5 All pipes shall be kept clean and free from cement, concrete and grout either inside or outside of the

uncoated sections.

9.5.6 Bevel protectors shall be kept in place throughout the coating application and even after the coating is

complete.

9.6 Cut back on concrete coating

The coating at each end of the pipe shall be beveled to a slope of approximately two to one (2:1). It shall be

terminate about 50 mm short of the end of the corrosion coating applied on the pipe surface.

9.7 Handling after application

Contractor shall take precautions to prevent detrimental movement of pipe after coating and to minimize

handling stresses whilst concrete is hardening and curing.

Identity of each pipe shall be preserved during and after the coating process by transfer of pipe information

to and outside of concrete coating at each end of the all pipes.

9.8 Curing

9.8.1 Immediately after concreting, the exposed surfaces of the concrete shall be protected during hardening

from the effects of sunshine, drying winds, rain, etc., and then after the initial set has taken place, the

concrete coating shall be properly cured. The coated pipe section shall be handled gently by suitable

means to prevent undue distortion.

9.8.2 Curing shall be performed by application of an approved curing membrane using sealing

compounds and shall meet the requirements of ASTM C-309. The curing compound material shall be

stored, prepared and applied in strict conformity with the instructions of the Manufacturer. The

ingredients of any such compound shall be non-toxic and non-inflammable and shall not react with any

ingredient of the concrete, the reinforcement, the anti-corrosion coating or steel pipe. The application of

the curing compound shall be done immediately after the coating is completed and preferably before the

CONCRETE WEIGHT

COATING

P.011974

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pipe is removed from the concrete coating apparatus. The surface of the concrete shall be lightly sprayed

with water before applying the curing compound. The membrane curing period shall not be less than 4

days, during which period the freshly coated pipes shall not be disturbed. The pipe surface shall be kept

wet during daylight hours for seven days after application of the concrete coating. The concrete coating

shall not be allowed to dehydrate.

9.8.3 Before handling and hauling of the concrete coated pipes, a check shall be made to make sure that the

concrete coating is properly cured. Stacking and shipment of the coated pipes shall be initiated only after

seven days provided that the concrete coating suffers no damage.

9.8.4 Curing of concrete coating may also be done by using jute bags, provided continuous wetting is ensured

by the Contractor.

10.0 TOLERANCES

10.1 Contractor shall maintain a surface tolerance of + 8 mm (5/16") maximum for the radial distance between

high and low areas of the surface. The diameter of each coated pipe shall be obtained at Three (3) or more

points, spaced at equal intervals between the end points.

10.2 The acceptance weight tolerance for any single pipe shall be limited to (-) 2% to (+) 5% of thecalculated

weight of concrete. The calculated weight shall be considered only the weight of concrete coating based on

approved concrete density and thickness.

10.3 Acceptable weight tolerance from the approved mix, during production shall be as follows:

I. + 3% for each type of aggregate

II. + 2% for aggregate as a whole

III. + 3% for the total quantity of water

IV. + 3% for cement

11.0 WEIGHING

11.1 The test specimen shall be selected at equal intervals during the course of production.

11.2 Contractor shall weigh each pipe when dry prior to shipment and 28 days after placing of concrete and

mark the weight with paint on the inside of the pipe.

11.3 In case of contract opts not to weight the pipes, the contract shall provide 20% extra concrete coating

thickness over the specified concrete thickness at no extra cost and time to the company.

12.0 INSPECTION AND TEST

12.1 After curing, every length of concrete coated pipe shall be non-destructively tested by suitable means such

as "ringing" to determine if any suspected defects are present. In case this indicates faulty coating, cores

shall be removed from coating and inspected. When defective coating appears from cores, the concrete

coating shall be removed from the pipe lengths.

12.2 Every length of concrete coated pipe shall be checked to verify insulation between steel reinforcement and

pipe by means of a megger or equivalent device. For this purpose provisions should be made during

placing of concrete such as to leave at least a point of exposed steel reinforcement whenever the latter shall

terminate inside of concrete coating.

12.3 During the tests above and before transporting of concrete coated pipes, every pipe length shall be visually

inspected to detect whether any damages and/or defects are present. Possible damages and/or defects with

their allowable limits are described at following section. Repairable concrete coating shall be clearly

marked while the non-repairable ones shall be removed from the pipe lengths.

13.0 COATING OF FIELD JOINTS

13.1 The Contractor shall coat the uncoated pipe surface at field welds in accordance with methods approved by

Owner / Owner’s representative. Contractor shall submit a detailed procedure for joint coating for Owner /

Owner’s representative approval.

CONCRETE WEIGHT

COATING

P.011974

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13.2 The reinforcement for the field welds shall be same as that for line pipe coating with the same number of

layers and the same space between layers as for the existing coating. The edges of this netting must be

carefully secured with galvanized wire to the reinforcement extending from the existing coating.

The reinforcement shall not make direct /electrical contact with the pipe.

Synthetic resin spacer blocks shall be used to keep the reinforcement away from the corrosion coated pipe

surface.

13.3 The composition of the concrete shall be the same as that of the concrete coating of the pipe.

13.4 When moulds are used if approved by the Owner / Owner’s representative, the Contractor shall prevent air

being trapped by applying mechanical vibrators or by striking the outside of the moulds with suitable

sticks.

14.0 REPAIRS

The following are repairs that will be permitted to coating due to unavoidable damage in handling and in

storage (This applies only to concrete that has hardened).

14.1 Spalling due to compression or shearing caused by impact against other objects. Spalling is defined as

damage, which causes a loss in concrete of more than 25 percent of the total thickness of the coating at the

point of damage.

14.2 Damage due to spalling of an area of less than 0.1 m2 (1 square foot) where the remaining concrete is

sound will be accepted without repairs.

14.3 Damage due to spalling of an area of more than 0.1 m2 and less than 0.3 m2 shall have the concrete

remaining in place over that area removed as necessary to expose the reinforcing steel throughout the

damaged area. Edges of the spalled area shall be under-cut so as to provide a key lock for the repair

material. A stiff mixture of cement, water and aggregate shall be trowelled into and through the

reinforcement and built up until the surface is level with the coating around the repair. The pipe shall then

be carefully laid with the repaired area at the top. The repaired area shall be moist cured for a minimum of

thirty-six (36) hours before further handling.

Should the damaged area be more than 0.3 m2, coating shall be removed around the entire damaged area.

A repair shall be made by satisfactorily restoring the reinforcement, forming the area with a metal form and

pouring a complete replacement of materials similar to that from which the coating was made. The

mixture shall be one (1) part of cement to three (3) parts of aggregate and the necessary water to produce a

slump not to exceed 100 mm (four inches). The resulting coating shall be equal in weight, density,

uniformity, thickness, strength and characteristics to the originally applied coating. The pipe shall then be

carefully laid in a position where it shall be allowed to remain for a minimum of 36 hours before further

handling.

14.4 CRACKING DUE TO PIPE DEFLECTIONS

Cracks that are in excess of 1/16th inch in width and extend over 180 Deg circumferentially around the

pipe or longitudinal cracks over 12 inch in length shall be repaired.

Repair shall be done by chiseling the crack out to a width not less than 1 inch throughout length upto

coating thickness. The crack shall be repaired with materials similar to form with coating materials.

15.0 MARKING

15.1 Every concrete coated pipe length shall be clearly marked by a suitable type of paint (i.e., red and/or white

lead paint). Markings out of concrete coating shall be made inside of pipe close to bevel end, in such a way

that the area involved by welding operations is not affected by paint.

15.2 For each concrete coated pipe length, at one of the two ends, the field identification number and the date of

concrete placing shall be marked, while the dry as well as the wet weight along with number of days after

coating shall be marked at the other end.

CONCRETE WEIGHT

COATING

P.011974

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15.3 In addition, contract shall develop a colour coding (band) system to be marked on the outside surface for

easy identification of the pipe for each concrete coating thickness, concrete density, pipe diameter, pipe

thickness and pipe materials variation.

16.0 UNLOADING, TRANSPORTATION, STORING AND HAULING

16.1 During loading, transport, unloading and hauling of inert aggregates, any contact and mixing with mud,

earth, grease and any other foreign material shall be carefully avoided. Precautions shall be taken to

prevent contamination, to maintain the cleanliness and against effects of hot or cold weather or other

adverse climatologically condition.

16.2 During the operations of loading, unloading and stock-piling, the pipe sections shall be handled in such a

way so as to avoid damages to pipe ends, protective and/or concrete coating.

16.3 Stacks shall consist of a limited number of layers such that the pressure exercised by the pipes' own Weight

does not cause damages to coating. Stacking with more number of layers shall be agreed upon with the

Owner / Owner’s representative provided that each pipe section is separated by means of spacers suitably

spaced so as to avoid stresses and compressed points of contact on the coated surface.

16.4 Once, the pipe sections have been on charge, the Contractor, complying with provisions on the contract,

shall execute their transport together with other materials, either supplied by him or be the company, from

the site of receipt of the coating yard and after concrete coating completion and acceptance, to delivery

point at laying field or storage areas as previously established providing each time the necessary storages.

16.5 Materials other than pipes and which are susceptible of deteriorating or suffering from damages especially

due to humidity or other adverse weather conditions, shall be suitably stored and protected.

∑ ∑ ∑

INTELLIGENT PIGGING P.011947

D 11097

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PTS - INTELLIGENT PIGGING (ILI)

DOC. NO : P.011974 D 11097 104

0 01.05.2018 Issued for Procurement BP PP SKH



D 11097

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TABLE OF CONTENTS

1.0 INTRODUCTION .................................................................................................................... 1

2.0 TECHNIQUE FOR INTELLIGENT PIGGING ............................................................................. 1

3.0 CODES AND STANDARDS ...................................................................................................... 1

4.0 PIG VELOCITY ....................................................................................................................... 1

5.0 PRE-INSPECTION ACTIVITY ................................................................................................. 2

6.0 PULL THROUGH TEST ............................................................................................................ 2

7.0 INSPECTION PIG RUN........................................................................................................... 3

8.0 PIG TRACKING ...................................................................................................................... 4

9.0 CONTINGENCY WORKS ......................................................................................................... 4

10.0 DEFECT SIGNIFICANCE ......................................................................................................... 5

11.0 MAPPING TOOL SPECIFICATIONS ........................................................................................ 6

12.0 ACTION DURING ABNORMAL SITUATIONS .......................................................................... 6

13.0 PRELIMINARY REPORT AND DEFECT VERIFICATION .......................................................... 7

14.0 VENDOR DATA REQUIREMENT: ............................................................................................ 7

15.0 DATA ANALYSIS .................................................................................................................... 8

16.0 FINAL WORK REPORT ........................................................................................................... 8

17.0 REPAIR CRITERIA & TYPE OF REPAIR ................................................................................ 10

∑∑∑∑ ∑∑∑∑ ∑∑∑∑


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1.0 INTRODUCTION

The intent of this specification is to describe the requirements of the In-line inspection (ILI) by Intelligent

Pigging of the pipeline. The specification is not intended to be all-inclusive and the use of this specification

does not relieve the Contractor to his responsibility to carry out all activities successfully as defined in

Scope of WORK. This activity is to be carry out to obtain the valid, interpretable and physically verifiable

data from the intelligent pig runs about the condition of the pipeline.

The objective of Intelligent Pig inspection is to generate the Baseline Data using High Resolution Magnetic

Flux Leakage (MFL) technology immediately after commissioning and Gas-in activity has been

accomplished. Such Baseline Data will form the reference for all future operations and monitoring for PIMS

(Pipeline Integrity Management System).

Contractor shall deploy intelligent pigging survey agency as per Owner approved vendor list. The agency

must be duly approved by Owner prior to execution of intelligent pigging survey.

2.0 TECHNIQUE FOR INTELLIGENT PIGGING

2.1 Intelligent Pigging (In line Inspection i.e. ILI) should be carried out by the use of High resolution inspection

tool based on Magnetic Flux leakage (MFL) Technology.

3.0 CODES AND STANDARDS

Following relevant recommended practices /standards /specifications shall be used in conjunction with this

specification. In the event of conflict between any of the following specification/ standard or between any

standard and this specification, the more stringent shall apply.

4.0 PIG VELOCITY

Irrespective of the gas flow velocity, it is desired that MFL tool maintains the velocity which is required to

maintain accuracy specified in the specification for various defect categories. The minimum diameter

SR. NO. RECOMMENDED PRACTICES /STANDARDS /SPECIFICATIONS

(i) ASME B 31.8 : Gas Transmission and Distribution Piping systems

(ii) ASME B 31.8S : Managing System Integrity of Gas Pipelines

(iii) ASME B 31G: Manual for Determining Remaining Strength of Corroded Pipelines

(iv) ASME PCC-2 Article 4.2: Repair of Pressure Equipment and Piping

(v) PNGRB T4S Regulations : Technical standards and specification including safety standard

for natural gas pipelines

(vi) POF Document : Specifications and requirements for intelligent pig inspection of

pipelines, 2009

(vii) POF Document : Guidance on achieving ILI First Run Success, December 2012

(viii) POF Document : Guidance on Field Verification Procedures for In-Line Inspection,

, December 2012

(ix) API 5L: Specification for Line Pipe

(x) API 1104 : Welding Pipelines and Related Facilities

(xi) API STD 1163 : In-line Inspection Systems Qualification Standard

(xii) API 5T1: Standard on Imperfection Terminology

(xiii) DNV RP F101: Recommended practice for Corroded Pipelines

(xiv) ASNT ILI –PQ : In-line Inspection Personnel Qualification and Certification

(xv) NACE SP 0102-2010 : In-Line Inspection of Pipelines

(xvi) NACE Publication 35100 : 2000 : In-Line Non-destructive Inspection of Pipelines

(xvii) BS 3683 : Glossary of Terms used in Non-Destructive Testing

(xviii) BS 7910 : Guidance on methods of assessing the acceptability of flaws in fusion welded

structures

(xix) IS 15678:2006: Intelligent Pigging of Pressurized Natural Gas Pipelines – Code of practice.


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negotiable for MFL shall be 90% of minimum ID of the pipeline. Contractor shall be required to maintain

the velocities of different pigs in such a manner that normal flow through the pipeline while a particular pig

is traveling is not required to be altered.

5.0 PRE-INSPECTION ACTIVITY

Following activities are envisaged prior to running of high resolution intelligent pig. The sequence shown

here is indicative which may vary during execution as per agreed schedule between Owner and Contractor.

6.0 PULL THROUGH TEST

Contractor is required to pre-calibrate the inspection tools (Intelligent pig) perform the pilot/loop test at his

inspection Centre before mobilization of these inspection tools to site. Owner at its discretion reserves the

right to witness and / or to appoint its authorized agency to witness the above pre-calibration/pilot/loop tests

to ascertain the diagnostic capability, mechanical performance requirements, reliability etc. of the inspection

tools to be deployed at SITE. During pull through test, the Owner representatives shall be allowed to share

the technical information related to the Corrosion Detection Pig including test pipe data, tool velocity,

magnetization level achieved and metal loss inspection performance achieved during testing. However, it is

clearly and expressly understood by the Contractor that such association of the Owner for witnessing the

pre-calibration/pilot/loop tests shall in no way absolve the responsibility of the Contractor either for the

performance of the inspection tools or his obligations under the CONTRACT. Owner shall bear the

expenses of his representative /authorized agency related to travel, (to and fro) boarding, lodging and other

incidentals during the period of their stay for witnessing above tests of inspection the above tests of

inspection tools at the inspection Centre of the Contractor. Pull through test report for each size of

Corrosion Detection pig shall be submitted within seven days of performing the test. Test rig shall contain

external, internal and mid wall defects, change in wall thickness, girth welds, tap-off etc. For each size,

separate rig shall be used for calibration.

For internally coated pipes, adequate care shall be taken by using soft cups in such a manner so that no

damage takes place to the internal coating of the pipe.

A detailed procedure for pull through shall be submitted by the Contractor at least 3 months prior to actual

execution of pull-through test.

6.1. Procedure document and Operation Manual

Contractor shall submit operation manual for pigs and procedure document for execution of the field

activities for the pipeline before commencing the job for Owner/consultant approval.

6.2. Electronic Geometry (CALIPER) Pig run

Before commencement of Intelligent pig run, the activities related to calliper pigging shall have been

successfully completed as per guidelines mentioned in clause number 14.3.2 a) (PART-14) of PTS –

Construction of natural Gas Pipeline (document number P.011947 D 11097 101) and GTS- Construction of

Gas Pipeline and Accessories (Document number 70000/740/GTS/0502).

6.3. Magnet marker installation

Contractor to supply and install adequate numbers of permanent magnet markers at 1.0 (one) Km interval of

the pipeline irrespective of permanent pipeline installations. These permanent magnet markers shall not be

retrieved back after completion of inspection work and shall not be taken back by Contractor. These magnet

markers shall have adequate strength so the same shall be detected by high resolution inspection pig during

inspection. Installation of permanent magnet markers on the pipeline surface – without removing the

coating shall be done by Contractor, as per the Installation instructions to be provided by contractor.

Contractor to submit to the Owner the sketch containing reference of magnet marker location with respect

to permanent features/installation available in the vicinity.

The GPS coordinate of these markers shall be recorded in the pipe book.

6.4. Inspection Pre- Pig runs

Prior to launching of MFL tool, Contractor shall complete all activities required to establish piggability and

adequate cleanliness of pipeline to verify the internal geometry of the pipeline with relation to ovality, dent


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etc. and to ensure that internal bore restriction at any location does not exceed the limitation of proposed

tools to be used subsequently through adequate runs of Gauge pig, Cleaning pig and Electronic Geometry

pig.

MANPOWER

A team of API 1163/ASME 31Q/ASNT ILI-PQ qualified personnel having min. 5 years experience in

handling similar tool shall be deployed in the site. Data processing engineer should also be API

1163/ASME 31Q/ASNT ILI-PQ qualified with min. 5 years experience and shall be certified by the tool

owning agency or an independent certifying agency. List of personnel along with their level qualification

certificate shall be submitted to the Owner/Owner’s Representative.

Following qualified manpower shall be available with the service provider as minimum and required

personnel shall be mobilized as when required:

i. System engineer- 1 no,

ii. Tool Operator- 1 no (Level-II),

iii. Technician- 2 nos,

iv. Analyst- 2 nos (Level –III),

v. Sizing expert- 1no,

vi. NDT engineer- 1 no,

vii. Rectification expert – 1 no. (Level –III)

7.0 INSPECTION PIG RUN

7.1. Intelligent Pig Run

Upon successful completion of all preceding activities (foam, cleaning, gauging, caliper runs) and based on

their results Contractor shall intimate about his readiness for running the high resolution corrosion detection

pig/Intelligent pig (MFL tool). Owner shall indicate the exact time of launching the corrosion detection pig

in consultation with Contractor. MFL Tool along with its battery life shall be capable for a travel length of

200 Km at minimum, covering the entire length of the Pipeline.

Contractor in presence of Owner/Owner’s representative shall track the movement of intelligent pig right

from launching till receiving.

The intelligent pig should be capable of identifying the following anomalies/metal loss keeping in view the

defect significance detailed out at para 9.0 below:

� General Corrosion

� Pitting Corrosion

� Metal Loss ( internal & external)

� Circumferential Gauging (dent with gouge)

� Axial Gauging

� Axial and circumferential slotting

� Location of girth welds, valves, lateral joints

� Circumferential cracks

� Proximity of any ferrous object to pipeline

� Manufacturing defects

� Dent

� Estimated strain in dent as per ASME B 31.8 appendix R

� Metal loss in dents


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� Arc strike, Pin Holes

� Artificial defect

� Scabs, Slivers

� Buckle

� Corrosion cluster

� Grinding

� Girth weld crack

� Girth weld anomaly

� HIC (hydrogen induced cracking)

� Lamination

� Longitudinal seam weld crack

� Longitudinal weld anomaly

� Ovality Pipe mill anomaly

� Pipe mill anomaly cluster

� SCC (Stress Corrosion Cracking)

� Spiral weld crack (for HSAW Pipes)

� Spiral weld anomaly (for HSAW Pipes)

� Wrinkle, etc.

100% length of the pipeline shall be inspected by running MFL tool to generate valid and physically

verifiable data and submit the detailed report for the entire length.

MINIMUM TOOL SPECIFICATION

The maximum acceptable sensor loss (primary sensors) and / or data loss is 3% and continuous loss of data

from more than three adjacent sensors or 25 mm circumference (whichever is smallest) is not acceptable.

8.0 PIG TRACKING

The movement of any type of pig put into the line during pre-inspection or intelligent pigging shall be

required to be monitor along the pipeline length from launcher to receiver trap. The pig tracking system

should be capable of working under over head high voltage transmission lines. Contractor to engage a

tracking system which shall be able to detect pig passage in the existing pipe cover. The transmitter should

have adequate battery life so that stuck up pig can be located within reasonable time frame. The pig tracking

system should be capable of locating the stuck up pig in the range of ±15 Meter. Contractor shall detail out

the complete methodology of pig tracking proposed to be deployed by him including complete technical

details of the equipment and device proposed to be used for this purpose.

It is proposed that pig tracking would be done in a discrete manner generally at 2 to 3 KM interval at pre-

selected locations. The exact KM chainage of these locations shall be decided at site in consultation with the

Contractor and Owner.

Minimum parameters for tracking devices e.g. alarm (sound), time of detection & location of detection shall

be included.

9.0 CONTINGENCY WORKS

In the event of MFL tool getting stuck in the pipeline during pigging activity, all the necessary activities for

retrieval of MFL tool including cutting, pulling back in operation shall be in Contractor’s scope at no cost to

Owner.

A detailed procedure to be developed and submitted by the Contractor for approval before commencement

of ILI run.


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After retrieval of the pig, decision to continue with the next phase of activities shall be taken by Owner.

This may require the repetition of entire pigging operation once again without any extra cost to the Owner.

10.0 DEFECT SIGNIFICANCE

10.1 The following minimum information/performance is required for the MFL inspection.

10.2 The best accuracy offered and guaranteed by the Contractor for each category of defect shall be clearly spelt

out. Contractor must define the pitting corrosion, general corrosion, metal loss and the accuracy offered by

him in each case for.

10.2.1 The external or internal metal loss/mechanical defects shall be identified, discriminated, sized (L x B x D)

and suitably reported in a mutually agreed manner. The pig should be able to measure and indicate the X &

Y coordinates.

10.2.2 Inspection of entire length of each segment to be completed in one single run.

10.2.3 To check the effect of inter-active corrosion if a cluster of pits are identified close to each other, values of

L1, L2, ........W1, W2 .....shall be reported (refer sketch below) and the location of each pit cluster is to be

identified with reference to permanent pipeline feature.

10.2.4 Any metal loss in the heat affected zone of the weld should be specifically highlighted in the report but may

not be sized.

10.2.5 Definitions for anomalies and imperfections shall be as per following codes and standards:

� API 1163: In-line Inspection Systems Qualification Standard

� API 5T1: Standard on Imperfection Terminology

� ILI pipeline operator’s specification (POF documents)

10.3 Accuracy of Defects

The best accuracy offered and guaranteed by the Contractor for each category of defect should be clearly

spelt out. The Contractor must define the "pitting corrosion", general corrosion, metal loss and the accuracy

offered by him in each case for

a) Depth of metal loss,

b) Axial and circumferential location of metal loss

c) Length of metal loss

10.4 Confidence Level and Probability of Detection

The intelligent pig should have as a minimum, the following capabilities with 90%confidence level and

95% probability of detection (POD).

10.4.1 DETECTION CAPABILITY AND SIZING ACCURACY


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IDENTIFICATION/CHAR

TERIZATION DEFECTS

(METAL LOSS)

MINIMUM DETECTION

CAPABILITY OF DEPTH

AT 95% POD

SIZING ACCURACY AT 90%

CONFIDENCE LEVEL

DEPTH LENGTH & WIDTH

GENERAL CORROSION

( [W≥3t] AND [L≥3t] )

0.1t ± 0.1t ± 10 MM

PITTING CORRISION

A < 1t x 1t

B > 1t x 1t < 2T x 2t

C > 2t x 2t < 3t x 3t

DETECTABLE

0.4t

-------

± 0.2t

± 0.2t

-----

±t or ±15MM

WHICHEVER IS MORE

±t or ±15MM

WHICHEVER IS MORE

AXIAL GAUGING

[W≥3t] AND [L≥3t]

0.20t ± 0.20t ± 20 MM

CIRCUMFERENTIAL

GAUGING

W ≥ 3t

0.15t ± 0.15t ± 10 MM

L - AXIAL LENGTH OF DEFECT

W - WIDTH OF DEFECT

t - WALL THICKNESS OF PIPELINE

LOCATION ACCURACY

A AXIAL

WITHIN PIPE

FROM MARKER

± 20 MM

± (1.0 M)

B CIRCUMFERENTIAL ± 10 DEGREE

11.0 MAPPING TOOL SPECIFICATIONS

11.1 XYZ mapping data acquisition shall preferably be done concurrently with the ILI tool to get a three-

dimensional virtual computerized view of the entire pipeline so that navigation can be done along the virtual

pipeline and locate individual defects (with GPS coordinates) and other features of the pipeline.

11.2 Bidder shall provide the IMU tool / GPS tool specification and measurement specification.

11.3 Geographical locations shall be reported in GPS coordinates with following accuracy:

Minimum positional accuracy of Latitude/ Longitude/Elevation

at confidence of 1 σ (one sigma).

± 1.0m

Axial position accuracy from reference marker 1:2000

Survey accuracy shall be of following specification:

� XYZ sampling rate (at 2 m/s speed): 5mm

� Circumferential orientation accuracy: 0.5 degree

� Survey accuracy (at 2 m/s speed): 1:2000

12.0 ACTION DURING ABNORMAL SITUATIONS

The objective of this section is to write down foreseeable abnormal circumstances for taking appropriate

measures, should such a condition arise during implementation of project. Owner/consultant has foreseen

the following abnormal conditions. However, if the Contractor foresees any other abnormal condition, he is

free to mention.

a) TOOL FAILURE


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It is required to get valid interpretable and verifiable data for entire pipeline. In case, MFL tool fails to

perform in line inspection to generate valid data for of the pipeline, extra runs shall be carried out to get

valid and physically verifiable data without any additional cost and time implication to the Owner.

b) STUCK-UP TOOL

The Contractor shall detail out a contingency plan as proposed by him in case any of the pigs gets stuck

up. The plan shall identify procedure for exactly locating the stuck up pig, detail procedure for retrieval

of pig, equipment, including support facilities required to retrieve the pig. If pig does not move from

stuck up location, by any of suggested measure, Contractor shall be fully responsible for the same. In

this case Contractor shall submit the retrieval procedure to Owner for approval. All cost towards

retrieval off the stuck up tool shall be in account of the Contractor without any cost implication to the

owner. In this case Owner reserves the right to charge any loss due to stuck-up tool.

13.0 PRELIMINARY REPORT AND DEFECT VERIFICATION

Contractor on completion of the 100% MFL tool run, to furnish a preliminary inspection report indicating

all detected defects including external & internal metal loss, other defects/ anomalies, location of girth weld,

valves, lateral joints & tees sizing of defects, chainage of defects, circumferential location, distance from

magnet marker/pipeline feature, pipe joint length etc to enable the Owner to locate the defect in the field.

The preliminary inspection report shall also include information about the data quality, general pipeline

conditions and major observations during inspection.

The preliminary site report shall be submitted by the Contractor along with the typical data logs of ILI. In

the absence of valid and full data, repeat ILI run shall be carried out by the Contractor to generate valid and

physically verifiable data at no cost to Owner. Maximum 2 runs will be allowed for one tool. In case the

tool fails twice, a new tool after proper pull-through test shall be deployed within 4 weeks or as per the site

condition, failing which the Owner reserves the right to mobilize a new agency at the cost of the contractor.

The preliminary report shall be submitted within two days after the tools has been recovered and cleaned up.

Preliminary report featuring min. 10 features shall be submitted within 2 weeks of job completion.

All metal loss features having metal loss equal to or greater than 5% of wall thickness to be reported.

Minimum 10 nos. dig verifications shall be carried out by the Contractor for establishing the success of the

MFL run, which will be jointly decided by Owner and Contractor. Repeat run after rectification is not

required, if success run is established by dig verification.

All defects recorded by the High Resolution tool shall be reported in the Contractors report.

Contractor shall depute his expert to observe verification by NDT at verification sites for proving that field

log detected anomalies confirm to wall loss and sizing, including axial and circumferential positions and

defect sizing within the limits of tolerance as per provision of this specification. In case the verifiable

defects are not found on the pipeline, the permanent features such as valves, tees, bends, external weld

metal (copper) deposition, cathodic protection cable termination or any other feature on the pipeline

including permanent magnet location shall match in the field with the reported locations. Pipe tally should

match with earlier survey data of the pipeline segment.

In case of non compliance of these defects to the tender requirements, the run shall be considered as

unsuccessful.

14.0 VENDOR DATA REQUIREMENT:

Following information is required to be furnished in the documents:

a. Direction of magnetization (axial/circumferential) and polarity of magnetic field.

b. Required minimal magnetic field strength H in kA/m at the inner surface of the pipe to meet the given

POD and accuracy.

c. The magnetic field strength H in kA/m as function of wall thickness and pig speed & grade, at the inner

surface of the pipe.

d. Required minimal induced magnetic flux density B in Tesla in the pipe wall to meet the given POD and

accuracy.


D 11097

104


e. Nominal circumferential distance of ID/OD discriminating sensors (if present)

15.0 DATA ANALYSIS

Owner shall participate in the analysis of the recorded data together with the engineering and other

personnel of Contractor. This analysis shall be carried out at Contractor's Analysis Centre to achieve the

following objectives:

i. To identify the locations of internal or external defects likely to jeopardize the normal safety and

operation of the pipeline.

ii. To arrive at general methodology of repair to be followed.

iii. Short-term measures to be taken in view of potentially hazardous defects, if found in any of the

pipelines.

Contractor shall provide all raw and processed data and his software package along with his compatible

hardware. The software package shall be user friendly.

16.0 FINAL WORK REPORT

The BIDDER shall include in his offer the most appropriate reporting procedure envisaged for the subject

pipeline.

The Owner has proprietary rights on the data acquired as part of this contract. Data thus acquired as part of

this contract shall not be copied, divulged or shared to third parties. The data as part of preliminary or final

reporting in all its forms either soft copies or hard copies shall be handed over to Owner only.

However, any reporting system shall include but not limited to the following:

- Preliminary site report for each pipe segment for each running of foam, cleaning, caliper, intelligent pig

(MFL) runs stating comments/observations of each run, pig condition, operating parameters and total

time required shall be submitted within two days.

Final report submission within 6 weeks or each pipe segment for each running of MFL tool.

- The Contractor shall make an assessment of the inspection data and Pipeline integrity using ASME

B31.8 and DNV RP F101 criterion and shall report the following:

I. Recommended safe Maximum Allowable Operating Pressure (MAOP) for pipeline surveyed.

II. Provide a list of the repair of defects, if any, carried out to operate the pipeline within the acceptable

and safe limits.

- A detailed report in respect of each pipe segment of running each of the pre-inspection Tool such as

cleaning pig, caliper pig.

- A detailed report on the geometry survey of each pipeline segment incorporating the

following supplemented with raw/processed data logs.

III. List of installations

IV. List of Significances with

• Feature information

• Feature type

• Feature description

• Feature log Distance

• Feature Clock orientation

• Feature length

• Feature depth (Change in ID)

V. Installation references

• Distance form next Installation

• Installation Distance


D 11097

104


• Installation type

- High Resolution tool (1) Velocity (2) Acceleration Plot

- Temperature Plot along the pipeline.

- Survey Log and enlargement areas of special interest

- Histogram showing summary, features report with maps etc, of metal corrosion distribution vs.

distance along pipeline shall include the following:

a) Total metal loss against distance of pipeline in KM.

b) General Metal loss against the distance of pipeline in KM.

c) Pitting Metal loss against distance of pipeline in KM.

d) Metal loss orientation plot against distance of pipeline in KM.

- ERF sentence plot (Pressure sentence plot) (Wall loss Vs feature length showing pressure ISO bar

- Recommend safe MAOP against detected defects of pipeline surveyed.

- Detailed report about running of the intelligent pig including but not limited to the operational and

functional details.

- Details describing the type, size, internal/external discrimination and location of individual metal

loss defects. The location and orientation of each defect should be suitably listed with reference to

permanent pipeline features, girth weld no., relative and absolute distance and severity of the

defect.

- List of anomalies and the pipe tally shall be compatible with excel files.

Details regarding ovality /misalignment defects

- A detailed report in respect of each defect for which sizing has to be done indicating its

length, width, depth, axial and circumferential location suitably referenced.

- Depth based feature distribution against pipe length of all metal loss features. All metal loss

features having metal loss greater than 5% to be reported.

- Severity analysis for all metal loss features having metal loss greater than 20% for all

detected features. -Individual evaluation feature report in great detail for 10 nos. significant metal

loss features of each segment.

- Plot of the magnetic field strength H in kA/m over the length of the pipeline measured at the inner

surface of the pipe.

- Suitable histograms between absolute distance of pipeline and no. of defects.

- Report on inter-active corrosion due to clustering of pits.

- Proximity of any ferrous objects to pipeline.

- Velocity and Temperature plot of MFL tool along the length of the segment.

- The format and pro forma of the above report shall be mutually agreed upon between the

successful BIDDER and Owner. All data to be given in graphical and Microsoft Excel format. All

the formats/ softwares used / software outputs to be in line with ‘PODS’ stipulations. List of

anomalies and the pipe tally shall be compatible with excel files.

REPORTING OPTIONS

The Contractor shall offer standard high resolution final report format based on ASME B31.8 code and

DNV RP F101 code. Contractor can also offer other codes (e.g RSTRENG) for calculation of the ERF

options and that is subject to Owner agreement/approval. Additionally Contractor shall determine bend

angle, bend radius or orientation of bends.

Details of repair criteria & type of repair for metal loss (isolated pitting), Metal loss

(General/gouging/slotting type) for both internal and external defect, weld defects, dent with gaouges

etc. shall also be part of the report.

- All the data generated by the Contractor shall be compiled in four copies of bound volume. All


D 11097

104


raw and final processed inspection logs along with the operating software necessary for

review/analysis of data shall also be submitted in 4 nos. CDs (master copy including copy). This

is required to facilitate selection of significant defects, their chainage and sizing. The software

should be user friendly. Compatible software data viewing shall be provided. This is required to

facilitate selection of significant defects, their chainage and sizing.

The software package as well as the data (database and raw data) shall be submitted only on the

best archive quality optical media (CD/DVD).

17.0 SUMMARY OF MAPPING TOOLS

The XYZ Mapping component of tool along with other data including geodetic survey, geometry and ILI

tool run data shall be capable for generating the following as a minimum:

� GIS compatible XYZ mapping information along with GPS co-ordinates of Marker locations,

Valves, Tees, Pipe welds and Features.

� REPORTS with XYZ coordinates of all items

� List of installations

� List of bends

� List of geometric anomalies

� List of GPS – marker / reference points

� XYZ coordinates of the pipe centerline

� XYZ coordinates of girth welds, valves, bends and other installations

� Bend information (angle, direction and radius)

� XYZ coordinates of anomalies (dents, ovalities “out of roundness”).

� Elevation Plot generated for XYZ mapping data.

� Plot of Pipeline on Google Earth or Maps /other equivalent mapping service using the XYZ mapping

information furnished.

The final report to be submitted by the Contractor should be in a format which is compatible to the PODS

so the same can be used by the other piping Contractor to be engaged in future for the same pipeline.

18.0 REPAIR CRITERIA & TYPE OF REPAIR

For all types of metal loss less than 10% (< .1 t) of nominal wall thickness and imperfections do not

encroach on the minimum permissible wall thickness no repair/rectification is required.

For metal loss of 10% and above, repair criteria and types of repair are as following:

A) Metal loss (Isolated pitting)

a) Internal pitting / external pitting

If depth of metal loss is within 10-20% of nominal wall thickness, full encirclement reinforcement

composite material sleeve to be installed as per ASME PCC-2 / BS EN ISO 24817 : 2015.

b) If depth of metal loss within 20 to 40% of nominal wall thickness; Clock Spring® permanent repair to

be carried out to the satisfaction of the Owner.

c) If depth of metal loss greater than 40% of nominal wall thickness; replacement of defective area

shall be carried out by new spool piece; with minimum 6 m long pretested pipe.

After shutdown, depressurization and isolation of the gas from the defective area, the section containing

the defect is removed as a cylinder and replaced. The replacement pipe section shall have strength that of

the pipe it replaces. The replacement pipe section shall be hydro tested before being connected to the

pipeline. The replacement pipe sections should be welded to the pipeline and inspected.

B) Metal loss (General/gouging/slotting type for both internal and external defect)

If depth of metal loss is within 10-20% of nominal wall thickness and length of defect is within 250mm, full


D 11097

104


encirclement reinforcement composite sleeve repair to be carried out as per ASME PCC-2 / / BS EN ISO

24817 : 2015.

Clock Spring® repair to be carried out, if depth of metal loss is within 10-20% of nominal wall

thickness and length of defect is greater than 250mm to the satisfaction of the Owner

Clock Spring® repair to be carried out, if depth of metal loss is within 20-40% of nominal wall

thickness; to the satisfaction of the Owner.

Replacement of defective area by new spool pre tested piece of 6 m minimum length to be carried out,

if depth of metal loss is greater than 40% of nominal wall thickness, whatever the length of the defect is.

C) Weld Defects

Replacement of defective area by new spool piece to be carried out, for all weld defects/ anomalies

identified during ILI including HIC and SCC, irrespective of the defect size.

D) Dent with Gouge

Replacement of defective area by new pipe to be carried out, for all dent with gouge identified during

pigging; irrespective of the defect size.

Owner shall associate its representative(s) and representative(s) of its Consultant at the ILI agency’s data

analysis center during final data analysis of the ILI results at their own expenditure at their

discretion. The analysis shall consist of following as a minimum.

a) Identification of all pipeline permanent features e. g. girth welds, valves, tees, sleeves, welds,

permanent magnet markers, external weld metal depositions (such as for cathodic protection cable

terminations)etc.

b) Potentially hazardous anomalies / mechanical anomalies including circumferential gouging, axial

gouging etc. affecting structural integrity of the pipeline.

c) Three-dimensional defect sizing (depth, length & circumferential width) for all "significant defects"

(defects ≥ 5% metal loss), grading of defects, differentiation between external and internal defects and

also differentiation between corrosion defects and mechanical defects.

d) Report on metal loss due to clustering of pits.

e) Preparation of final processed inspection logs and preparation of complete work report giving

interpretation of the inspection logs and giving defect sizing due to metal loss and mechanical damage

and their gradation.

f) Providing all the raw and processed data along with the software package for enabling

Owner/Consultant to study the data, if required. The software shall be user friendly and shall be

capable of operating in windows platform.

g) Magnetic strength graph to be submitted for entire length of pipeline as one of the criteria for

establish the success of the MFL tool run and for review and acceptance. The same shall be

verified during pull through and tool run. The value shall not be greater than the specified value.

h) Contractor shall demagnetize the pipeline at no extra cost to Owner if applicable and required

∑ ∑ ∑


D 11097

104


ANNEXURE-I

PROFORMA FOR HIGH RESOLUTION MFL INSPECTION PIG DETAILS

DIAMETER OF HIGH RESOLUTION MFL TOOL: ____

Sr.

No.

Description Bidders Details or

Yes/

1.0 Bidder to confirm that the MFL inspection tool is of High

Resolution tool

YES

/NO

2.0 Bidder to confirm that the HR MFL inspection tool is owned

by him

YES

/NO

3.0 Wall thickness range in MM

4.0 Magnetization level to be achieved in the different pipe thickness.

OR Enclose graph indicating relationship

between magnetic field strength and wall thickness

5.0 A Speed range in m/s for data generation as per bid

specification.

6.0 b Maximum speed m/s at which the tool can be operated.

7.0 Device if proposed for pig speed control to achieve valid,

interpretable and quality data as per detection and

Sizing specifications of tender document.

8.0 Temperature range

9.0 Maximum pressure

10.0 Minimum pressure for gas pipelines

11.0 Weight of tool

12.0 Number of Modules of tools and total tool length

13.0 Bend radius able to negotiate

14.0 Capability of inspecting Maximum length in single run

15.0 Axial sampling rate (frequency or distance)

16.0 Circumferential sampling rate

17.0 Total number of primary sensors

18.0 Total number of secondary sensors

19.0 Data storage capacity

20.0 Battery life

21.0 Maximum limit on adjacent sensors damage during the run in order

to generate data as per bid specification.

22.0 Maximum % of primary and secondary sensors damage permissible

during the run in order to generate the data as per bid specification.

23.0 Minimum % of ID that the MFL inspection pig pass without

damaging pig and pipe

24.0 Capability to identify following as a minimum

24.1 General corrosion YES

24.2 Pitting corrosion YES

24.3 Circumferential gouging YES

24.4 Axial gouging YES

24.5 Location of girth weld, valves and lateral joints YES


D 11097

104


24.6 Circumferential crack YES

24.7 Proximity of any ferrous object to pipeline YES

24.8 Manufacturing defects YES

24.9 CAPABILITY OF MFL INSPECTION TOOL

25.0 Axial accuracy of locating defect from reference marker/pipeline

25.1 Axial accuracy of locating defect within pipe from upstream weld p

25.2 Circumferential Accuracy

25.3 shall be able to discriminate between external & YES

25.4 Able to size (LXBXD) all defects having depth 0.10t and more in YES

25.5 shall be able to detect minimum 0.10 t wall thickness loss with an YES

25.6 shall be capable of completing the intelligent pigging in one YES

25.7 Any other specific information

26.0 Schematic sketch of HR MFL inspection tool. YES

/NO

∑ ∑ ∑

PTS-WARNING TAPE P.011947

D11097

105

ONGC BANTUMILLI TO ULLAMPARU PIPELINE KG

BASIN


PTS - WARNING TAPE

DOC. NO. P.011947 D 11097 105

0 01.05.2018 Issued for Procurement SK SKH BK

Rev. Date Description Prepared by Checked by Approved by


D11097

105

Rev. 0 ONGC Bantumalli to Ullamparru Pipeline Project Page 1 of 1

TABLE OF CONTENTS

1.0 INTRODUCTION & SCOPE ..................................................................................................... 1

2.0 DEFINITIONS ........................................................................................................................ 1

3.0 REFERENCE CODE ................................................................................................................. 1

4.0 FEATURES .............................................................................................................................. 1

5.0 QUALITY ASSURANCE (QA) ................................................................................................... 3


D11097

105


1.0 INTRODUCTION & SCOPE

This specification is applicable for warning tape installation on pipeline. This document covers the

technical specifications for the procurement of Warning Tape. Warning Tape shall be laid on the ground

above the gas pipeline (main line) in order to indicate their presence.

2.0 DEFINITIONS

Client shall mean GAIL (INDIA) LIMITED

Manufacturer means the Manufacturer of the warning tape well as its sub contractor(s).

PTS means the present <<Particular Technical specification

P.011947/D11097/004>> and all its appendices, if any.

EPC Contractor/Contractor The party which carries out all or part of Engineering, Procurement,

Construction, Pre-commissioning & Commissioning of the project. It

shall mean EPC Contractor in the present context.

Third Party

Inspection Agency (TPIA) means the Inspection Agency to be appointed by the EPC contractor

Consultant /Owner Shall means TRACTEBEL Engineering Pvt. Limited /

Representative The entity of the Client or the company nominated by the Client to

design the natural gas transport or distribution system and to specify the

equipment

3.0 REFERENCE CODE

EN 12613 – Plastics warning devices for underground cables and pipelines with visual characteristics

4.0 FEATURES

4.1. Material

Warning Tape, Type 1 as per EN 12613 shall be used for the BORERI TO CFCL-III, GADEPAN

PIPELINE PROJECT

The material of Warning Tape shall be Virgin warning tap material shall be of High Density Polyethylene

& Non-Bio degradable type. It shall have Non- Toxic & Anti -Rodent Properties. with warning sticker /

stamp. The material shall be having the density between 940 to 0.958 kg/m3 at 27 deg. Celsius as per IS

7328.

The tape shall be uniform in colour, texture and finish and shall be free from holes and foreign materials.

Rodent repellent chemicals to be added to the plastic master batch for protection against rodents.

The material and colour, if used, for printing shall have no detrimental effects on the environment.

4.2. Mechanical properties

Mechanical properties of the Warning Tape (Type I) shall be in accordance with the code EN 12613.

Minimum tensile withstand load in longitudinal direction shall not be less than 200 N. The test piece shall

not exhibit a reduction of more than 20% of its width after removal of the specified load.

4.3. Colour

The Warning Tape shall be of golden yellow colour with letters printed in red of indelible type with high

abrasion resistant. This colour must not take any alteration in the course of time.

4.4. Dimensions

Warning Tape shall have following dimensions:


D11097

105


Width 500 ± 5 mm

Thickness 0.5 mm (Minimum)

Negative tolerance on the thickness is not allowed.

4.5. Marking

4.5.1. The warning tape shall be marked at intervals not exceeding 1 meter. Marking on the tape shall be

approved by owner. The marking shall be legible and durable. The warning tape must be printed with

“Caution: High Pressure Gas Pipeline Below” in both English and Hindi language, Chainage marking

along with Owner’s logo and Owner’s 24 Hours Emergency Number -----------------, ----------------- at a

frequency of every meter. In addition, name or trademark of the manufacturer, year of manufacture and

reference of code of manufacture of warning tape shall be included in the marking.

4.5.2. Vendor shall submit proposed Artwork to be marked on the Warning Tape for approval from Owner /

Owner’s representative.

4.6. Tests

All the tests and test procedures for Warning Tapes shall be as per EN 12613 or as per required National/

International standards mentioned in EN 12613. In addition, all requirements pertaining to statutory

requirements, if any, as specified from time to time shall be complied.

The required tests are briefed as below:

4.6.1. Colouring

Three separate tests shall be carried out in accordance with:

• As per normative annexure B of EN 12613, using 20% ammonium sulphide.

• As per EN ISO 175, using 10% nitric acid & 20% sodium carbonate solution.

The tests shall be repeated for each colour (if any).

There shall be no discolouration or change of the initial colour of the warning tape after the tests.

4.6.2. Tensile Withstand Strength

The test sample shall be selected as mentioned in EN 12613. The test samples shall be preconditioned for

not less than 12 h at 23±2 o C. Static loads shall be carried out to the samples over a period of 10 s.

After the test, the test piece shall withstand without starting to separate at weak points (if any) for not less

than 5 minutes. Also it should no exhibit a reduction of more than 20% of its width after removal of

specified load.

The minimum tensile withstand load for the warning tape in the longitudinal direction shall be not less than

200 N.

4.6.3. Visual Warning Characteristics

The test shall be carried out in accordance with normative Annexure A of EN 12613.

4.6.4. Permanence of Printing

The test shall be performed as per CL. 9.3 of IEC 60898:1995.

The test is made by rubbing the marking by hand for 15 sec with a piece of cotton soaked with water and

again for 15 sec with a piece of cotton soaked with aliphatic solvent hexane with a content of aromatics of

max. 0.1% by volume, a kauributanol value of 29, an initial boiling point value of approx. 65oC, a dry

point of approx. 69oC and a density of approx. 0.68 gm/cm3.

After the test, the marking shall be easily legible.

4.6.5. Test of laying Characteristics

The test is for the assessment of transverse rigidity of the warning tapes.

2


D11097

105


The test shall be performed as per EN 12613.

4.6.6. Warning Tape Virginity Test

Differential Scanning Calorimeter (DSC) Scan test along with the temperature of melting (Tm) shall be

performed for the Warning Tape and its raw polymer i.e. virgin low density polyethylene (LDPE).

The Differential Scanning Calorimeter (DSC) Scan curve of the Warning Tape obtained from its DSC Scan

test along with its Temperature of Melting (Tm) shall then be compared with the DSC Scan curve and the

Temperature of Melting (Tm) of its raw polymer (i.e. virgin LDPE).

To ensure the virginity of the Warning Tape, the DSC Scan curve and Tm of the Warning Tape (finished

product manufactured from the raw polymer) shall match on overlapping with its corresponding raw

polymer’s DSC Scan curve and Tm.

4.7. Packing

The warning tape shall be delivered in rolls of minimum 50 meters. Packing size to be mentioned to ensure

uniformity in delivery conditions of the materials being procured. Bidder shall submit the packing details

during offer and also compiled with at the time of delivery. Packaging of the Warning Tapes shall be such

that there won’t be any deterioration due to Ultraviolet (UV) effect during transportation and storage of the

Warning Tapes prior to use.

5.0 QUALITY ASSURANCE (QA)

Manufacturer shall prepare detailed Inspection Test Procedure (ITP) and submit for approval from Owner /

Owner’s representative.

LIST OF CROSSINGS P.011947

D 11097

107

GAIL (INDIA) LIMITED

BANTUMILLI TO ULLAMPARU PIPELINE PROJECT KG

BASIN


LIST OF CROSSINGS

DOC. NO. : P.011947 D 11097 107

0 01.05.2018 Issued for Procurement BP PP SKH


Center line Chainage In

(M)

(As per Alignment Sheet) Start ChainaHe (M) End ChainaHe (M)

1 CS-01 Asphalted Road ( From NaHodupalom - To SH-113 ) AR 3 419.97 416.07 424.33 419.97 8.26 HAIL-BUPL-ALN-001

2 CS-02 Kommatippa Branch Channel LC 3 2896.92 2884.52 2916.53 2896.92 32.01 HAIL-BUPL-ALN-002

3 CS-03 Asphalted Road (From Kotha Pusalamarru - To SH-113 ) AR 3 5193.38 5188.26 5198.09 5193.38 9.83 HAIL-BUPL-ALN-003

4 CS-04 Enamadurru Channel LC 3 6790.22 6776.42 6804.16 6790.22 27.74 HAIL-BUPL-ALN-004

5 CS-05State HiHhway-113 ( From Kalipatnam - To Bhimavaram

)SH 3 7008.66 7003.21 7017.88 7008.66 14.67 HAIL-BUPL-ALN-005

6 CS-06 Uppukodu Drain DR 3 7327.93 7289.51 7364.83 7327.93 75.32 HAIL-BUPL-ALN-005

7 CS-07 Unlined Drain DR 3 8036.21 8032.31 8039.81 8036.21 7.50 HAIL-BUPL-ALN-005

8 CS-08 Asphalted Road ( From Bhimavaram - To Dirusumarr ) AR 2 9116.55 9110.06 9122.21 9116.55 12.15 HAIL-BUPL-ALN-006

9 CS-09 Metalled Road ( From Enamadurru - To Chinna Haruvu ) MR 2 9447.81 9443.91 9451.27 9447.81 7.36 HAIL-BUPL-ALN-006



12 CS-12 Hunupudi Drain DR 2 10792.05 10765.61 10817.13 10792.05 51.52 HAIL-BUPL-ALN-007


14 CS-14 Metalled Road ( From Field - To Yamunepalle ) MR 1 12141.63 12133.55 12145.27 12141.63 11.72 HAIL-BUPL-ALN-007

15 CS-15Matsyapuri Road(ASP) ( From Bhimavaram - To

Matsyapuri )AR 1 12679.33 12672.20 12687.07 12679.33 14.87 HAIL-BUPL-ALN-008

16 CS-16 Vissakoderu Channel LC 1 13099.62 13094.33 13107.55 13099.62 13.22 HAIL-BUPL-ALN-008


18 CS-18 Vissakoderu Channel LC 1 14333.74 14313.34 14367.50 14333.74 54.16 HAIL-BUPL-ALN-009


20 CS-20Asphalted Road ( From HoraHanamudai - To

Bhimavaram EnH.Co )AR 3 16489.16 16479.62 16523.93 16489.16 44.31 HAIL-BUPL-ALN-010

21 CS-21 Tallikodu Channel LC 3 16509.76 16479.62 16523.93 16509.76 44.31 HAIL-BUPL-ALN-010

22 CS-22South Central Railwa ( From Bhimavaram RS - To

Pennadapalem RS(N )RY 4 16921.24 16901.02 16944.51 16921.24 43.49 HAIL-BUPL-ALN-010

23 CS-23 Unlined Channel ULC 3 17559.95 17551.75 17577.68 17559.95 25.93 HAIL-BUPL-ALN-011

24 CS-24 Metalled Road ( From Pennadapalem - ) MR 3 17800.04 17796.09 17802.66 17800.04 6.57 HAIL-BUPL-ALN-011

25 CS-25National HiHhway-65 ( From Bhimavaram - To

Viravasaram )NH 3 18085.64 18080.60 18091.76 18085.64 11.16 HAIL-BUPL-ALN-011

26 CS-26 Unlined Channel ULC 1 19707.32 19702.49 19715.03 19707.32 12.54 HAIL-BUPL-ALN-012

27 CS-27 Metalled Road ( From Vendra - To Pennada )R MR 1 19711.36 19702.49 19715.03 19711.36 12.54 HAIL-BUPL-ALN-012

28 CS-28 Metalled Road ( From FishPond - To Pennada ) MR 1 20198.53 20195.05 20226.87 20198.53 31.82 HAIL-BUPL-ALN-012

Cross Section

No.Drawing Title

Type of

Crossing

Width of Crossing In

(M)Ref AliHnment DrawinH No.

AR=Asphalted Road, BR=Brick Road, CT=Cart Track, DR=Drain, EW=Express Way, LC=Lined Canal, MDR=Mejor District Road, MR=Metal Road, MUR=Mud Road, NH=Netional HiHhway, NL=Nala, ODR=Other Distric Road, OR=Other Road, RCC=RCC

Road, RI=River, RY=Railway, SH=State HiHhway, ST=Stream, ULC=Unlined Canal, UMR=Unmetal Road, VR=VillaHe Road, WBM=Bitumen Road

Class

Crossing Chainage Details

(As per Alignment Sheet)

Sr. No.

Design Cumulative

Chainage

(Starting from

Bantumilli)

Rev. 0 - 01.05.2018 Page 1 of 6


(M)


Cross Section

No.Drawing Title

Type of

Crossing





Class



Sr. No.

Design Cumulative

Chainage

(Starting from

Bantumilli)

29 CS-29 Adarikodu Channel LC 1 20212.57 20195.05 20226.87 20212.57 31.82 HAIL-BUPL-ALN-012

30 CS-30 Viravasaram West Channel LC 1 20539.37 20526.53 20550.76 20539.37 24.23 HAIL-BUPL-ALN-012

27 CS-27 Field Chanal FC 1 15725.56 15721.50 15726.80 21858.48 5.30

26 CS-26 Asphalted Road AR 1 15718.75 15715.40 15721.50 21865.29 6.10

25 CS-25 Asphalted WBM Road AR 1 14490.12 14487.04 14496.34 23093.92 9.30

24 CS-24 Field Chanal FC 1 13862.96 13852.60 13865.67 23721.08 13.07

23 CS-23 Field Chanal FC 1 13348 13340.00 13351.73 24236.04 11.73

22 CS-22 Canal ULC 1 11946.36 11940.82 11950.60 25637.68 9.78

21 CS-21 Unined Canal ULC 1 11932.24 11917.06 11940.82 25651.80 23.76


19 CS-19 Basavarajukodu Drain DR 1 10588.26 10563.45 10633.44 26995.78 69.99

18 CS-18 Gonteru Drain DR 1 9793.9 9757.74 9824.00 27790.14 66.26




14 CS-14 Drain-Rapaka Channel-drain ULC 3 7842.37 7830.95 7852.74 29741.67 21.79


12 CS-12 RCC Road RCC 3 6146.21 6131.74 6155.80 31437.83 24.06


10 CS-10 RCC Road RCC 3 5720.61 5711.65 5724.05 31863.43 12.40

9 CS-09 Koderu No.1 Branch Canal ULC 3 5475.26 5467.56 5481.81 32108.78 14.25


7 CS-07 BhaHHeswae Drain DR 2 4158.91 4141.30 4176.39 33425.13 35.09


5 CS-05 Jnnuru Unlined Channel ULC 3 2792.01 2780.59 2802.38 34792.03 21.79


3 CS-03 MOHALLURU DRAIN DR 3 1987.41 1971.68 2005.75 35596.63 34.07

2 CS-02 Narsapur Unlined Canal ULC 3 689.73 36894.31

Rev. 0 - 01.05.2018 Page 2 of 6


(M)


Cross Section

No.Drawing Title

Type of

Crossing





Class



Sr. No.

Design Cumulative

Chainage

(Starting from

Bantumilli)

1 CS-01 SH-41 SH 3 669.75 658.47 717.16 36914.29 58.69

Rev. 0 - 01.05.2018 Page 3 of 6

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LEGEND:- B=BORING, C=CASSING, CC=COCRETE COATING, CS=CS CONDUIT CASING, OC=OPEN CUT, UC=UNCASED, COS=CONCRETE SLAB, HDD=HORIZONTAL DIRECTIONAL DRILLING, TB=THRUST BORING

Total Length in Metres 485.11 189.38 581.28 43.49 600.00 252.00 - - - 1,150.00 - 363.00 446.00 275.00 45.00 -

CS-01 Asphalted Road ( From NaHodupalom - To SH-113 )HAIL-BUPL-CS-

001AR 3 419.97 416.07 424.33 - - 8.26 - - - - OC+COS 1.5 - - 9.00 - - -

- - - - - - - - - - - - -

Total Length - - 8.26 - - - - - - 9.00 - - -

CS-02 Kommatippa Branch ChannelHAIL-BUPL-CS-

002LC 3 2896.92 2884.52 2916.53 - - 32.01 - - - - B+C 1.5 - - - - 34.00 -

- - - - - - - - - - - - -

Total Length - - 32.01 - - - - - - - - 34.00 -

CS-03 Asphalted Road (From Kotha Pusalamarru - To SH-113 )HAIL-BUPL-CS-

003AR 3 5193.38 5188.26 5198.09 - - 9.83 - - - - OC+COS 1.5 - - 10.00 - - -

- - - - - - - - - - - - -

Total Length - - 9.83 - - - - - - 10.00 - - -

CS-04 Enamadurru ChannelHAIL-BUPL-CS-

005LC 3 6790.22 6776.42 6804.16 - - 27.74 - - - - B+C 1.5 - - - - 30.00 -

- - - - - - - - - - - - -

Total Length - - 27.74 - - - - - - - - 30.00 -

CS-05 State HiHhway-113 ( From Kalipatnam - To Bhimavaram )HAIL-BUPL-CS-

007SH 3 7008.66 7003.21 7017.88 - - 14.67 - - - - B+C 1.5 - - - - 17.00 -

CS-06 Uppukodu DrainHAIL-BUPL-CS-

008DR 3 7327.93 7289.51 7364.83 - - 75.32 - - - - OC 1.5 - - - 77.00 - -

CS-07 Unlined DrainHAIL-BUPL-CS-

009DR 3 8036.21 8032.31 8039.81 - - 7.50 - - - - OC 1.5 - - - 10.00 - -

Total Length - - 97.49 - - - - - - - 87.00 17.00 -

CS-08 Asphalted Road ( From Bhimavaram - To Dirusumarr )HAIL-BUPL-CS-

010AR 2 9116.55 9110.06 9122.21 - 12.15 - - - 24.00 - OC+COS 1.5 - - 13.00 - - -

CS-09 Metalled Road ( From Enamadurru - To Chinna Haruvu )HAIL-BUPL-CS-

011MR 2 9447.81 9443.91 9451.27 - 7.36 - - - 12.00 - OC+COS 1.5 - - 8.00 - - -


012DR 2 10193.9 10178.93 10202.12 - 23.19 - - - 24.00 - OC 1.5 - - - 25.00 - -

Total Length - 42.70 - - - 60.00 - - - 21.00 25.00 - -


013DR 2 10607.36 10601.81 10615.19 - 13.38 - - - 24.00 - OC 1.5 - - - 15.00 - -

CS-12 Hunupudi DrainHAIL-BUPL-CS-

014DR 2 10792.05 10765.61 10817.13 - 51.52 - - - 60.00 - OC 1.5 - - - 54.00 - -


015DR 1 12136.13 12133.55 12145.27 11.72 - - - 12.00 - - OC 1.5 - - - 14.00 - -

CS-14 Metalled Road ( From Field - To Yamunepalle )HAIL-BUPL-CS-

016MR 1 12141.63 12133.55 12145.27 11.72 - - - 12.00 - - OC+COS 1.5 - - 12.00 - - -

Total Length 23.44 64.90 - - 24.00 84.00 - - - 12.00 83.00 - -

CS-15Matsyapuri Road(ASP) ( From Bhimavaram - To

Matsyapuri )

HAIL-BUPL-CS-

017LC 1 12679.33 12672.2 12687.07 14.87 - - - 24.00 - - B+C 1.5 - - - - 17.00 -

CS-16 Vissakoderu ChannelHAIL-BUPL-CS-

018LC 1 13099.62 13094.33 13107.55 13.22 - - - 24.00 - - B+C 1.5 - - - - 15.00 -

Total Length 28.09 - - - 48.00 - - - - - - 32.00 -


019DR 1 14208.73 14204.9 14212.15 7.25 - - - 12.00 - - OC 1.5 - - - 9.00 - -

CS-18 Vissakoderu ChannelHAIL-BUPL-CS-

020LC 1 14333.74 14313.34 14367.5 54.16 - - - 60.00 - - B+C 1.5 - - - - 56.00 -


021DR 1 15191.22 15180.78 15203.34 22.56 - - - 24.00 - - OC 1.5 - - - 25.00 - -

Total Length 83.97 - - - 96.00 - - - - - 34.00 56.00 -

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CS-20Asphalted Road ( From HoraHanamudai - To Bhimavaram

EnH.Co )

HAIL-BUPL-CS-

022AR 3 16489.16 16479.62 16523.93 - - 44.31 - - - - OC+COS 1.5 - - 45.00 - - -

CS-21 Tallikodu ChannelHAIL-BUPL-CS-

023LC 3 16509.76 16479.62 16523.93 - - 44.31 - - - - B+C 1.5 - - - - 46.00 -

CS-22South Central Railwa ( From Bhimavaram RS - To

Pennadapalem RS(N )

HAIL-BUPL-CS-

024RY 4 16921.24 16901.02 16944.51 - - - 43.49 - - - B+C 1.5 - - - - - 45.00

Total Length - - 88.62 43.49 - - - - - 45.00 - 46.00 45.00

CS-23 Unlined ChannelHAIL-BUPL-CS-

025ULC 3 17559.95 17551.75 17577.68 - - 25.93 - - - - OC 1.5 - - - 28.00 - -

CS-24 Metalled Road ( From Pennadapalem - )HAIL-BUPL-CS-

026MR 3 17800.04 17796.09 17802.66 - - 6.57 - - - - OC+COS 1.5 - - 7.00 - - -

CS-25National HiHhway-65 ( From Bhimavaram - To

Viravasaram )

HAIL-BUPL-CS-

027NH 3 18085.64 18080.6 18091.76 - - 11.16 - - - - HDD 160.00 - - - - - HDD

Total Length - - 43.66 - - - - 160.00 - 7.00 28.00 - -

CS-26 Unlined ChannelHAIL-BUPL-CS-

028ULC 1 19707.32 19702.49 19715.03 12.54 - - - 24.00 - - OC 1.5 - - - 15.00 - -

CS-27 Metalled Road ( From Vendra - To Pennada )RHAIL-BUPL-CS-

029MR 1 19711.36 19702.49 19715.03 12.54 - - - 24.00 - - OC+COS 1.5 - - 13.00 - - -

CS-28 Metalled Road ( From FishPond - To Pennada )HAIL-BUPL-CS-

030MR 1 20198.53 20195.05 20226.87 31.82 - - - 36.00 - - OC+COS 1.5 - - 32.00 - - -

CS-29 Adarikodu ChannelHAIL-BUPL-CS-

031LC 1 20212.57 20195.05 20226.87 31.82 - - - 36.00 - - B+C 1.5 - - - - 34.00 -

CS-30 Viravasaram West ChannelHAIL-BUPL-CS-

033LC 1 20539.37 20526.53 20550.76 24.23 - - - 36.00 - - B+C 1.5 - - - - 26.00 -

Total Length 112.95 - - - 156.00 - - - - 45.00 15.00 60.00 -

- - - - - - - - - - - - -

- - - - - - - - - - - - -

Total Length - - - - - - - - - - - - -

- - - - - - - - - - - - -

- - - - - - - - - - - - -

Total Length - - - - - - - - - - - - -

CS-27 Field Chanal FC 1 15725.56 15721.5 15726.8 5.30 - - - 12.00 - - OC 1.5 - - - 7.00 - -

CS-26 Asphalted Road AR 1 15718.75 15715.4 15721.5 6.10 - - - 12.00 - - OC+COS 1.5 - - 7.00 - - -

CS-25 Asphalted WBM Road AR 1 14490.12 14487.04 14496.34 9.30 - - - 12.00 - - OC+COS 1.5 - - 10.00 - - -

Total Length 20.70 - - - 36.00 - - - - 17.00 7.00 - -

CS-24 Field Chanal FC 1 13862.96 13852.6 13865.67 13.07 - - - 24.00 - - OC 1.5 - - - 15.00 - -

CS-23 Field Chanal FC 1 13348 13340 13351.73 11.73 - - - 12.00 - - OC 1.5 - - - 14.00 - - HDD

CS-22 Canal ULC 1 11946.36 11940.82 11950.6 9.78 - - - 12.00 - - OC 1.5 - - - 12.00 - -

Total Length 34.58 - - - 48.00 - - - - - 41.00 - -

CS-21 Unined Canal ULC 1 11932.24 11917.06 11940.82 23.76 - - - 24.00 - - OC 1.5 - - - 26.00 - -

CS-20 Asphalted Road AR 1 11676.66 11666.29 11687.66 21.37 - - - 24.00 - - OC+COS 1.5 - - 22.00 - - -

CS-19 Basavarajukodu Drain DR 1 10588.26 10563.45 10633.44 69.99 - - - 72.00 - - HDD 1.5 410.00 - - - - -

CS-18 Gonteru Drain DR 1 9793.9 9757.74 9824 66.26 - - - 72.00 - - HDD 1.5 200.00 - - - - -

Total Length 181.38 - - - 192.00 - - 610.00 - 22.00 26.00 - -

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CS-17 Asphalted Road AR 2 9257.68 9248.33 9261.07 - 12.74 - - - 24.00 - OC+COS 1.5 - - 13.00 - - -


CS-15 Asphalted Road AR 3 7904.56 7893.14 7914.93 - - 21.79 - - - - OC+COS 1.5 - - 22.00 - - -

CS-14 Drain-Rapaka Channel-drain ULC 3 7842.37 7830.95 7852.74 - - 21.79 - - - - OC 1.5 - - - 24.00 - -

Total Length - 34.53 43.58 - - 48.00 - - - 57.00 24.00 - -


CS-12 RCC Road RCC 3 6146.21 6131.74 6155.8 - - 24.06 - - - - OC+COS 1.5 - - 25.00 - - - HDD

Total Length - - 45.85 - - - - - - 47.00 - - -


CS-10 RCC Road RCC 3 5720.61 5711.65 5724.05 - - 12.40 - - - - OC+COS 1.5 - - 13.00 - - -

CS-09 Koderu No.1 Branch Canal ULC 3 5475.26 5467.56 5481.81 - - 14.25 - - - - OC 1.5 - - - 16.00 - -


Total Length - - 52.42 - - - - - - 40.00 16.00 - -

CS-07 BhaHHeswae Drain DR 2 4158.91 4141.3 4176.39 - 35.09 - - - 36.00 - HDD 1.5 180.00 - - - - - HDD


Total Length - 47.25 - - - 60.00 - 180.00 - 13.00 - - -

CS-05 Jnnuru Unlined Channel ULC 3 2792.01 2780.59 2802.38 - - 21.79 - - - - OC 1.5 - - - 24.00 - -


CS-03 MOHALLURU DRAIN DR 3 1987.41 1971.68 2005.75 - - 34.07 - - - - OC 1.5 - - - 36.00 - -

Total Length - - 73.13 - - - - - - 18.00 60.00 - -

CS-02 Narsapur Unlined Canal ULC 3 689.73 0 0 - - - - - - - HDD 1.5 200.00 - - - - - HDD

CS-01 SH-41 SH 3 669.75 658.47 717.16 - - 58.69 - - - - HDD 1.5 - - - - - -

Total Length - - 58.69 - - - - 200.00 - - - - -

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Rev. 0 - 01.05.2018 Page 6 of 6

PTS - HDD

P.011947

D 11097

106


BANTUMILLI TO ULLAMPARU PIPELINE IN KG


PTS – HORIZONTAL DIRECTIONAL DRILLING (HDD)

DOC. NO. P.011947 D 11097 106



PTS - HDD

P.011947

D 11097

106

Rev.0 ONGC Bantumilli To Ullamparu Pipeline Project Page 1 of 1

TABLE OF CONTENTS

1.0 SCOPE................................................................................................................................. 3

2.0 REFERENCES ...................................................................................................................... 3

3.0 GENERAL REQUIREMENTS ................................................................................................. 3

4.0 DESIGN AND ENGINEERING OF PIPELINE ........................................................................ 4

5.0 CHECK FOR PIPE COLLAPSE OVERBURDEN PRESSURE AND ALSO ALLOWABLE

COLLAPSING PRESSURE .................................................................................................... 7

6.0 CHECK FOR RADIUS OF CURVATURE ................................................................................. 7

7.0 CALCULATION OF MAXIMUM PULLING FORCE REQUIREMENT AND COATING STRESS ... 8

8.0 CALCULATION OF STRESS, WHICH ARE INDUCED AT VARIOUS STAGES OF DRILLING ... 8

9.0 CROSSING DRAWINGS ...................................................................................................... 9

10.0 OTHER DATA TO BE PROVIDED BY CONTRACTOR ............................................................. 9

11.0 METHODOLOGY FOR HDD ................................................................................................ 10

12.0 REQUIREMENT OF HDD ................................................................................................... 11

PTS - HDD

P.011947

D 11097

106


1.0 SCOPE

This document establishes the minimum basic requirements of various activities of detail design,

engineering and construction of pipeline to be performed by an agency/ contractor entrusted with the

responsibility to install pipeline at crossings (i.e., Major Rivers, Lined / Unlined Canal / Stream, etc.) by

using Horizontal Directional Drilling (HDD) technique.

This specification shall be read in conjunction with the requirements of scope of work, all specifications,

documents, drawings and other requirements included in the Contract between Owner and Contractor.

Requirements related to installation pipeline crossing including, but not limited to, survey, design and

engineering, supply of materials, site preparation, fabrication of pipe string, joint coating application,

drilling, reaming, pullback, testing, tie-in, clean-up and restoration, and as-built drawing are addressed in

this specification.

2.0 REFERENCES

2.1 Codes And Standards

Reference has been made in this specification to the latest edition/revision of the following codes,

standards and specification.

ANSI B 31.4 : Pipeline Transportation Systems for Liquids and Slurries

ANSI B 31.8 : Gas Transmission and Distribution Piping System.

API RP 1102 : Steel pipeline crossing railroads and highways

Part 192 Title 49 : Transportation of Natural and other Gas by Pipeline (US Department Of

Transportation Pipeline Safety Standards).

OISD 141 : Design construction requirements for cross country hydrocarbon pipelines

PNGRBP : Petroleum and Natural Gas Regulatory Board

2.2 Project Documents

The following project documents/specification shall be applicable for this specification.

• Specification for Onshore Pipeline Construction

• Specification for welding of onshore pipeline for Gas Transmission

• Standard Specification for Hydrostatic Testing of Onshore Pipelines

3.0 GENERAL REQUIREMENTS

The Contractor shall be deemed to have visited, inspected and examined the work area(s) and its

surroundings and to have satisfied himself with the form and nature thereof, including sub-surface

conditions, hydrological and climatic conditions, accessibility, the extent and nature of the work and

materials and equipment necessary for the completion of the work. The Contractor shall be deemed to have

obtained all necessary information and provided for all risks, contingencies and all other circumstances,

which may influence the work.

The Contractor shall execute the work with due care and diligence and in compliance with all laws, bylaws,

ordinances, regulations, etc. of the land.

The Contractor shall take full responsibility for the suitability and safety of all operations and methods

involved in the work.

If specified in the Contract, Contract shall carryout all geotechnical investigation & hydrological

investigation (as applicable) for lined / unlined canals / stream, rivers etc. In case of river & lined/ unlined

canal / stream crossings contractor shall carry out scour calculation based on the above.

All Reports and Calculations shall be submitted to Owner for approval.

PTS - HDD

P.011947

D 11097

106


In case the Owner has carried out the surveys and soil investigations carried out along pipeline route

including crossing locations. The details of the surveys, soil investigations and other data collected by the

Owner shall be presented in the drawings or documents enclosed with the Contract for the information of

the Contractor. The Contractor shall be deemed to have reviewed and satisfied himself with regard to the

details provided. Contractor shall not be entitled for any compensation in terms of time or cost in case of

any variation in actual site conditions from the data furnished in the Contract.

Where in the Contractor's opinion the survey and Investigation data are not found to be sufficient in detail,

it shall be the responsibility of the Contractor to assess requirement of any additional surveys and/ or soil

investigations or any other data collection that may be deemed necessary for proper execution of the

works. The Contractor shall be responsible for carrying out all such surveys and collect additional data/

information at no extra cost to Owner.

Details of the permissions/ clearances obtained by the Owner from agencies/ authorities having jurisdiction

in the area where the work is to be performed will be indicated in the documents enclosed with the Contract

for the information of the Contractor. It shall be the responsibility of the Contractor to comply with all the

conditions and requirements issued by the agencies/ authorities. In case any of the permit / authorization is

required to be obtained from the relevant authorities for performance of the work, the same shall be

obtained by the Contractor.

Owner shall make available the Right-of-Use (ROU) acquired for the works covered in the Contract to the

Contractor. The Contractor shall carry out the construction works within the ROU acquired by Owner. In

case any additional land is required for drill rig set-up, fabrication, storage and other purposes, it shall be

the responsibility of the Contractor to make arrangement for all such additional land at no extra cost to

Owner. The Contractor shall also arrange for access to the work site by constructing temporary roads or

any other means where required at no extra cost to Owner.

The Contractor shall provide all services and labour, Inclusive of supervision thereof, all materials except

those specifically indicated as "Owner Supplied Materials", all equipment, appliances or other things of

whatsoever nature required in or about the execution of the work, whether of a temporary or permanent

nature.

The Contractor shall provide and maintain all lights, guards, fencing, signs, barricades, detours, flagmen, or

watchmen, etc., when and where necessary or required by Owner or by any duly constituted authority

and/ or by the authorities having jurisdiction thereof for the protection of the work and properties or for the

safety and the convenience of public and/ or others.

The Contractor shall ensure that the construction activities shall not cause inconvenience to public nor shall

there be any undue interference with normal use of facility and watercourse, as applicable.

Compliance with the requirements of this specification or the Owner’s approval of any aspect of any

drilling operations covered by this specification shall in no way relieve the Contractor of his ultimate

responsibility for the satisfactory completion of the work authorized under the Contract.

Contractor shall be deemed to have obtained all necessary information with regard to risks, contingencies

and all other circumstances, which may influence the work.

The Contractor shall provide full access to the Owner for monitoring of all work areas during all phases of

work.

For the purpose of this specification the following definitions apply: Words 'Shall' and 'Must' where used

indicate that provision is mandatory.

Words 'Should' and 'Will' where used indicate that a provision is not mandatory but is recommended as

good practice.

'May' used as a verb to indicate that a provision is optional.

4.0 DESIGN AND ENGINEERING OF PIPELINE

4.1 The minimum requirements of limits of each crossing shall be as defined in the preliminary drawings

furnished by Owner/Consultant. Contractor may change the limits slightly to suit his requirement and

installation technique, with prior written approval from Owner and authorities having jurisdiction.

Contractor has to provide actual values.

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4.2 The entry and exit points of the pipeline at ground level shall not come within the limits of crossing as

defined for individual crossings.

4.3 Following survey / test shall be performed by contractor before detail engineering:

4.3.1 Detailed soil investigations and Hydrological data collection in the proposed crossing locations so as to

obtain site-specific soil data.

4.3.2 Boring/coring into all type of soil/rock shall be done in each of the river crossing locations.

4.3.3 Conducting Standard penetration tests and collecting disturbed and undisturbed Soil samples from

boreholes.

4.3.4 Collection of soil and ground water samples for chemical testing

4.3.5 Record water table in the boreholes.

4.3.6 Laboratory tests on soil/water samples collected from boreholes.

4.4 Topographic Survey Data

Contractor to carry out fresh topographical survey across the river along the pipeline alignment. This

topographic survey values are to be utilized to calculate effective linear waterway width as per IRC-5-1998.

Moreover, more stringent of effective linear waterway width value out of one given in tender document and

the other as calculated again using fresh topographic survey data is to be followed in calculations of scour

depth.

4.5 Hydrological Data verification / collection

Contractor to verify / collect and furnish authentic hydrological data i.e. Design Discharge, HFL etc. as

provided in tender documents by making local enquiries and enquires from government authorities from

the regulatory agencies for each of the crossings. The data shall include but not limited to the following:

4.5.1 High Flood Level (HFL)

4.5.2 Discharge at HFL

4.5.3 Velocity of flow at HFL

4.5.4 Other river details such as meandering etc

4.5.5 Calculation of Scour Depth & Furnishing Scour Profile

4.5.6 Flood data, bank erosion rate, sedimentary load etc. if required, for detail engineering.

4.5.7 Existence of any bridge or barrage or any other hydraulic structures within ten kilometers (10KM)

upstream and downstream of the crossings for each river crossings site from the local/regional agencies

such as CWC, Department of Irrigation, Flood Control Authority, PWD etc. The data shall be

maximum of the recorded data in the last 25 years.

4.6 Formula for Mean Scour Depth

Formula for Mean Scour Depth below HFL should be as per IRC : 78-2000.

Dsm = 1.34 x [ Db2] 1/3

Ksf

Db = Design Discharge per meter width of effective linear waterway (as

Per IRC-5)

Ksf = Silt factory for a representative sample of bed material obtained,

upto the level of anticipated deepest scour.

Dsm = Mean Scour Depth below HFL.

4.7 Formula for Maximum Scour Depth

For calculation of maximum scour depth following formula to be used.

PTS - HDD

P.011947

D 11097

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Maximum Scour Depth = 1.27 dsm

Below Highest Flood level (HFL)

But if at the above calculated scour depth level:

a. Strata is not hard, i.e. N valves are not greater than 50.

b. Pipeline passes through soil layer, which is likely to be subjected to liquefaction during earthquake.

Then in that case following formula is to be used.

Maximum Scour depth below HFL = 2.0 dsm

4.8 Pipeline Profile

The Contractor shall determine the suitable pipe profile for the drilled crossing considering the following.

Also, tracking during pilot drilling shall be done under witness of owner / owner's representative.

The profile selected shall be such that following minimum requirements of cover to be complied with at the

crossing locations:

4.8.1 Pipeline parameters such as diameter, wall thickness, grade, type of coating, minimum cover, scour

profile/ level and elastic bend radius, maximum permissible over burden, number of pipes to be pulled

together etc, as specified in the documents/ drawings enclosed in the Contract.

4.8.2 Level of the pipeline considering the Geo-technical hydrological data shall be provided by the Owner

for basic route detail. However, detailed survey data shall be collected by the Contractor.

4.8.3 Minimum entry and exit angles based on the drill rig proposed.

The proposed angle of entry angle shall be between 10-150 whereas proposed angle of exit shall be

between 8-120. Contractor may vary the angles based on his convenience and also requirement of the

drilling machine.

Entry and exit points shall be outside the specified crossing limits.

4.8.4 RL of top of pipeline

Note:

In case any additional cover over and above the above minimum cover is stipulated by the Authorities, the

Contractor shall ensure compliance with the requirements of the Authorities.

Minimum Cover shall be measured from the lowest level of road, rail, Canal, water ways etc. including its

ROU to the top of casing pipe or carrier pipe as per type of crossing

The plane containing the pipe axis shall be perpendicular to the horizontal plane. There shall be no bending

of the longitudinal pipe axis at depths shallower than two meters below ground level.

Any additional requirements of the Authorities having jurisdiction over the area regarding minimum level

of pipeline such as requirement of port authorities on account of regular maintenance dredging,

requirements of irrigation department with regard to de-silting etc. where applicable.

4.8.5 Radius of Curvature

The design to be based on minimum radius of curvature of HDD section corresponding to 1000 times the

OD of the carrier pipe.

Crossing Type Minimum Cover Requirements

Road / Highways for casing 1.5 m from bottom of road to top of pipe

River Crossings a. 2.5 m below scour level in case of normal

b. 1.5 m below scour level in case of rocky

Lined Canal / Streams other

water bodies

1.5 m below scour level

PTS - HDD

P.011947

D 11097

106


4.8.6 Value of constants, which is to be considered in design of pipeline profile.

1. Pre installation test pressure = 1.5 times the design pressure

2. Post hydrostatic test pressure = 1.5 times the design pressure

3. Density of Bentonite = 1068 kg / m3 or 0.0012 kg / cm3

4. Friction factor when pipe is in

bentonite hole = 0.8

5. Friction factor when pipe is on = 0.2

Roller

6. Co-efficient of Drag = 0.0024 Kg/ cm2 or 239 N/m2

7. Poisson ratio = 0.3

5.0 CHECK FOR PIPE COLLAPSE OVERBURDEN PRESSURE AND ALSO ALLOWABLE

COLLAPSING PRESSURE

To check that the empty pipeline is safe from collapse at any point along the drilled crossing section,

Contractor shall carry out calculations for determining the maximum permissible overburden on pipe.

Drilling hole shall be checked against collapse/ cavity under overburden and pipe shall be checked against

buckling/ collapse under axial tension and bending stresses. Contractor shall submit these calculations to

Owner for approval.

4.9 Allowable collapsing pressure is calculated based on two equations

i. Theoretical Elastic curve Equation

ii. S. Timoshanko’s equation

Theoretical Elastic curve equation is given by:

P = 2E

(1-λ2) [ ( D/t) ( D/t-1)2]

λ = Poisson’s ratio

D = Outside diameters of pipe

t = Pipe thickness

E = Modules of elasticity of steel

S. Timoshanko’s equation is given as:

P = 2E

(1-λ2) [ţ/D] 3

4.10 Overburden pressure is given by:

Overburden pressure = [h1 (DS) + h1 (DM) + h2 (DD)] g

DS = Saturated Density of soil

DM = Mud Density

DD = Dry Density

H1 = Column height from water level to top of pipe

H2 = Column height from grade to top of pipe

The calculated overburden pressure should be less than allowable collapsing pressure.

6.0 CHECK FOR RADIUS OF CURVATURE

Contractor shall determine the minimum allowable elastic bend radius for the pipe from the following

considerations:

6.1 Pipeline longitudinal stress during installation

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Total maximum longitudinal stress in the pipeline due to tension and bending at any location shall not

exceed 90% of the SMYS of the pipe material. Contractor shall, evaluate the maximum tension forces to

which the pipeline is subjected for following phase of its installation during the pulling operation.

• Stress in the pipe at the beginning of the pull

• Stress in the pipe upon finish of the pull-in

• Stress in the pipe due to over-bend

The combined stresses in the pipeline shall not exceed 90% of Specified Minimum Yield Strength

(SMYS) of line pipe material at any time during the pulling operations.

Contractor shall also calculate the total length of pipeline required as well as the maximum tension required

on the pull head of the rig.

6.2 Pipeline equivalent stress during final hydro test.

After installation, the pipeline shall be hydrostatically tested to a minimum test pressure equal to 1.5 times

Design Pressure for gas pipeline. The combined equivalent stress in the pipeline due to bending and test

pressure shall not exceed 90 % of the SMYS of pipe material.

6.3 Pipeline maximum equivalent stress during service

Permissible values of pipeline maximum equivalent stress during service shall be governed by the

requirements of ASME B31.4 /31.8, as applicable.

The minimum allowable radius of curvature for the pipeline shall be the highest value of the minimum

pipeline elastic bend radius as computed from the considerations outlined as above.

Contractor shall submit all calculations for Owner's approval.

7.0 CALCULATION OF MAXIMUM PULLING FORCE REQUIREMENT AND COATING STRESS

For each crossing, Contractor shall device a suitable combination of the following in order to optimize the

crossing design in terms of pipeline stresses and pull force requirements.

• Back-reamed hole diameter

• Bentonite density

• Pipeline submerged weight in bentonite (and means to achieve that weight)

Contractor shall indicate the maximum shear stress in the pipeline coating that will result due to the above

parameters and other design characteristics described in this section.

Contractor shall furnish all calculations for Owner’s approval. If shear stress on pipe coatings is, in the

opinion of Owner, beyond the permissible limits, Contractor shall revise the above parameters to reduce

shear stress on pipe coating to permissible limits.

Following two stages are envisaged for calculation of Maximum pulling force:

a. When pipe is entirely on rollers.

b. When pipe is fully down hole.

In calculation of Maximum Pulling Force following forces are to be considered.

a. Force to counter cohesion (drag).

b. Force to counter buoyancy.

c. Force to counter curvature.

All the forces are to be calculated for Drill Pipe String, Carrier Pipe and OFC conduit pipe.

Maximum pulling force requirement should be less than the pulling capacity of the Drilling machine with

approximately factor of safety of nearly 3.

8.0 CALCULATION OF STRESS, WHICH ARE INDUCED AT VARIOUS STAGES OF DRILLING

8.1 Stress on pipe when it is on fully on conveyors / rollers

PTS - HDD

P.011947

D 11097

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Case I: a. Spanning stress due to self weight and weight of water Filled in pipe.

b. Hoop stress due to pre installation test pressure.

Case II a. Spanning stress due to self weight and weight of water Filled in pipe.

b. Tensile stress due to pulling force required to move the pipe.

8.2 Stress induced in pipe at the first point of curvature when it is pulled down hole.

a. Curvature stress when pipe is down hole.

b. Pulling force required when part of pipeline is on roller and partly it is down hole.

8.3 Stress on Pipe during pullback

a. Curvature stress when pipe is fully down hole.

b. Tensile stress due to pulling force required to move the pipe.

8.4 Stress on Pipeline when it is installed

a. Curvature stress when pipe is fully downhole.

b. Hoop stress due to post hydrostatic test pressure/ operating pressure.

8.5 Combined equivalent stresses

Combined equivalent stress is to be found using Von Mises Equation

Combined Stress = (S12 + S2 2) – (S1 X S2)

S1 & S2 are values of stresses.

This combined stress should be less than 90% of SMYS (Spec Min Yield stress) value for pipe material.

9.0 CROSSING DRAWINGS

Contractor shall, based on results of design and engineering carried out by him, prepare construction

drawings for each river crossing and shall submit the same for Owner/Consultant's approval, Construction

drawings shall indicate the pipeline profile with levels furnished at sufficient intervals. Details such as,

entry, exit points and angles, radius of curvature, etc. shall also be indicated. Contractor shall also calculate

the total length of pipeline required as well as the maximum tension required on the pull head of the rig.

All construction works shall be carried out in accordance with the construction drawings, approved by

Owner/consultant.

Before commencement of any installation works, Contractor shall furnish for Owner/consultant's

approval all design calculations as specified above.

10.0 OTHER DATA TO BE PROVIDED BY CONTRACTOR

a. Proposed schedule for carrying out HDD works.

b. Methodology for carrying out HDD work and for installation of pipeline shall cover but not limited to :

• R.O.W Preparation

• Handling, hauling, storing and stringing of pipes and other materials

• Pipe string

• Lining-up, welding & field joint completion

• Installation

• Bending

• Hydrostatic testing ( Pre-installation, Post Installation and Final hydrostatic test)

PTS - HDD

P.011947

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• De watering-cleaning – drying

• Idle time preservation of pipeline

• Final clean up

• Disposal of surplus soil & bentonite slurry& corrosion inhibited test water

• Documentations

c. Inspection and testing schedule.

d. Drawing showing pipeline profile.

e. Sample log sheets for pilot hole.

f. Equipment layout for HDD works.

11.0 METHODOLOGY FOR HDD

11.1 Pipe String Preparation

The line pipes, which is pre-coated with 3LPE/LLP Coatings is strung and welded together in single length

and 100% radiographed & NDT test as per project specification requirement. All welded joints to be coated

with DIREX - Heat-Shrink Sleeves and then the pipe string shall be hydrostatically tested.

11.2 HDD Operation

HDD is a two-stage operation.

11.2.1 First stage consists of drilling a small pilot along the designated directional path.

11.2.2 Second stage involves enlarging this pilot hole to a diameter that will accommodate the carrier pipe and

pulling the bundled carrier pipe back into enlarged hole.

11.3 Pilot Hole

The pilot hole is drilled with a HDD rig. Pilot hole directional capability is accomplished by using a 5” Dia

non-rotating drill string with an 9-7/8” bit attached to the angular offset of 1 to 1-1/2 degree .The actual

path of the pilot hole is monitored by a state-of-art magnetic guidance system .The actual path of the pilot

hole is monitored during drilling by taking periodic readings of the inclination and azimuth of the leading

edge. These readings, in conjunction with measurements of the distance drilled since the last survey, are

used to calculate the horizontal and vertical coordinates along the pilot hole relative to initial entry point on

the surface.

11.4 Ream and Pull Back

After the completion of pilot hole, depending on the drilled cuttings and actual soil encountered during the

pilot hole, combinations of cutter and reamers are used to enlarge the hole. The cutter is fixed to the 5”dia

drill string which will be rotated and pulled/pushed through the pilot hole with the cutting action of

bentonite pumped through the drill string and the teeth of cutter body.

Once the cutting passes are complete a non-rotating swivel will be attached to the pull head welded to the

pipeline section to prevent for torsional stress on the pipeline. Steel conduit with HDPE duct is also

attached to the main pipeline pull head before the pull head is attached to the swivel. An overhead bend is

formed, by lifting the product pipe to the correct height to allow smooth entry in the borehole.

11.5 Drilling Accuracy

It is generally anticipated that there is a deviation in actual verses designed pilot hole course of +/- 0.1% of

the horizontal drilled length.

11.6 Horizontal survey Control

In order to assure proper horizontal and vertical alignment of the HDD crossing, a computerized survey

system is utilized. This survey system allows for real time readings measured from a steering device

located at tip of the drill bit.

PTS - HDD

P.011947

D 11097

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12.0 REQUIREMENT OF HDD

12.1 Depth at which pipe is to be laid is more and it is difficult to lay the pipe by any convenience method at

required depth.

12.2 Bed and slope of river / Nala / Pond / Canal bank is not to be disturbed (As per statutory/environmental

requirements).

12.3 Continuous & Heavy flow in Canal / river & Time constraint

∑ ∑ ∑ .

GENERAL TECHNICAL

SPECIFICATION

GTS 740 502

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GENERAL TECHNICAL

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The work site location will be specified in a separate PTS.

As soon as the Contract is signed, the Contractor will proceed with the setting-up of the site installation in accordance with the stipulations of his price bid and as agreed with the Owner according to relevant approved drawings.

The Contractor shall excavate all the topsoil if necessary from the site and provisionally store it. The topsoil shall be treated in such a way that it remains free of weeds until it is put back again. The site shall be levelled, sealed and hardened with a layer of stone chippings (size 0-40, thickness 25 cm) and a top layer 12-20 (thickness 10 cm). The surface to be occupied will depend on the category of site installation and shall constitute one single unit for the section of the Owner. The Contractor’s installation shall be located no more than 200 metres away from the Owner premises.

The Contractor shall take all the necessary precautions to ensure that the site always remains dry and practicable. It must be possible to reach the site with trucks and cars from the public road. The site shall be arranged in accordance with the conditions set out in the building site regulations.

1.2. ��

The entire terrain on which a site installation is to be located will be screened off by the Contractor with provisional fencing supply by the Contractor consisting of 2 metres high removable elements. The fencing shall be locked securely, display the necessary notices and be of such a design that it can only be dismantled with the use of tools. This enclosure shall be fitted with a lock and chain. The Contractor must hand over 2 keys to the Owner’s representative.

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The term site installation shall be taken to include the area set aside for the storage of equipment.

The Particular Technical Specification shall determine to which category the site installation belongs. Each installation shall comply fully with all the local rules of the building site regulations and the statutory provisions.

If necessary, the Contractor shall take all necessary steps to ensure the timely acquisition of the licences for connections to the utilities and drainage from the Authorities involved.

During the work the Contractor must procure and maintain the installation and equipment which are necessary for the functioning of the workshop and additional equipment.

The Contractor shall make all the necessary arrangements to cater for an uninterrupted supply of fuel, lubricant, electricity, water, telephone, etc. during the work.

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a) Site installation Category 1 (installation for the laying, among other things, of pipelines)

b) Site installation Category 2 ( installation for special point)

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/0502

Rev. 1 – 14/09/09 Part 1 - Page 2 of 2

c) Site installation Category 3 (installation for, among other things, the construction of a new main station - e.g. mixing or compression station)

d) Site installation Category 4 (installation, for example, for such things as the construction of a new regulating station or adaptations to an existing one, diversion works and reconstruction works)

Due to the diversity of the work site location and the local conditions the site installation required for the Owner's representatives as well as for the recognised inspection agency will be stated in a separate PTS.

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When the Contractor takes over the materials, he shall immediately store the materials supplied by the Owner in accordance with the code of good practice and the conditions set out in the building site regulations and GTS part 4. The Contractor shall provide a covered and locked storage area to store the protected materials. Each covered and locked storage area is provided with lighting. The material shall be stored in the immediate vicinity of the site offices.

1.4. � ��

The installation shall remain at the disposal of the Owner until restoration of the site is completed. After the site installation has been dismantled and removed, the Contractor shall restore the terrain to its original condition to the satisfaction of all Parties Concerned.

GENERAL TECHNICAL

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Before the Contractor may effectively occupy the construction sites, the axis of the pipe will be staked-out. The polygonal points and the worksite limits will also be staked-out at the same time.

The staking-out will be carried out in the presence of the Contractor by the Owner or by a topography office commissioned by the Owner. The Contractor will make a request to the Owner and/or the Engineer to carry this out at least fifteen days before writing effective start-up and the general schedule of the works.

All drawings used for staking-out the axis and for the laying of the pipe in general shall correspond to the list “Approved for construction”. The Contractor will make the working area necessary for staking-out the axis accessible beforehand. Any trees and bushes that hinder the topometric works shall be uprooted if the necessary permits have been issued.

The staking-out will consist of a regular sequence of wooden posts. The dimensions of these posts, supplied by the Contractor, shall be 500 x 40 x 40 mm. The posts (white) will be set in the ground in a straight line in judiciously chosen places. Each change of direction in the horizontal plane will be indicated by an extra post (yellow), set in the ground at the intersection of the theoretical extensions of the straight parts. The co-ordinates of each of these posts will always be determined in relation to the basic polygon. The x, y and z co-ordinates will be recorded using the general co-ordinate system specified by the Owner.

Alongside roads or hardened surfaces, the posts will be replaced by yellow paint marks for changes of direction and white paint marks for straight and intermediate points. The Owner and/or the Engineer hand over to the Contractor a diskette and a printed list with the co-ordinates of the axis and the polygonal points.

The Contractor will take over the axis staking-up at least once a week by signing an "Axis staking-up acceptance report ".

From the time of signing, the Contractor will assume the responsibility for the preservation and maintenance of the axis staking-out. Consequently, the Contractor should have sufficient knowledge of the axis staking-out co-ordinates to be able to replace the posts correctly if they become damaged, wholly or partly, or if they disappear or for any other reason. In the event that the Contractor remains in default in this regard, the task of replacing will be carried out by the Owner. The costs incurred thereby will be charged to the Contractor. The effectively staked-out axis shall be strictly adhered to when laying the pipe. Deviations will only be permitted provided prior approval has been received from the Owner.

The distances between the axis and the horizontal measurements mentioned on the drawings are given for information only. They may vary according to the correct layout of the existing pipelines, the presence of any underground or surface obstacles (whether foreseeable or unforeseeable), the special conditions described in the PTS, the conditions stipulated on drawings or in quantity notes, etc.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502


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The information required to locate underground utilities and others will be requested by the Contractor from the various utilities holders. The Contractor will to this end make all the contacts necessary with these firms at the start of the works. Detection of the existing pipelines will be jointly carried out by the representatives of the firms concerned, the Owner and the Contractor and will be confirmed in a report. The Contractor shall provide the necessary assistance for the staking-out of the existing pipelines of the Owner. This assistance includes, among other things, a person with an all-terrain vehicle and the supply of all the necessary wooden poles with red caps.

The Contractor must ensure the correct layout of these installations by means of soundings carried out manually under his own responsibility. He will carry out these soundings at each change of direction in the horizontal plane and in straight sections at least:

� every 20 m on the straight sections if the installation lies less than 5 m from the pipeline to be laid;

� every 50 m if this distance is more than 5 m.

Generally speaking, the Contractor will take soundings in every place where he deems this to be necessary to be sure of the exact location of existing pipelines.

He shall survey topometrically all data regarding the location of the exiting pipelines according to the standard of the Owner (x, y and z co-ordinates) and supply to the Owner and/or the Engineer a diskette with the surveyed data in a file format agreed by the Owner and a printout. The sounding report shall also be completed and transmitted to the Owner.

After the survey and once the sounding reports and/or drawings have been drawn up, the sounding holes will immediately be closed and the site shall be restored as required.

From this time on, the Contractor is responsible for keeping the data.

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Any marker posts, lighting, survey points for cathode protection etc. of the existing pipelines as well as property markers will be surveyed by the Contractor in accordance with the survey system of the Owner and incorporated in the drawings. Such survey will be carried out in relation to the basic polygon. A copy thereof will be hand over to the Owner and/or the Engineer and added to the inventory of fixtures.

If necessary, the Contractor will remove certain marker posts and property markers before the start of the works and store them temporarily. Once the pipeline has been laid, these posts shall be put back with the aid of the measurements previously taken. Any removals or replacements will be carried out under supervision and to the complete satisfaction of a representative of the Parties Concerned for the marker posts and of the owners or tenants as far as the property markers are concerned.

Any damaged marker posts or any that have disappeared will be replaced by the Contractor.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502


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The Contractor shall notify the parties involved in writing (unless otherwise specified by the parties involved) at least fifteen days prior to the effective occupation of the construction sites.

The occupation of the construction sites by the Contractor may only be carried out after drawing up a pre-works inventory of fixture (see appendix) signed by the parties involved.

Prior to the occupation of the worksite, a form will be drawn up by a representative of the Owner and of the Contractor with the depths jointly measured of the top soil at the plots of land concerned by the pipe. The thickness of the top soil is measured every 50 metres with a minimum of one per plot. The measuring of the depth of the top soil is the responsibility of the Contractor.

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Otherwise stated by the Owner, the overall duration of the works at every point of the pipe route, from the opening of the working area to complete restoration of the site, may not exceed eight weeks.

If the duration of occupation per section of the pipe route is exceeded, the Owner will take the necessary steps in accordance with Article 6.2.2. of the GTS to regroup the different phases.

All direct and indirect costs and damage resulting from exceeding the contractual duration of occupation will be charged to the Contractor.

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The width of the working strip and its partitioning for Works in line and the extra width of the working strip for S.P. are set out in standard drawing.

With regard to excess depths incurred for construction reasons (e.g. ditch intersections), the soil storage area may be widened by 1 m per complete layer of 50 cm of excess depth. This area should be notified beforehand to the representative of the Owner and/or the Engineer who must give his agreement to this on the basis of the Contractor’s construction drawing.

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� The Particular Technical Specifications (PTS) will specify where the working strip must be narrowed.

� Where necessary, the Contractor will reduce the working strip at his own initiative, possibly to the strict minimum required for the proper execution of the works, to meet local needs and requirements, which he should normally have taken into account during his survey of the construction sites at the time of the drafting of his price bid and during the subsequent detailed study carried out following the signing of the Contract.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502


� The Contractor will comply with all obligations in this connection as laid down by the parties involved.

� Any reduction in the working strip of less than 10 metres in length and/or 2 metres in width shall not be compensated.

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� Normally the Particular Technical Specification or the drawings will specify where the working strip must be reversed in the special operating stipulations for carrying out work.

� If necessary, the Contractor will carry out conversions to meet local needs and requirements which he should normally have taken into account during his survey of the building sites at the time of the drafting of his price bid and during the subsequent detailed study carried out following the signing of the Contract.

� The Contractor will comply with all obligations in this connection as laid down by the Parties involved.

� An application for a price supplement from the Contractor will only be considered if it concerns a reversal of the working strip that it was impossible for him to know about before concluding the Contract. The price supplement will in this case be confirmed on the basis of the one-off price for conversions indicated in the relevant pricelist.

� One conversion of the working area comprises both the reversal at the start and at the end.

� � � 2 .�& ��

Working strip at ditch intersections, will be worked-out in such a way that the working strip is continuous. If the ditch has to be channelled locally, the top soil of the working strip will be taken away and stored in the area provided for this purpose. The temporary culvert pipe will be backfilled with stone-free soil up to the level of the working way. Once the terrain is restored, the encasements and sand will be removed again, the ditch reformed and the top soil replaced.

N.B.:

Throughout the duration of the works, the Contractor should make the required provisions to guarantee uninterrupted water flow from all ditches running alongside the roads. He should also take the required precautions not to damage the culverts nor hinder the flow of water.

� � ) .�& �� 0�1�& �� & �0�1��

� � ) ! "��

The working site, working strip marking and warning signs equipment will be supplied and set out by the Contractor. He will take all useful and necessary measures to keep in good condition the markers and signs throughout the entire duration of the works. The Contractor shall safeguard the Owner from all damages derived from this marking that may be claimed from the Owner by the injured parties.

The Contractor shall keep the removed fences from the working strip enclosure (wire, poles, etc…) at the disposal of the tenant, unless the latter agrees to their clearing away.

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� � ) � .�& �� & ��

a) Planning and occupation time

The marking-off of the working site is carried out after the acceptance of the pipe axis staking-out.

In all cases, the fencing of the working strip and the access ways shall remain until the height of the new sown grass (if any) is such that it can withstand the passage of animals, unless arrangements are made with the Parties Concerned for early removal.

b) Execution

The marking-off will take account of the configuration of the working strip set out in the contractual documents or the configuration deriving therefrom, in particular the width, reversal, the trees to be felled or spared and the fenced or already built plots of land.

The marking-off will consist of a row of posts with red-painted tops along the boundaries of the working strip. The sizes of these posts and their distance from each other (max. 30 m) will be chosen in such a way that they remain visible from one pole to the next regardless of the site configurations. In places where after a certain period of time the vegetation threatens to overgrow the markers, the Contractor will adjust the dimensions of the posts from the time of insertion to ensure that they are visible from one pole to the next throughout the entire duration of the works. The posts will be at least 1 m high.

Each row of posts will be provided with a fence that effectively isolates the working area from the surroundings, on the one hand, to prevent people, animals and in general anything not connected with the works from gaining access to the working area and also to avoid situations where the Contractor and other persons involved in the works go beyond the working area.

The marking-off of grassland shall be carried out and maintained according to the rules of the trade in order to prevent any escape of or injury to cattle.

The Contractor shall also ensure that any earth piled up along the fence does not allow the cattle to cross the enclosure.

The necessary care must be taken by the Contractor to avoid fence bonds being unfasten. No bonds or nails will be left behind inside or around the worksite.

The wire may not be attached using a stapling machine. The Contractor is liable for all injury to cattle and damage to agricultural machines caused by lost bonds.

Identical marking-off shall be placed by the Contractor around the complete construction sites (working strip, accesses, additional working zones) whenever this involves a special point, a particular section or a station.

c) Specific work

The marking-out will be adapted to local needs and/or requirements. In particular, the marking-off on grazing land will consist of a strong fence. This fence will be constructed of posts maximum 6 metres apart, unless the existing one is made of stronger material or is of a more robust construction. Three rows of barbed wire will be strung along the inner side of the posts.

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At road intersections, the working strip will be temporarily closed off by means of posts one metre high bearing appropriate signs. As required, the enclosure will be provided with electric fence, if necessary with its own power supply, similar to the existing fencing around the plot. In this case, the Contractor will ensure that wrong handling during access does not lead to a cut-off of the power supply of the electric fence. Barbed wire may not be used in plot used by horses. However, round galvanised electric fence or electrified nylon wire or strips may be used. In sheep pastures, an adequate fence or an electrified nylon mesh should be used. For pastures for deer, ostriches or other species animals, the provisional fence shall have the same properties as the existing fence.

d) Access ways

The access ways requested by the users/owners in the inventory of fixtures shall be provided for in the marking-off; these shall be constructed in such a way that every part of these access ways prevents the cattle from wandering across the working area. The Contractor will ensure that the cattle do not break through an access way or enclosure due to neglect by any person. He shall in this eventuality be responsible for any consequences.

Any access way shall remain inaccessible for a maximum of 5 working days during the above-ground welding of the pipe sections, the excavation of the trench and the laying of pipes in the trench. The access way shall be reinstated at the latest by the day after the laying of the pipes in the trench. The Contractor will provide the required encasements for telephone cables and other cables when finishing off the access way. The user/owner will be notified orally at least three days before closing off the area and visited together with the Owner’s negociator. Such access ways, of which the number must be limited as much as possible, shall have sufficient width depending on the type of cultivation. In the case of arable land, they must allow for the passage of the agricultural machines to be used; in the case of pasture land, they must not impede the passage of the herd or flock and must be sufficiently robust, wide and enclosed.

� � ) ) 6�& ��

a) Kilometre points (KP)

The Contractor will place a marker-post every kilometre, starting from the zero-point line in accordance with the developed length. The post will show the cumulative chainage in kilometres from the zero-point line corresponding to the mechanical construction.

b) Numbering of the special points and special sections

The Contractor will insert a marker post at every special point and every special section showing the number according to the Particular Technical Specifications of the special point or particular section concerned, as well as the distance in kilometres between the insertion point of the marker post and the zero-point line.

c) The working polygon

� If some or all of the markers of the basic polygon are shown on such places and their lines cannot be guaranteed to remain throughout the duration of the works, the Contractor will extend a working polygon connected with the original basic polygon.

� The markers of the said working polygon will be located in such a way that they remain throughout the entire duration of the works without any danger of being moved for one reason or another. The distance of the markers from each other is determined on the basis of the site configuration.

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� The Contractor may under no circumstances move or destroy a basic polygon marker without the prior agreement of the Owner. This agreement requires that the Contractor has made the measurements and calculations of the working polygon with respect to the basic polygon and has had them approved by the Owner. The aforementioned working method shall be followed to be able to make the co-ordinate transformations to the basic polygon for all site modifications; this is carried out for the purpose of drawing up the Technical Archives.

� The Contractor should replace the basic polygon during the reinstatement.

d) Underground obstacles

The Contractor shall provide suitable markings for underground obstacles in order to prevent any damage. He shall base this on information from building plans, the special conditions for execution of work in the Particular Technical Specifications and supplementary information resulting from his investigations and soundings.

e) Surveillance and signalling

In addition to the legal obligations relating to signalling, lighting and surveillance, the Contractor will, in places where safety demands, set in place signalling, lighting and/or surveillance systems.

� � ) 2 � ��

The Contractor will supply and install all road signs, working site warning signs etc in accordance with the local authorities requirements. The Contractor is also responsible for their daily maintenance.

� � 2 ��

� � 2 ! �� *��

In the presence of the Owner and/or the Engineer, the Contractor or a topographical agency commissioned by the Contractor, draws up the longitudinal profile of the ground along the pipeline axis and based on the basic or the working polygon for terrain changes in the vertical plane and every 30 meter (in local co-ordinates system for x, y and z co-ordinates) and supplies the data on diskette in format agreed by the Owner and printout to the Owner and/or the Engineer before excavating the arable soil.

The profile will be related to the general official local contour marks (ordinance survey) and with characteristic points that are not in danger of being moved during the works (among others, borders of land plots, enclosures, hedges, walls, streams, waterways, roads, pylons, etc.). The scales are : length scale 1/1000 - height scale 1/100.

This profile will serve as a basis for the "longitudinal design".

� � 2 � ��

In order to acquire sufficient knowledge concerning the building sites, the type and the characteristics of the top soil and the sub-soil, the actual position of underground and surface obstacles (which may or may not already be specified in the documents of the contract), the Contractor will take all necessary steps with the Parties involved and he will carry out all the necessary site explorations, investigations, detection trenches and soundings. The Contractor bears full responsibility for these exploration activities.

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� � 2 ) %��

The Contractor should draw up a "length profile design" in accordance with which he will decide to lay the pipe. When drawing up the design, the Contractor will take account of the site configurations, the obstacles above and below ground, the known drainage networks, the theoretical profile of waterways (ditches, streams, etc.) the conditions set out in the documents of the Contract and the conditions and obligations laid down by the Parties involved.

This profile should also show the position of the accessories of the pipe (ballast, anchoring, mechanical protection, encasement, covering plates, cable, etc.). Without in any way diminishing the responsibility and the obligations of the Contractor, 3 copies of the profile should be submitted to the Owner for approval at least five working days before bending the pipes and before the civil engineering works so as to determine whether the Contractor has taken of account the aforementioned conditions.

Any change to the "length profile design" as a result of comments made by the Owner and/or the Engineer, impossibilities for carrying out the work and/or local situations (actual location of the boring or drilling work carried out, correct position of underground obstacles encountered during excavation, etc.) shall be submitted to the Owner and/or the Engineer for approval without delay before carrying out the work. The aforementioned specifications apply to the works in line as well as to the special points and the particular sections.

Otherwise stated

The scales are as follows:

� line: length scale 1/1000

height scale 1/100

� special points: length scale 1/100

height scale 1/100

� particular sections: length scale 1/500

height scale 1/100

For every special point and particular section, which may or may not already be specified in the documents of the contract, this profile should be realised according to the axis of the pipeline and over the entire agreed length.

� � 4 $��*��1�& ��1�& ��

The summary below shows some of the work that must be carried out. The list is not exhaustive.

� � 4 ! .�&��

� � 4 � 7� �� *�� 1�& ��

The Contractor will be responsible for :

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� All ground levelling work.

� Removal of rocks, solid masses or other materials that would not be removed by the usual levelling machinery.

� Removal of walls, small walls, hedges, undergrowth and shrubbery.

� Removal of trees or remains of trees in accordance with the specifications of Art. 2.2.5.9.; all works that facilitate the creation of a working surface suitable for the building and the laying of the installation.

The Contractor will observe the obligations deriving from:

� Hereditary rights of way, well rights or actual access ways.

� The presence of springs, underground streams, wells, cisterns, drainage pipes, collectors, ponds, surface drains, ditches, surface waters, marshes etc. Demolition materials resulting from the removal of obstacles such as walls, hedges, shrubs, etc. should be transported to a recognised waste disposal site. They may not be buried on site. The costs of dumping shall be borne by the Contractor. Cattle troughs or other drinking systems for cattle shall immediately be reconnected to the existing water supply system or be provided with water by some other means or be replaced.

� Springs and underground streams shall be protected with the greatest care. The spring area adjacent to the worksite should be fenced off for the purpose of avoiding disturbance thereto by the site equipment. It goes without saying that any dumping of a polluting product is forbidden.

A collector or drain shall be laid for the purpose of carrying water over the trench.

� The Contractor should notify the Owner if he is carrying out work in the vicinity of a spring and will submit the necessary measures to him.

� The presence of fences within the working area. These fences, including trees, on the borders of plots of land, will be measured in good time by the Contractor if they do not appear in the layout plan or if they or their position do not conform to the layout plan.

� The presence of underground pipelines. It is forbidden to drive over underground pipelines without protection. The Contractor shall make the necessary agreements with the Parties Concerned and consequently place the necessary protective plates or take other measures.

� Provisional moving and relocation or - provided the prior written permission of the Owner and/or the Engineer and the Parties Concerned has been obtained - the permanent removal of wells, cisterns, drainage pipes, collectors, ponds and pools, surface drains, ditches, hereditary rights of way (with approval of the person holding the title), actual access ways, posts, stables and sheds, greenhouses, shelters, small walls, bushes, trees, hedges and hedgerows.

� � 4 ) �� * � ��1�+��

The Contractor is responsible for :

� the building of temporary bridges or any partial provisional backfill of rivers, streams, ditches, etc. with subsoil or imported material whereby he shall also ensure this backfill does not restrict possible upstream flow;

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� the design and installation of provisional access ways for the site as well as those for the benefit of third parties, adapted to local circumstances (steeply rising terrain, slopes, roads, railways, etc.);

� retaining and possibly strengthening verges.

In this regard, the Contractor should ensure in particular that he does not close off any streams, drainage pipes or collectors.

The Contractor may not carry out these works without the prior agreement of the Owner and the Parties involved (a copy of this agreement shall be sent to the Owner). Moreover, he shall accommodate their requirements and recommendations.

In farming, horticultural and forestry areas the Contractor should provide access ways to facilitate normal activities on the areas on either side of the working strip.

� � 4 2 /��

In order to keep the installations in use and the infrastructure operational, the Contractor will be responsible for all movements and/or provisional and/or definitive connections of:

� electricity, telephone, water, natural gas, television or other pipes or distribution lines, both below and above ground, both private and public;

� lampposts, etc.;

� pipes, etc.;

� access roads;

� cattle drinking troughs, water wells, cisterns, springs, drains;

� in general, he will be responsible for all underground and above ground objects and constructions in accordance with the requirements of the Parties involved.

Throughout the entire duration of the site, the supply of water and electricity in all plots of land must be maintained.

� � 4 4 %� ��0�� 1��1��

The Contractor will ensure the maintenance of the drainage and rainwater discharge, surface water and groundwater from land that traverses the working area or from land that lies outside the working area but which is affected by the works. He will arrange for any drainage and dewatering necessary for the work and will be responsible for any damage caused to the aforementioned areas of land and to constructions, installations and crops thereon. Only noise-inhibited pumps will be used. Only electric pumps will be used in the vicinity of houses.

The Contractor will pump the trench dry before backfilling. He will in particular ensure that any water resulting from dewatering, drainage or released for any other purpose or for any other reason will not be released in such a way that the water causes a nuisance in those places or damage is caused by mud. He will apply for a discharge licence from the authorities concerned.

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� � 4 8 �� -�� -��

Width of the excavation :

� After the working strip has been delimited and except otherwise specified in the Particular Technical Specification, the soil will be dug out over the entire width of the driveway and the trench. The storage of this soil depends on the diameter of the pipe and the width of the working area associated therewith and is carried out single-sided, soil-store side, or double-sided, soil-store side and driveway (see relevant typical drawing).

� During any excavation activities, as much as possible of the soil will be dug out and piled up separately from the other excavation material. This applies to excavations for, among other things, drain repairs, wells, inspection pits, etc.

� The earth will be removed and piled up at least 0.5 m from the fence.

� Throughout the entire duration of the works, the Contractor will ensure that the piled-up soil remains free of weeds. The herbicides used will be a “short action type”.

If:

� The subsoil consists of several layers each layer will be stored separately from the others and later replaced in accordance with the original stratification and if these layers differ in density, elasticity or hydraulic permeability, the B-soil may, if desired, be laid on the driveway.

� The subsoil contains clay and/or hard rock, the Contractor will also dig out the topsoil at the place where the excavated clay and/or rocky soil is to be piled up.

� The working strip crosses a wooded area, the arable soil shall be excavated over the entire working strip width and piled up.

� The arable soil layer is less than 15 cm, the arable soil shall excavated over the entire working strip width.

� � 4 3 ��

When crossing pasture land, the turf is worked with a rotary cultivator. If the grass is higher than 10 cm, it shall be cut and removed. It is only after these preliminary operations that the soil may be dug out and piled up as described in article 2.3.5.6. In pasture lands on rocky ground, only the high grass shall be cut according to local methods.

� � 4 5 ��

The Contractor is obliged, when crossing special areas, such as woodland, heathland and peat bog land to dig out the uppermost humus layer and handle it in the same way as the top soil under cultivation and pasture land.

� � 4 9 �� * � �� 1��

The Contractor will remove the vegetation within the working strip width and prune or fell down the trees. After marking out the working strip, the Contractor will only start felling down trees when the recognised

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negotiator has had the opportunity to count the exact number of trees to be felled down in the presence of the landowner.

The trees will be felled down in such a way that they fall within the working strip. The treetrunks shall be carried away. The sawn-off branches and the shrubs shall be destroyed on the spot or removed. The stumps shall be dug out over the entire working strip width and destroyed or carried away.

As a general rule, these trees are the property of the respective owners. The Contractor should comply with the instructions of the latter as regards the felling down and possible transportation of the felled trees to the nearest thoroughfare. Otherwise, such trees are the property of the Contractor and should be carried away at his expense.

However, in certain places, it may be required that tall trees, valuable shrubs or plantations are not felled down or dug out despite the fact that they are in the prospective working area and the working strip will accordingly be narrowed at this point. This concerns mainly the part of the working strip where the top soil and the ground from the trench are temporarily stored.

The Contractor is not entitled to any payment if the local narrowing of the working strip involves a length which is less than 10 m.

The Contractor shall take the necessary measures to protect the other trees and the branches of the trees, for example by applying wooden facing, etc. Prunings and shrubbery shall be destroyed on site or taken away. The tree roots will be dug out over the entire width of the working strip, destroyed or taken away.

All work in this connection will be carried out in accordance with methods that have been approved by the Owner and the Parties involved. It will be carried out in a manner that rules out the possibility of damage to trees, buildings, electricity, telephone or other distribution lines, residences, roads, etc. located in the vicinity of the working area.

Wounds to pruned or damaged trees will immediately be treated with a suitable product.

� � 4 !: 6 � ��;��+��

When the pipe line crosses mining or quarry area or where earthworks and underground installations are found, the Contractor will make the necessary arrangements and take steps to ensure safety in and around the construction sites, especially with regard to possible subsidence, collapse or landslip.

� � 4 !! �� * �+� ��

As a general rule, all the works will be carried out in accordance with the requirements of the governing Authority. All the means and measures will be taken in order to reduce as much as possible the adverse effects on the natural environment.

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Rev. 1 – 14/09/09 Part 2 - Page 13 of 13 � VS3 / 12 / e:\pradeep data\00_general technical specifications\gts revised 2009_gdf suez\mech 2008\70000_740_gts_502_part2.doc

APPENDIX (For information only)

PRIOR INVENTORY OF FIXTURES DRAWN UP IN THE PRESENCE OF BOTH PARTIES CDF IMP OPSRA Pipeline :

Owner :

Width of the path : m. Contractor :

Subcontractor : Date :

PLOTS OF LAND LOCATED ON THE TERRITORY OF THE MUNICIPALITY : NIS :

DS no.

Land Register

Div. Sect. No.

Surface

ha a ca

Place name or street and no.

Nature and cultivation

Length of the access way (m)

OWNER CRS : Name : First name : Address : Account :

USER CRS : Name : First name : Address : Account :

Special remarks (underground works, access roads, etc.)

The user will not be able to bring the plots of land concerned back into use until such time as the confirmation of the release of the land (section A or B) has been signed for agreement after the works. In the event of any breach of the foregoing conditions, any compensation for damages to be paid by the OWNER will be limited to damage within the working area described above.

Advance payment on possible damage to be paid : m x EUR = .............. EUR

Signature of the owner or user For agreement

Signature of the member of staff of the OWNER responsible for negotiations

Read for agreement The representative of the Contractor

Read for agreement The expert

White : OWNER - Yellow : Contractor - Blue : Subcontractor - Pink : User

OWNER : Date :

S S S

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4. DELIVERY AND HANDLING OF THE MATERIAL

4.1. GENERAL

The description and quantities of the materials supplied by the Owner and/or to be supplied by the Contractor are described in the PTS and in the part lists.

The Contractor takes delivery of the items after a joint inspection with the Owner, after which the acceptance note drawn up by both parties is signed jointly.

When the materials are being handed over, the Contractor must take the required measures to:

� comply with the conditions of edited by the Owner in the purchase specification;

� avoid any form of damage and pollution;

� have sufficiently qualified personnel and equipment in relation to the quantity and type of deliveries available to handle and/or string them quickly;

� facilitate the acceptance inspections.

All equipment used for taking delivery of, handling and/or stringing the materials must be approved by the Owner and or the Engineer and accompanied by a certificate drawn up by a recognised inspection organisation.

The application period for the supply of material (Owner's supply) will be at least 10 working days. The delivery shall be requested to the representative of the Owner on the site.

All contacts between the Contractor and the Owner’s suppliers must always be made through the presentative of the Owner on the site.

All documents delivered together with the materials must immediately be handed over to the Owner.

For pipeline elements (pipes, fittings, bends, etc.), the thickness specified in the parts lists are minimum thickness.

4.2. METHOD OF DELIVERY

4.2.1. Pipes

The Owner will specify in the purchase order the location of his store site and depot.

The Contractor himself must take responsibility for the collection of the Owner’s material.

a) Except otherwise stated by the Owner if the pipes are stored in the Owner depot, transportation to the site and unloading shall be borne by the Contractor.

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b) If certain materials are delivered directly to the site, this will be mentioned in the Particular Technical Specifications. In this case, the Contractor will only be responsible for unloading on the construction site. The Contractor chooses the unloading site and ensures that the access roads are sufficiently stable and accessible for the trucks of the supplier (min. length of trailer = 14.5 m). At least 5 working days prior to delivery, the Contractor sends an order form and a detailed plan indicating the unloading place and access roads to the representatives of the Owner/and or the Engineer on the worksite.

N.B.

The attention of the Contractor is drawn to the fact that uncoated pipes may be supplied with a plastic coating that has to be removed and evacuated to an approved waste disposal site.

4.2.2. Other materials (see part lists) and additional quantities

These can be collected by the Contractor from the Owner store or depot after prior written request sent to the Owner’s representative on the worksite.

If the PTS states that the Owner is responsible for delivery to the site, the Contractor will order the materials to deliver per full load in places accessible to trucks. Unloading is borne by the Contractor. Transport costs for incomplete loads will be charged to the Contractor.

4.3. ACCEPTANCE PROCEDURES

4.3.1. Owner depot or store site

Delivery shall be taken over by the Contractor during loading of the trucks. Every material element must be inspected by the Contractor for visible defects. For pipe elements, this is when uplifted. Defects are noted and reported jointly in the take over report (delivery note). In the absence of the Contractor, they are noted by the Owner and are not refutable.

4.3.2. Direct deliveries on the site

The take over by the Contractor of the pipe elements or other material directly deliver on the worksite will be carried out during the uplifting of the elements.

4.3.3. Take over report

The take over report is drawn up jointly (Contractor and supplier or Owner) and must, among other things, include the following information :

� the length of each pipe and the individual number;

� the identification number of the equipment and pipeline element;

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� any visible damage (scratches, dents, etc.);

� an estimation in dm² of the defects in the pipe external coating, visible or detected by means of a holiday detector (for test voltage see GTS part 9);

� any remarks regarding the deliveries.

4.4. MATERIAL TO BE SUPPLIED BY THE CONTRACTOR

4.4.1. Supplies

The materials indicated as “Contractor supply” on the part lists are supplied by the Contractor. For direct supplies to the worksite, the Contractor shall present the material supplied at least 2 working days prior to assembly to the Owner in order to control jointly the quantities supplied.

All costs resulting from late deliveries or from supply of damaged or defective material shall be borne by the Contractor. When some materials cannot be supplied, the contractor shall submit another option in writing to the Owner and/or the Engineer, taking into consideration the initially fixed term of delivery. The option is not accepted without the Owner’s prior written consent. For the electrical equipment instruments and installation located in hazardous area classified as class 1 zone 0, 1 and 2 the Contractor will hand over to the Owner and/or the Engineer the required certificate of conformity.

4.4.2. Extra supplies

Materials not listed on the part lists and that are required for normal operation shall be listed by the Contractor and communicated in writing to the Owner prior to the start of the works. This material shall be purchased by the Contractor with the written consent of the Owner and or the Engineer.

4.5. DEFECTS NOTED IN PIPELINE ELEMENT AND/OR EQUIPMENT AND THEIR METHOD OF REPAIR

Damage and defects that are noticed at the time of delivery and expressly described in the take over report will be borne by the Owner. The repair and removal of damaged parts shall be carried out by the Contractor at the expense of the Owner for a price corresponding with the price list.

Damage and defects noticed after delivery must be repaired at the expense of the Contractor, as well as any extra costs due to the inspection work of the recognised inspection organisation. In the event of any non-conformity of the material at the time of delivery, the Contractor must immediately inform the Owner and or before accepting the delivery. If this condition is not observed, the Contractor will be the sole responsible for all the consequences resulting therefrom.

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70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 4 - Page 4 of 7

4.5.1. Defect noted in pipeline element

Any defects noted in the pipeline element may under certain conditions be repaired. Nonetheless, the final decision whether or not to use repaired pipeline element rests with the Owner and/or Engineer.

4.5.1.1. Surface defects in the metal

Surface defects noted in the pipe metal may be removed by grinding/polishing as long as the thickness of the wall, obtained after grinding, remains within the tolerances of the relevant standard and codes.

All repaired superficial defects shall be examined by the inspection organisation by means of ultrasonic, electromagnetic or penetrant testing. If these wall thickness tolerances cannot be respected, the damaged part must be cut away. The undamaged parts will be bevelled again and bear an identification number, etc.

4.5.1.2. Dents in the metal

The pipes must show no evidence of dents. The damaged part shall be cut out and the undamaged parts will be bevelled again and bear an identification number, etc.

4.5.1.3. Defects to the external coating

Defects to the external coating must be repaired by the Contractor as specified in GTS part 9.

4.5.2. Defects to equipment and accessories

All defects must be reported to the Owner and/or the Engineer. Defects noted in the equipment (shut-off valves, safety valves, relief valves, regulator, etc.) must be repaired by the equipment supplier in order to maintain the guarantee. Defects to accessories (fittings etc.) must be inspected by the recognised inspection organisation and repaired according to their instructions by the Contractor.

4.6. STORAGE AND HANDLING OF MATERIALS

The Contractor shall provide separate storage areas for all materials delivered by the Owner. Pipes, pipe parts and equipment must be handled with sufficient care so that all damage is avoided.

4.6.1. Storage and handling of equipment

The Contractor shall pay special attention to the handling and storage of control devices (regulator, filters, shut-off valves, operators, meter, etc.) so that this equipment is supported adequately and in a correct manner and completely protected against infiltration of dirt and humidity.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 4 - Page 5 of 7

The Contractor should enquire with the Owner and/or the Engineer which method should be used for lifting special devices. The Contractor shall ensure that all openings in the equipment are sealed. The Contractor should provide all the means required to ensure that the external coating, paint and metallic paint are not damaged.

4.6.2. Storage and handling of pipes

The Tenderer shall enclose a stacking drawing with his bid. The pipeline elements may not come into direct contact with the ground or be placed on unsuitable supports. Encrustation's of gravel, stones, wood, etc. must be carefully avoided. Continuous contact of the pipeline parts with each other - in particular, pipes stacked cross-wise - is forbidden. To this end, cushions, wickerwork, bags of straw or other flexible materials must be provided over a sufficiently large surface area. The Contractor will assure the stacking of pipes in such a way that rules out any permanent deformation of the pipeline element taking account of their weight and resistance.

The maximum stacking height for PE-coated pipes, depending on the diameter of the pipe, is shown in the table below :

Nominal diameter Number of layers, stack height

≤ 150 12

200 - 250 10

300 - 350 8

400 - 450 6

500 - 650 5

> 700 3

Between the ground surface and the first layer there shall be a free height of 20 cm. The pipes shall be placed on a suitable support so that damage to the coating and deformation of the pipes are avoided. The bottom layer of pipes will be sufficiently supported at the sides to ensure stable stacking. The lower pipes shall be supported from 0.75 m from their ends and crosswise at least every 4th meter.

During periods of high temperature, the Owner may require protection of the coating against the sun. Newly manufactured pipes that are delivered directly by the pipe supplier to the site may contain static electricity which must be discharged before handling the pipes. All supplementary material (supports, cushions, wickerwork, etc.) must be delivered in suitable quantities by the Contractor. The use of hooks without teflon protection is not permitted.

4.6.3. Storage areas

The Contractor shall provide the following storage areas on the site :

� A covered and locked storage room for the storage of all small material and all materials or packagings that are not weather-resistant.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 4 - Page 6 of 7

� A marked-off stacking area for all large material that is weather-resistant.

4.6.4. Stringing of the pipes (pipeline construction)

The Contractor specifies the method of handling in the execution method file. The pipes shall be distributed by the Contractor along the pipeline alignment in the working area. He shall ensure that they do not hinder the traffic and shall prevent their lying too long in a situation that would be harmful to them (intactness, quality of coating). Transportation will be effected with suitable equipment to prevent damage to pipes and terrain. In rainy weather or on unstable subsoil, transportation will only take place with vehicles fitted with caterpillar tracks. The pipes must be laid on wooden blocks at least 0.15m x 0.15m x 1m or sand bags. The blocks or sand bags shall be provided by the Contractor.

4.7. PIPE OFF CUT

4.7.1. General

The Contractor shall keep a detailed inventory of the pipes received, per type of pipe, and a note of their location. On every 15th and 30th day of the month, the Contractor shall provide the Owner and or the Engineer with a detailed summary of:

� the pipes off-cut that can still be used in the lifetime of the Contract (minimum length, without defects and numbered, see Article 6);

� the rejected pipes, stating the reason for their rejection.

Before the end of the leak tests, the Contractor must provide the Owner with an inventory of the surplus pipes.

The term “surplus pipe” is defined as:

any pipe that can immediately be reused (undeformed, numbered, coating and chamfers in good condition), bearing the individual pipe number, stamp of the recognised inspection organisation, origin, type and length.

4.7.2. Pipeline construction

Only complete lengths of pipe element will be taken back by the Owner; all other pipe surpluses are the responsibility of the Contractor. Before termination of the strength and leak tests the Contractor will draw up a final account of the pipes and transmit it to the Owner and or the Engineer.

Settlement formula :

X = Tr - (Tp + Tc + Cr + Lr)

where :

Tr = length of the pipes delivered and accepted on the working sites.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 4 - Page 7 of 7

Tp = length of the pipes effectively laid

Tc = 1.5 ‰ permitted loss

Cr = length of the remaining whole pipe elements

Lr = length of defective pipes element rejected for reasons which are not imputable to the Contractor

X = length invoiced to the Contractor (non re-usable pipe element or missing pipes).

4.8. RETURNING SURPLUS MATERIALS

The Contractor shall be responsible for collecting, transporting and unloading surplus material. This material must be sufficiently clean so that it cannot be distinguished from new. Returned material shall always be accompanied a document that shall be drawn up by the Contractor and countersigned by the Owner and or the Engineer. Material that is defective and/or unaccepted by the Owner will be charged to the Contractor.


Only whole and unbent pipes element in perfect condition shall be accepted. They must be transported to the Owner's storage site.

4.8.2. Station construction

� Only surplus pipes longer than 1m and bearing an individual number will be returned to the Owner’s storage site. They shall bear the stamp of a recognised inspection organisation and shall again have chamfers along both sides;

� All unused equipment and small material must be returned to the Owner's warehouse.

4.9. USEFUL INFORMATION

4.9.1. Owner's storage site, warehouse and workshops addresses

To be specified in the PTS.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/0502

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GTS/0502

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SPECIFICATION

70000 740

GTS/0502

Rev. 1 – 14/09/09 Part 5 - Page 1 of 5

5. ��

5.1. ��

Changes in direction may be made by use of

� elastic bends;

� field cold bends (of coated pipe);

� hot bends (of uncoated pipes);

� factory-made elbows;

� mitred or wrinkle bends are not permitted.

Changes in direction are performed on the basis of the plan view and the longitudinal profile of the bottom of the trench. So the insertion of any change in direction element enables the pipe to be laid without any stress whatsoever.

The field of application of each method is described below.

5.2. ��

Elastic changes in direction of the pipe string are only permitted if the bending radius of the concerned section is at no point less than 1,200 times the outside diameter (O.D.) of the pipe.

In each case the working method must be submitted for agreement to the Owner and/or the Engineer.

The use of smaller bending radii should be substantiated with calculations and approved by the Owner and or the Engineer and the recognised inspection organisation.

5.3. �� "��

When cold bending coated pipes, the following specifications must be met :

� The bending radius must be at least 40 times the outside diameter of the pipe, except for 2” pipes where the bending radius must be at least equal to 5 times the outside diameter of the pipe.

� Regardless of the diameter of the pipe heating is not permitted.

� Bending will be performed with machines that ensure continuous bending without wrinkles or undulations in the curved pipe section.

� A bending mandrel is compulsory if D/e ≥ 50 (outside diameter / thickness).

� A bending mandrel must be used if, during bending, wrinkles or undulations occur or if the ovalisation tolerances cannot be respected.

� For the longitudinal seam welded pipes the seam weld will be positioned at the neutral axis of the bend.

� When the ambient temperature is less than 0°C it is forbidden to bend P.E.-coated pipes.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/0502

Rev. 1 – 14/09/09 Part 5 - Page 2 of 5

� The thickness of the pipe wall on the outside of the bend must remain within the tolerance limits given for the pipes. One test bend of minimum 10° is made when starting the site operation. The coating of this bend is removed completely to allow inspection of the pipewall. The coating is repaired afterwards.

� Clamping metal to the inside of the bend must be such that the inner diameter of the pipe remains within the ovalisation tolerances. The Owner will perform random sample checks. If necessary, the coating will be removed completely for this purpose.

� For successive bent pipes with a longitudinal welded joint, this joint shall be alternatively on the upper and lower side.

� For helical seam welded pipes that contain a coils connecting weld, bending may only be carried out on the pipe sections that are laid at least one pipe diameter from the welded joint.

� Ovalisation after bending will be maximum 2.5% of the outside diameter of the pipe. If wrinkles occurs, the permissible fault depths shall be less than 0,01 times the distance between two consecutive peaks. A gauging plate of soft steel (length = 1.5 x O.D.) shall be pulled through the field bends to check compliance with the above requirements. The plate dimensions will depend on the characteristics of the pipe and the different permissible tolerances.

For the longitudinal seam welded pipes the seam weld will be positioned at the neutral axis of the bend.

� Tolerance on ovalisation: the same tolerance as for the pipes.

� The field cold bends may not be cut in the curved section.

� They may nevertheless be cut in their straight section as long as the straight length specified below remains at each extremity of the pipe:

For pipes DN50 up to and including DN400:

� 500 mm at each extremity.

For pipes DN500 and higher:

� 2 times the outside diameter of the pipe at each extremity.

� the maxima deflection angle for the given diameter per deflection :

Diameter Minimum internal deflection

Maximum deflection angle per step

4” 12 cm 1.5°

6” 17.5 cm 1.5°

8” 20 cm 1.4°

10” 20 cm 1.2°

12” 20 cm 1.0°

16” 23.5 cm 0.8°

20” 23.5 cm 0.6°

24” 23.5 cm 0.6°

30” 30 cm 0.5°

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/0502

Rev. 1 – 14/09/09 Part 5 - Page 3 of 5

36” 30 cm 0.5°

40” 30 cm 0.5°

48” 32 cm 0.4°

5.4. ��

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The “Long Radius” and “Short Radius” elbows comply with the relevant codes and standards.

The “Long Radius” and “Short Radius” bends used in high-pressure installations may not be cut.

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� The hot bends shall be manufactured from uncoated line pipe element.

� The bends will be manufactured in accordance with the relevant PTS.

� See part 4 for the supplier, of the line pipe elements as well as the method of delivery and the acceptance procedures.

� The tenderer shall enclose a short list with the workshops specialised in hot bending and induction bending he intends to use as sub-contractor to fabricate the hot bends. He will include also the manufacturing process used.

� The Owner and or the Engineer has the right to reject a sub-contractor without any explanations.

� Prior to start the construction works.

The Contractor will submit to the Owner and or the Engineer a list with all the necessary information concerning the workshops selected to fabricate the hot bend.

� Before coating the bare hot-bend the pipe will be sand blasted on the entire length (see part 18 of the GTS).

� All the tasks related to the manufacture of the hot bend will be under the charge and the responsibility of the Contractor, they can be resume as :

� cost of manufacturing, testing, inspection, etc;

� transport to and FRO the workshop, handling, etc;

� external coating of the bare bends.

� Prior to fabricate the hot bends the Contractor will control and confirm the deflection angle mentioned on the drawings supply by the Owner.

� The locations when the use of a hot bend is requested are mentioned on the alignment sheet and detail drawings.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/0502

Rev. 1 – 14/09/09 Part 5 - Page 4 of 5

The hot bends may not be cut in the curved section. They may nevertheless be cut in their straight section as long as the straight length specified below remains at each extremity of the pipe:

� For pipes DN 50 up to and including DN200:


� For pipes DN 250 up to and including DN400:


� For pipes DN500 and higher:

� 2 times the outside diameter of the pipe at each extremity.

5.5. ��"�� -��

When the Contractor draws up his construction plan, he will make a list of the pipes to be curved, mentioning the following:

� the sequence number of the longitudinal profile;

� the individual number of the curved pipe;

� the deflection angle;

� the direction of the curved pipe

� LC (Lower Curve)

� UP (Upper Curve)

� LHC (Left Horizontal Curve)

� RHL (Right Horizontal Curve)

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 502

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70000 740

GTS/ 502

Rev. 1 – 14.0.09 Part 6 - Page 1 of 1 � 20 /

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GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 502

Rev. 1 – 14.0.09 Part 6 - Page 1 of 12 � 20 /

6. ��

Applicable documents :

� API 1104 Nineteenth Edition , Sept. 1999 � The present GTS.

General :

� API 1104 is applicable and all paragraphs of the present GTS as specified below.

� The line welds will be, to the extend possible, welded by an automatic or semi-automatic process. The requirements for automatic welding will be according to Section 12 of API 1104 as amended in this GTS under Section 6.5. "Automatic Welding".

� Manual welding will be used for all other welds where, in principal, automatic or semi-automatic welding is not possible or not justified for technical or economical reasons. This can apply, e.g., in the case of steep hills in the line, crossings, tie-ins, stations, special points, in city environment and other situations where access with the automatic or semi-automatic welding machines is limited.

� The Contractor must clearly state in his bid where automatic, semi-automatic or manual welding will be applied, and what type of welding process he intends to use.

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Only qualified welders, according to the requirements of Section 6 of API 1104, will be used for the manual welding processes.

� The Contractor will take all the necessary measures to implement the welder qualification tests.

� The qualification tests will be made using a coupon of a line-pipe. Every welders will execute a test weld using a qualified procedure.

� A welder who has successfully completed the qualification test shall be qualified.

� Every welder shall execute for his qualification test a weld at least on half the circumference of the pipe starting from the top of the pipe until the bottom.

� If the W.P.S. specifies a procedure for a single welder.

� The welder will execute the weld test on the entire circumference of the pipe.

� A welder can only participate once to the qualification test. If he didn't completed successfully the qualification test session, he will be disqualified for the present contract.

� Before production welding is started, the Contractor will submit to the Owner and or the Engineer and/or appointed Third Party Inspection Agency :

� the list of the qualified welders; � the procedures for which they are qualified; � the records of the welding performance test; � the validity dates of the qualifications.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 502

Rev. 1 – 14.0.09 Part 6 - Page 2 of 12 � 20 /

� If during welding, question arise about his competence (e.g. too many repairs), the Owner, Engineer and/or Third Party Inspection Agency may require a re-qualification, eventually after an additional welder training.

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6.2.1. General

The welding procedures qualifications must be performed according to the requirements of Section 5 of API 1104, the additional requirements specified on this GTS.

The characteristics of the pipeline elements are described in the PTS.

A welding procedure qualification must be performed for :

� each welding procedure used; � each diameter and thickness (see PTS); � for each type of steel, from a different origin (steel mill and/or pipe mill).

The use of the same welding procedure qualification for different thickness and/or different origin of steel is only acceptable after written approval of the Owner and/or Engineer.

6.2.2. Preliminary Welding Procedure Specifications (WPS)

� The Tenderer shall attach to his bid every preliminary Welding Procedure Specifications (WPS) he intends to use during the execution of the work. He will indicate where and under what circumstances these WPS are applicable i.e. line welding, repair welding, tie-ins, stations, etc...

� Once the Owner has approved and ordered the work, the Contractor shall submit a list of required final WPS he plans to qualify and use. The required material for the qualification tests should be added.

� After approval by the Owner and/or Engineer of these documents, the Contractor can start with the qualification welding.

� The Tenderer will quote a price per WPQ, since the total number of procedures depends on different factors, which are not known at the moment of the bidding.

6.2.3. Additional essential variables

Referring to API 1104 (Sections 5.3. and 5.4.), following additional essential variables are also applicable :

� 5.3.2.3. and 5.4.2.5. Diameters and wall thicknesses

� Line pipes

Each diameter and wall thicknesses shall be subject to a different WPQ.

� 5.3.2.5. and 5..4.2.6. Filler metal and number of beads

� The type and size of electrodes, and the brand name used for the welding in an uphill or downhill direction must be submitted for approval by Owner and/or Engineer.

� In addition, the change in filler metal from a different Supplier will require new qualification of the applicable WPS.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 502

Rev. 1 – 14.0.09 Part 6 - Page 3 of 12 � 20 /

� A charge in the number of beads will also require a new WPQ.

� 5.3.2.13., 5.4.2.8. Pre- and post-heat treatment, tune between paces, cooling rate (i.e. heat management)

� The preheat temperature must be specified in the WPS and checked during welding. The prescribed preheat temperature may not be exceeded by more than 100° C. If the ambient temperature is lower than 5° C and/or the weld joint is damp, the pipe must be preheated to a temperature of minimum 50° C.

� The line between paces must be specified.

� Post-weld heat treatment and/or controlled cooling of the welded joint must also be specified in the WPS and respected during welding.

� 5.4.2.2. Base material

Any base material, even from the same type but from a different steel mill and/or pipe mill will result in a separate WPQ, except when written approval is given by the Owner and/or Engineer for a waiver.

� 5.4.2.3. Joint design

Minor changes to a joint design, as specified in WPS, cannot be made without re-qualification, except when written approval is given by the Owner and/or Engineer.

� 5.4.2.9. Direction of welding and number of welders

� For each WPS, the number of welders will be specified.

� The welding position and direction of welding for each welder will be specified.

6.2.4. Qualification tests

6.2.4.1. Introduction

The qualification test will be executed as described in Section 5.6. of API 1104, as amended by the requirements of this GTS.

Qualification tests must be carried out with the material from same origin (steel mill and pipe mill) as the material that will be welded by the Contractor in the field.

The pipes for the qualification tests must be provided by the Owner.

The number of qualification welds to be executed depend on the scope of work and eventually the origin of the pipe material.

The number of qualification tests can therefore only be determined after procurement of the pipes, and will be notified in writing by the Owner and/or Engineer.

The Owner, Engineer and/or the Third Party Inspection Agency will attend the welding, mechanical testing, and non destructive testing of WPQ.

6.2.4.2. Additional general requirements

In addition to the test specified in Section 5.6. of API, the following testing will be done during the Welding Procedure Qualifications :

GENERAL TECHNICAL

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Rev. 1 – 14.0.09 Part 6 - Page 4 of 12 � 20 /

� Non-destructive testing

� Visual examination � X-ray testing � Manual ultrasonic testing � Electromagnetic examination

� Additional destructive testing

� Charpy impact testing in the weld metal and Heat Affected Zone (HAZ) � Macrographic examination � Hardness testing

Further details are provided below.

6.2.4.3. Non-destructive testing

1. Visual examination

The qualification test welds must be usually examined, on the inside and outside.

The acceptance criteria for the visual examination are stipulated in Part 7, Article 7.2.1.1 of the GTS.

2. Radiographic Examination

Each qualification test weld will be 100 % examined by radiography, according to the requirement of Section 11.1. of API 1104.

The Radiographic Examination will be performed by filmy x-ray method (not gamma ray) and will be done according to a written procedure drafted and/or approved by a Level III according to American Society of None Destructive Testing (ASNT) (or equivalent).

The x-ray operate must be Level II according ASNT (or equivalent).

The acceptance criteria are specified in the Section 9.3. of API 1104.

3. Ultrasonic testing

Each qualification test weld will also be 100 % examined by the ultrasonic method, according to the requirement of Section 11.4. of API 1104.

The acceptance criteria are specified in Section 9.6. of API 1104.

The ultrasonic testing will be executed, after the x-ray examination and interpretation of the films.

The results of both examination methods will determine the acceptability of the qualification test welds.

4. Magnetic particle examination (MT)

This examination will only be performed after acceptance by visual - radiographic and ultrasonic testing.

The weld will be 100 % electromagnetically tested, after grinding out the reinforcement on the internal surface.

The testing method must be in agreement with Section 11.2. of API 1104.

GENERAL TECHNICAL

SPECIFICATION

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Rev. 1 – 14.0.09 Part 6 - Page 5 of 12 � 20 /

The classification of the indications and the acceptance standards are defined in Section 9.4. of API 1104.

The additional macrographic examination will be preferentially located in the areas where imperfections are observed with the MT method.

6.2.4.4. Destructive tests

� Before the tests are carried out, test welds using a cellulose electrode may be rendered hydrogen-free. This is carried out by heating the test weld to a temperature of 200 - 250° C for a minimum of six hours.

� The destructive tests must be in accordance with Section 5.6. of API 1104.

� The following destructive tests must be performed on the welding qualification test pieces :

1. Impact testing

� 3 sets of 3 full size Charpy V - notch specimens must be taken in each process qualification weld in transverse direction to the weld :

� 1 set of specimens will be located in the middle of the weld thickness, with the notch located in the HAZ;

� the other 2 sets of Charpy V notch specimens will also be taken in the middle of the weld thickness with the notch located in the deposited weld material. These two sets must be taken at 180° C from each other, i.e. 1 set at the top of the weld and the other set at the bottom of the weld.

� The test temperature of all Charpy V tests is -20° C.

� The acceptance criteria are :

The average value of a set of 3 specimens shall not be less than 35 J/cm².

In addition, the lowest individual value of only one of the three specimens shall not be less than 28 J/cm².

2. Macrographic examination

4 macrographic examination of the full cross-section of each qualification weld will be performed. The location of these macrographic examination will, by preference, be estimated in the area where imperfections were observed during the electromagnetic examination of the weld. These locations will be indicated by the Owner, Engineer and/or appointed Third Party Inspection Agency.

3. Hardness testing

A serie of 10 hardness measurements will be taken at the level of the penetration bead in each cross section taken for macrography :

� 2 measurements will be in the base metal � 2 in the HAZ � 6 in the weld metal (from HAZ to the middle of the weld).

The average value of these measurements in the base metal, HAZ and weld will be max. 370 HV 10. An individual value may be max. 400 HV 10.

GENERAL TECHNICAL

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Rev. 1 – 14.0.09 Part 6 - Page 6 of 12 � 20 /

6.2.5. Qualification of the welding procedures for repairs

Welding procedures for repairs will be submitted by the Contractor for approval by the Owner, Engineer and/or Third Party Inspection Agency.

Each repair welding procedure must be qualified according to API 1104.

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6.3.1. Welding conditions

The welding conditions as specified in Section 7 of API 1104 are applicable.

In addition, the following conditions are applicable :

� All welds and weld repairs shall be carried out in accordance with qualified welding procedures, by qualified welders.

� In the event of wind, rain or low temperatures which may affect the stability of the arc, welding tents or other suitable protection shall be used.

One end of the pipe shall be sealed off during welding to avoid drafts which may influence the stability of the arc.

The protective measures are subject to approval of the Owner, Engineer and/or Third Party Inspection Agency's representative on site.

� The welding procedures must specify the requirements concerning the interpass temperatures and the acceptable rest times between the different runs.

In any case, the rest times between the different runs shall be kept to a maximum. The first three layers must always be performed without rest times. Only the necessary time for eventual brushing or grinding is allowed.

� Interruption in the welding for more than 30 minutes can only be allowed if the weld grove is filled up more than 40 % of the wall thickness.

� All welds must be completely filled at the end of a working day.

� The required pre-heat temperature (as stated on the qualified welding procedure) must be checked on each weld at the moment that the welding will be started. No welding should be performed if the minimum pre-heat temperature is not reached or exceeded by 100° C.

� If the welding is interrupted at the end of the welding pieces, isolating blankets should be put on the weld to avoid a quick cooling of the weld.

� The pipe elements to be welded shall be supported in a suitable manner without damaging the coating of the pipe. The height of the supports (wooden blocks or sands bags) must be such that each weld is at least 40 cm above the ground.

� After welding all weld spatter will be removed by grinding and/or brushing.

� Successive beads should not stop and/or end at the same place. The stops and starts of successive beads should be at least 10 cm shifted.

GENERAL TECHNICAL

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Rev. 1 – 14.0.09 Part 6 - Page 7 of 12 � 20 /

6.3.2. Preparation of the welding work

6.3.2.1. Verification of good condition of pipes and fittings

The Contractor shall check the condition of the pipes and fittings. Any defects (scratches, indentations, chips in the bevels, etc.,) shall be reported to the Owner and or the Engineer and the Third Party Inspection Agency.

6.3.2.2. Preparation of the pipe ends

The Contractor shall take account of the fact that the pipe ends may be protected with an anti-rust primer.

The ends of the pipes (bevel and root face) shall be cleaned with a metal brush, file or grinder. The bevels shall have an even surface free from laminations tears, scale, slag, grease, paint, etc...

If the pipes are delivered on site without prefabricated weld levels (i.e. plain ends), the bevelling will be performed on site by the Contractor, according to the requirements of the qualified welding procedures.

The levelling should be done as close as possible before the start of the welding pieces.

6.3.2.3. Joint preparation

The pipe ends are bevelled according to the pipeline technical delivery conditions.

If pipes of unequal thickness must be joined, the Contractor shall carry out the necessary additional joint preparation himself to bring the joint preparation into line with fig. 15 of standard ASME B 31.8.

Should a cut be made, the cutting material and the working method shall be subject to the approval of the Owner and or the Engineer and the Third Party Inspection Agency.

The unprocessed pipe ends shall be ground so that the bevels and root faces meet the requirements of the WPS.

The markings shall be transferred to the pipe element which does not contain this information. In the absence of these data, the pipe element in question shall be rejected and considered unfit for reuse.

6.3.2.4. Alignment

a) General

For both longitudinally seam and helical seam welded pipes, the pipes shall be positioned so that the ends of the longitudinal or helical welds of two successive pipes are offset from each other by at least 100 mm, measured on the circumference.

b) Pipeline fabrication

All longitudinal seam welds must be in a circular sector of 45° along either side of the lowest traced line of the pipe.

c) Station construction

For pipeline branches, a distance of 100 mm shall be maintained between the longitudinal seam or helical seam weld and the butt weld of the branch.

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The zone cut out of the pipe shall be examined by ultrasound beforehand (zone of 100 mm along and around the complete weld).

If a distance of 100 mm cannot be maintained between the longitudinal or helical seam weld and the butt weld of the branch, the longitudinal seam or helical seam weld of the pipe shall be examined ultrasonically beforehand over a distance of at least one diameter along either side of the zone to be cut.

If these checks reveal any unacceptable imperfections, another zone shall be sought.

6.3.2.5. Handling of pipes during welding and support of the pipeline

The pipes shall not be manipulated during the welding of the first run (root bead). Thereafter they shall be supported on wooden blocks or sand bags without creating any additional stresses.

6.3.3. Arrangement of the pipe elements

6.3.3.1. Pipeline fabrication

working in line:

The length of the pipes to be welded shall be at least twice the pipe diameter, with a minimum of 1 m.

On either side of each circular joint, only one round joint shall be permitted within a distance of 8 m.

6.3.3.2. Gas Stations (and valve stations)

The number of welds shall be limited to a strict minimum. Should a bridging sleeve be used, it shall be at least 1 x ∅ in length.

The welds shall be carried out as pipe-to-pipe connections. Thus for a butt weld where moulded pieces are used, the pipe sections shall be welded to them first.

Tie-ins-butt welds which cannot be hydrostatically tested for strength shall be performed on pipes having the same wall thickness.

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6.4.1. Numbering

6.4.1.1. Pipeline fabrication

In accordance with the provisions of Part 2, the Contractor shall indicate the kilometre points along the working strip.

The welds between KP 0 and KP 1 are numbered 000/0001, 000/002, 000/003 etc. The welds between KP 1 and KP 2 are numbered 001/001, 001/002, 001/003 etc. All tie-in welds between KP 0 and KP 1 are numbered 000/101, 000/102, 000/103 etc.

These numbers are shown on the radiographic images preceded by the digit code number of the pipeline.

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6.4.1.2. Gas station construction and valve stations

In the gas stations, the welds shall be numbered according to the Owner particular numbering system or numbering system approved by him and/or Engineer.

Example of a gas station numbering system (for information only) :

9.99.999 / STXX / 9999 where;

9.99.999 = the code number of the installation of the Client ST = standard 'ST' to indicate 'STATION' XX = the first two letters of the name of the gas station 9999 = maximum of four figures for the individual weld number.

6.4.1.3. Applying the weld numbers

The Contractor will submit for approval to the Owner and or the Engineer the way he will indicate the weld number on the pipes.

The Contractor shall apply the weld number next to each weld in a correct and legible manner using an indelible product.

6.4.2. Welding data records

The Contractor shall provide the Owner and/or the Engineer on a daily basis with all the information for inspection and technical files, i.e. for every weld, root head, filler beads and finish beads :

� the ID of the welders who have carried out the welds; � the weld number � the date of the execution of the weld � the individual numbers of the joined pipes and/or accessories, their grade, nominal thickness, origin and

length � the WPS used � the number of repairs or cut out welds, the reason for repair and the date of repair.

All these data must be signed by both the Owner and or the Engineer and the recognised inspection organisation.

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General

Line welds will be welded by an automatic or semi-automatic method : exceptions to this general requirement must be approved by the Owner, Engineer and/or Third Party Inspection Agency..

The requirements are those stipulated in Section 12 of API 1104 "Automatic welding", as amended below by this GTS.

The amendments are given in accordance with the respective articles of API 1104 - Section 12.

Art. 12.1. : Acceptable procedures

Add :

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The welding process and the type of welding machine must be detailed in the bid documents, including the eventual name(s) of the subcontractor(s) and/or supplier of the welding machine(s).

Art. 1.2.2. : Procedure qualification

� The qualification procedure shall be done on the same pipes that must be welded on site for this project. The pipes will be provided by the Owner.

� One procedure qualification must be done per :

� diameter � thickness � origin of the pipe (steel mill and/or pipe mill).

� The conditions for the procedure qualification must be as close as possible to the conditions that will be met on site.

� The mechanical testing will be the same as for the qualification testing of manual weld (see Section 6.2.4. of this GTS).

� The non-destructive testing will also be the same as specified in Section 6.24. of this GTS, except that the UItrasonic Testing (UT) will be performed by the automated UT method that will be used on the field welds and by the same non-destructive testing company.

The requirements for the field testing are specified below.

Art. 12.4. : Procedure specification

12.4.1. General

� A preliminary WPS shall be added to the bid documents with all information as stated below.

� The origin and/or brand name of the major parts of the machine will be stated, i.e. welding machine, levelling machine, clamps, ...

12.4.2. Specification information

12.4.2.1. Process

A detailed description must be given.

12.4.2.2. Pipe and fitting material

Pipes will be provided by the Owner.

12.4.2.3. Diameters

As specified in the PTS.

12.4.2.4. Wall thickness

As specified in the PTS.

One qualification must be done per diameter and thickness, and combination (e.g. if different thicknesses must be welded together).

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12.4.2.5. Joint design

� One sketch per diameter and thickness, or any combination of thicknesses.

� A detailed description must be given of the bevelling machine, including brand name and/or name of manufacturer.

12.4.2.6. Filler metal

In addition, the type, size and brand name of the filler metal shall be given.

12.4.2.10. Time between paces

� The qualification parameters must be the same as those that will be utilised on site. Under these conditions, a weld that has been started must be completed.

12.4.2.11. Type of lining clamp

A detailed description of the clamp and how it operates must be given. In addition, the brand name or a name of manufacturer must be given.

12.4.2.12. Cleaning

In addition, the cleaning after welding must be specified.

12.4.2.13. Preheat treatment

The method of measuring the preheat temperature shall also be specified.

12.4.2.14. Post-heat treatment

The use of isolation blankets during the cooling-off of the weld should be specified, and also applied during the qualification testing.

12.4.2.16. Shelding flux

The American Welding Society (AWS) classification number and brand name number shall be given.

12.4.2.18. Other factors

Some of these factors are :

� the use of a tent or any other means of weather protection � the composition of the welding team, and their qualifications � The time required for :

� preparation of welding � welding cycle � cleaning

� number of welds that is foreseen on site per hour (for different diameters and thicknesses)

Art. 12.5. : Essential variables

In addition to API requirements, the following amendments are applicable :

12.5.2.2. Pipe material

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Pipes from different steel mills and/or pipe mills will be qualified for each origin.

12.5.2.4. Wall thickness

� Each thickness/diameter combination will be qualified separately. � The welding of different thicknesses shall also be qualified separately.

12.5.2.5. Pipe diameter

See 12.5.2.4.

12.5.2.6. Filler metal

A change in type, diameter and/or brand name of filler metal will require re-qualification.

12.5.2.11 Shielding flux

A change in AWS classification and/or brand name will require re-qualification.

12.5.2.12 Speed of travel

In addition, the total welding time, as stated in the welding procedure, should not change beyond ± 10 %.

Art. 12.6. : Qualification of welding equipment and operators

The destructive and non-destructive testing, as defined above, must be performed.

Art. 12.7. : Records of qualified operators

The company must keep detailed records of the welding operators on site, in a manner that an operator performing repeated bad welds may be identified. The Owner, Engineer and/or third party agency may request his renewal from the site. He may only be re-qualified after complementary training and approval by the Owner/engineer.

Art. 12.8. : Inspection and testing of production welds

� In addition, the amendments of this GTS will apply.

� All automatic welded joints will be inspected by automatic UT, as described in Section 7.9. of this GTS.

Art. 12.9. : Acceptance standards for NDT

See GTS Part 7 "Inspection and testing of production welds".

Art. 12.10. : Repair and removal of defects

The same criteria apply as for the manual welds (see 7.7. of this GTS).

Art. 12.11. : Radiographic testing

The testing of the automatic and semi-automatic welded joints shall be done by automatic UT (AVT) (See Section 7.9.).

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PART 7

Inspection and testing of production welds




C 27/08/03 Updated MRT MRY DKB




GENERAL TECHNICAL

SPECIFICATION

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Rev. 1 – 14/09/09 Part 7 - Page 1 of 8

TABLE OF CONTENTS

7. INSPECTION AND TESTING OF PRODUCTION WELDS ................................................................................ 2

7.1. GENERALITIES ................................................................................................................................................. 2

7.2. TESTING OF WELDED JOINTS AND ACCEPTANCE CRITERIA ............................................................... 2

7.2.1. Non-destructive testing .............................................................................................................................. 2

7.2.2. Other test methods ..................................................................................................................................... 3

7.2.3. Destructive tests ......................................................................................................................................... 3

7.3. IDENTIFICATION OF INCOMPETENT WELDER(S) .................................................................................... 4

7.4. IMPLEMENTATION OF THE NON-DESTRUCTIVE TESTS ......................................................................... 4

7.5. ANNOUNCEMENT OF TEST RESULTS ......................................................................................................... 4

7.5.1. General ....................................................................................................................................................... 4

7.5.2. Welding of tie-ins, special points, and repairs ........................................................................................... 4

7.6. INSPECTION OF FILMS BY CONTRACTOR ................................................................................................. 5

7.7. LOCAL REPAIRS AND CUT-OUT OF DEFECTIVE WELDS ........................................................................ 5

7.7.1. General ....................................................................................................................................................... 5

7.7.2. Pipeline construction .................................................................................................................................. 5

7.8. SHARING OUT THE TEST COSTS .................................................................................................................. 6

7.9. INSPECTION AND TESTING OF AUTOMATIC WELDED JOINTS............................................................. 6

7.9.1. General ....................................................................................................................................................... 6

7.9.2. Details of the AUT procedure .................................................................................................................... 6

7.9.3. Implementation of AUT ............................................................................................................................. 7

7.9.4. Acceptance standards for AUT .................................................................................................................. 7

7.9.5. Calibration blocks ...................................................................................................................................... 8

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7. INSPECTION AND TESTING OF PRODUCTION WELDS

7.1. GENERALITIES

� The Inspection and testing of the field butt welds will be done according to the requirements of API 1104, and these of this GTS.

� The line welds will be to the extend possible welded by an automatic or semi-automatic paces. The inspection of these welds will be done by an Automated Ultrasonic System (AUT). The requirements for these inspections will be treated under Section 7.9. "Inspection and testing of automatic welded joints".

� The inspection and testing of the production welds will be supervised on site by the Owner, Engineer and/or third party inspection agency.

7.2. TESTING OF WELDED JOINTS AND ACCEPTANCE CRITERIA

The welded joints shall be tested prior to painting or coating.

7.2.1. Non-destructive testing

7.2.1.1. Visual inspection

The visual inspection shall be interpreted in accordance with API 1104 with the following additional requirements :

� Arc ignition points :

� ≤ 0.5 mm : acceptable if ground out � > 0.5 mm : unacceptable and cut out

� Mass clamp craters :

� ≤ 0.5 mm : acceptable if ground out

� 0.5 mm - 1.5 mm : acceptable if ground out and welded according to repair procedure

� > 1.5 mm : unacceptable and cut out

7.2.1.2. Radiographic testing

� Radiographic testing with x-rays shall be carried out in accordance with the provisions of API 1104.

� Gamma-rays shall only be used in case that the use of x-rays equipment is not possible and is agreed y the Owner, Engineer or third party inspection agency.

7.2.1.3. Ultrasonic testing

7.2.1.3.1. Test method and acceptance criteria

� Manual UT shall be carried out in accordance with ASMEV - Art. 5 and API 1104.

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� The automatic or semi-automatic welded line pipe joints shall be tested by an automatic UT system (See 7.9.).

7.2.1.3.2. Scope of the test

a) Minimum test planned

� Manual welded joints will be 100 % tested by x-ray, and eventually also by manual UT, if deemed necessary by the Owner, Engineer and/or third party inspection agency, e.g. if there is doubt concerning the quality of the weld on basis of the interpretation of the x-ray films.

� For the stations and valve stations all welds will be inspected by x-ray, eventually complemented by UT if deemed necessary by the Owner, Engineer or third party inspection agency.

� Welded joints which are welded with the use of external clamps (e.g. tie-ins) shall be tested by 100 % x-ray and 100 % UT.

b) Supplementary tests

Further to a decision by the Owners and a Engineer and the third party inspection agency (for example in the event of cracks), all the welds carried out in the course of that day may be tested with ultrasound and if necessary this inspection may be extended to all welds. If these tests bring to light any defective welds, the Contractor shall carry out the repairs at his own expense.

7.2.2. Other test methods

As well as the non-destructive tests described above, the Owner and/or the Engineer and the third party inspection agency may decide to carry out additional destructive or non-destructive tests, such as :

� magnetic particle test � liquid penetrant test � weld sampling � any other destructive or non-destructive test methods.

The acceptance criteria for the magnetic partial test and liquid penetrant test are defined on the basis of the following standards:

� Magnetic particle test :

� Method : ASME V - Art 7 � Acceptance criteria ASME VIII- Div 1 - App 6 and API 1104.

� Liquid penetrant test :

� Method ASME V - Art 6 � Acceptance criteria ASME VIII- Div 1 - App 8 and API 1104.

The acceptance criteria for the weld samples shall be the same as for the welding procedure qualification.

7.2.3. Destructive tests

In case of doubt of welding quality (i.e. too many repairs), the Contractor may be ask to cut out one production weld with a minimum of 50 cm of material on either side of the weld.

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Rev. 1 – 14/09/09 Part 7 – Page 4 of 8

The production welds to be cut out shall be selected by the Owner’s representative on site or the Engineer. The Contractor shall present this production weld for destructive testing to a recognised laboratory.

7.3. IDENTIFICATION OF INCOMPETENT WELDER(S)

The Contractor shall, within the limits of the welding procedure, form welding teams and keep track of there works in the field in such a way that incompetent welders can be identified at any time.

If the tests show that the majority of imperfections can be traced to the same welder(s), the third party inspection agency and the Owner and/or the Engineer can require the exclusion of this/these welder/s.

At the consent of the Owner, Engineer and/or third party inspection agency, excluded welders may eventually be proposed for additional training and re-qualification.

7.4. IMPLEMENTATION OF THE NON-DESTRUCTIVE TESTS

Radiographic examinations will be carried out daily after completion of the welding on the stretch of line and/or special point, station, ...

The necessary safety precautions, as specified in the Site Safety Procedure, to be drafted by the Contractor, will be taken before start of the inspection.

7.5. ANNOUNCEMENT OF TEST RESULTS

Only binding for work carried out during normal working hours.

7.5.1. General

The results of the non-destructive tests carried out during the course of the day shall be sent to the Contractor in writing by the Owner or the Engineer or by the third party inspection agency, subject to the agreement of the Owner, on the morning of the following working day before noon.

7.5.2. Welding of tie-ins, special points, and repairs

7.5.2.1. Radiographic testing

Subject to the approval of the Owner and/or the Engineer and the third party inspection agency, in urgent cases, the third party inspection agency shall inform the Contractor verbally of the provisional test results within the hour following the photograph by interpreting the wet film.

The results shall not be definitive until the dry film has been examined.

The deadline for verbal communication of the definitive results shall be twelve hours following the announcement of the results when they have been interpreted from the wet film. The definitive results shall be communicated as described in Article 7.5.1.

7.5.2.2. Visual and ultrasonic testing

The results of these tests shall be given verbally at the time of the test.

Written communication of the results shall be carried out in the same way as described in Article 7.5.1.

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7.6. INSPECTION OF FILMS BY CONTRACTOR

Before carrying out any repairs, the Contractor may inspect the relevant film himself. The film remains the property of the Owner.

7.7. LOCAL REPAIRS AND CUT-OUT OF DEFECTIVE WELDS

7.7.1. General

The Contractor shall be obliged to repair welds or re-weld or cut out welds which are deemed defective by the third party inspection agency. This shall be carried out within normal working hours.

Each repair of a defective weld, whether local or total, shall be carried out within the two working days following the announcement of the results by the third party inspection agency. The performance of the repairs implies that the Contractor agrees with the interpretation of the non-destructive testing.

Section 10 of API 1104 is applicable, with the following requirements :

� all cracks other than shallow crater cracks or star cracks (see 9.3.10. of API 1104) shall not be repaired by welding. The cracks must be removed by cutting out the weld;

� all other defects (except superficial defects) detected by non-destructive testing can only be repaired by welding after approval by the third party representative on site;

� only superficial defects that can be removed by grinding do not need to be approved, provided the minimum thickness of the pipe is respected. After grinding, the ground area will be inspected by liquid penetrant (PT) or magnetic particle examination (MT);

� all areas to be repaired by welding must also be inspected by PT or MT after grinding, to make sure that all defects are removed;

� the weld repairs must be re-inspected by x-ray, UT and or MT as required by the third party representative on site;

� a second weld repair is not admitted, and the weld must be cut out in case defects are detected in the repairs;

� in case a weld must be cut out, a zone of a least 5 cm of the pipe material must be removed on both side of the weld. The new bevel should be checked by PT on the absence of defects;

� the cut out welds should be identified with the weld number and kept in stock for eventual further investigations.


Cut-out welds shall be repaired by welding in a connection sleeve. The repair shall be prepared and undertaken in accordance with the requirements of this specification.

If local circumstances permit, and subject to the agreement of the Owner and third party inspection agency, a cut-out weld may be remade without using a connection sleeve by displacing the adjacent pipe elements. The cut, as well as the new bevels, the positioning of the pipes and the performance of the new weld shall be carried out in accordance with the current specifications.

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Rev. 1 – 14/09/09 Part 7 – Page 6 of 8

If there are separate procedures for tie-in welding and line welding, a cut-out weld shall be replaced according to the same welding procedure as for a tie-in weld.

7.8. SHARING OUT THE TEST COSTS

Costs relating to testing and supervision shall be charged to the Contractor insofar as they are incurred at his request outside normal working hours.

Testing during normal working hours.

Visual inspection

Radiographic testing

Ultrasonic testing

Other test methods

Destructive testing

Minimum inspection prescribed in Articles 7.2.1., 7.2.2., 7.2.3.

Owner Owner Owner Owner Owner

Inspection above the minimum of Articles 7.2.1., 7.2.2

Contractor Contractor Contractor Contractor --

Inspection of repairs Contractor Contractor Contractor Contractor --

The costs shall be divided between the Owner and the Contractor in proportion to the total test costs for the work in question, in other words :

costs charged to Contractor = total test costs x (% defective welds / 100 + % defective welds).

7.9. INSPECTION AND TESTING OF AUTOMATIC WELDED JOINTS

7.9.1. General

All requirements for inspection and testing, as described above, remain valid except that all automatic and semi-automatic welded joints will be inspected by Automatic Ultrasonic Testing (AUT) in stead of RX.

The AUT must be performed according to a detailed inspection procedure (see 7.9.2.) by an experienced Inspection Organisation accepted by the Owner, Engineer and/or third party inspection agency.

7.9.2. Details of the AUT procedure

A detailed AUT procedure must be drawn up by the Inspection Organisation. This inspection procedure must be approved by the welding Contractor and submitted to the Owner, Engineer and/or third party inspection agency for review and approval.

One AUT procedure must be made for each diameter, thickness and weld configuration.

The AUT procedures shall contain at least following information :

� number of UT probes (type, angle, frequency and focus) on both sides of the weld, including the TOFD probes;

� a sketch with the cross section of the weld, the different zones of the weld covered by the respective probes and placement of the probes;

� description of the scanner;

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� description of cables coupling system and electronic equipment; � detailed description of the UT instrument, computer and printing equipment; � different type of mapping and data presentation used during inspection; � calibration set-up; � maximum temperature of the weld that can be inspected; � inspection time for different diameters; � number of welds than can be performed per hour (under normal field conditions); � amount of water required.

In addition, the operational requirements and restrictions of AUT system should be given, e.g. accessibility to welds, steep kills in the field, conditions of welds and surrounding zones, ...

The required material for the fabrication of the calibration blocks should also be specified.

The procedure should also give a description (with sketch) of the calibration blocks for each diameter and thickness and the delay necessary for the fabrication of these blocks.

7.9.3. Implementation of AUT

The UAT should be performed as close as possible behind the welding team, in agreement with the welding contractor, and all completed joints should be tested the same day of welding.

Welding imperfections (especially systematic defects) should be reported directly to the welding contractor, to reduce the eventual repair rates.

The written reporting shall comply to Section 7.5.1. of the GTS.

7.9.4. Acceptance standards for AUT

The classification of indications and acceptance standards as defined in Section 9.6. of API 1104 are applicable.

The threshold settings of the AUT equipment should be agreed on before the start of the AUT inspections on site.

The Inspection Organisation, welding Contractor, Owner, Engineer and/or third party inspection agency, should during the AUT inspections of the qualification welds, define these threshold settings.

The different mappings that are required, should be defined during the qualification tests, and clear interpretation of these mappings for the different types of defects (cracks, linear defects, volumetric defects) should be given.

Special attention should be paid to geometric indications that are similar to those caused by weld imperfections but are not relevant to acceptability according to API 1104.

Once all parties are agreed with the threshold settings and form presentation (colour codes, amplitudes, range of transit distance, ...) no changes should be made in these settings and way of reporting them.

Different settings can only be used by the third party inspection agency during their interpretation of the results (E;G. other amplitude settings), but the mapping resulting from these settings will not be respected in order to avoid confusion by the different parties.

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7.9.5. Calibration blocks

The Inspection Organisation will manufacture the calibration blocks with material provided by the Owner. The dimensions of the pipe sections to be provided by the Owner, should be specified by the third party inspection agency.

The Owner should provide the specified pipe sections, for each diameter, thickness and origin of the steel (steel mill and/or pipe mill).

Measurements of the ultrasonic wave propagation will be performed by the Inspection Organisation inspection agency, in order to determine if material from a different origin behave in a similar manner, and if 1 calibration block (for a given diameter and thickness) can be used for different type of steel or not.

The number of calibration blocks will therefore depend on the outcome of results the measurements.

The Inspection Organisation should draft a report of these measurements, and explain why the selected number of calibration blocks have been manufactured and the conditions where these calibration blocks can be used. The identification of the blocks should be clearly marked on the blocks, so that no confusion is possible during the inspection on site.

The applicable calibration block for the inspections on site should be given on the daily reports on site.

The Inspection Organisation must also include a sketch of each calibration block (per diameter and thickness) showing the different holes, notches, ... that have been put on the blocks.

These sketches must be added to the AUT procedures (see 7.9.2.)

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

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GENERAL TECHNICAL

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GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 8 - Page 1 of 6

8. ��

8.1. �� !�

The Contractor shall not start any activity before approval of all work procedures (of all necessary steps during the construction) by the Owner/Engineer and the Recognised Inspection Organisation.

The Contractor shall at all times endeavour to prefabricate as many elements as possible. He shall specify on the basis of the location plan the cross-sections and ISOs where assembling joints will be provided.

He will ensure that :

� the parts can be transported;

� the differences can be accommodated on site;

� as many assembling joints as possible shall be located in the underground section

� the paint can be applied to the above-ground section;

� the joints do not coincide with supports.

The Contractor shall indicate the assembling joints on a drawing which he shall submit for approval to the Owner and/or the Engineer 10 working days before the start of the works. If certain prefabricated parts must be tested beforehand, this will be mentioned in the Particular Technical Specification. The finishing layer of paint is always applied after the completion of the strength and leak tests.

� Remark:

Tees fitting with ≥ 36” and butt weld ends or butt weld and flanged ends valves ≥ 24” may have a different built-in length. The Contractor shall wait for these parts to be supplied before cutting the pipe parts concerned in prefabrication and shall adapt his work organisation accordingly.

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Before the prefabrication is started, the Contractor shall ensure that all welders’ certificates, procedures and weld numbering comply with the conditions specified Part 6. The Contractor shall request all materials that he deems necessary for the prefabrication. The Contractor shall draw up a drawing that he shall submit at least 5 working days before commencement to the Owner and or the Engineer and to the recognised inspection organisation. The radiologist and inspector from the recognised inspection organisation shall be called in at least 4 working days beforehand together with the representative of the Owner. The Contractor draws up a welding manual that complies with the conditions of part 6, article 6.4.

Furthermore, the Contractor shall draw up a list “Follow-up of non-destructive testing”. This list includes, in addition to the weld number, the date, nature and results of the non-destructive test, the number of the report and the signature of the Inspector from the recognised inspection organisation and the number of the corresponding isometric symbol for each weld. This list is submitted every week to the representative of the Owner and the Inspector from the recognised inspection organisation at the worksite meeting in the workshop. No prefabricated part shall leave the workshop without the aforementioned procedure having been followed.

The welded joints on prefabricated parts may already be metallized and painted prior to the commencement of the tests. Final layers or cladding may only be applied after these tests. The Contractor shall apply a metallization and paint layer, with the exception of the final layer, before transporting the parts to the site.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 8 - Page 2 of 6

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The Contractor must approve the levels and layout of the Civil Engineering Works (if done by others) in a acceptance document before beginning his assembly work. Any remarks made afterwards shall not result in any claims.

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The Contractor shall supply all mobile and stationary equipment such as transporters, scaffolding, lifting machinery, welding units, compressors, grinding machines, hammers, spanners, torque wrenches and fittings.

He shall also supply all the required consumer items such as electrodes, grinding discs, lubricants, fuels, acetylene, oxygen, etc. These tools and equipment shall be supplied on time and in sufficient quantities so that the work schedule can be adhered to at all times. The Contractor shall be responsible for the storage and maintenance of the equipment used.

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Each supplied parts shall be checked by the representative of the Owner upon arrival on the worksite. To this end, the Contractor shall inform the representative of the Owner of this at least 2 working days in advance.

Each part shall be identified with a part number corresponding to the isometric symbol and accompanied by a copy of the list “Follow-up of non-destructive testing”. When handling materials, the Contractor should take the following matters into consideration:

� The lifting power of the equipment used (crane, hoisting gear) must be adapted to the weight of the materials to be handled;

� The Contractor must check before hoisting that the crane has been anchored sufficiently firmly and that the pressure exerted by the lateral supports of the crane will not lead to the collapse of underground trenches or damage to existing installations. The necessary load spreader plate shall be placed under the lateral supports;

� The load will always be guided from the ground (e.g. by means of a rope);

� A hoisting plan should be drawn up by the Contractor for heavy and complex parts, which he shall hand over to the Owner or the Engineer for approval. Such hazardous handling operations shall also be mentioned in the work procedure that the Contractor hands over to the Owner before starting the works.

� The Contractor shall take the necessary care in his work and organisation to take account of existing installations. Crane supporting legs in restricted area may only be carried out provided the agreement from the representative of the Owner has been obtained and provided load spreader plates are implemented;

� The Contractor shall ensure that prefabricated parts can be laid without removing supporting beams from the shoring;

� Hoisting loads above installations under pressure is in principle forbidden. When no other possibility exists, the Contractor should discuss this beforehand with the representative of the Owner and or the Engineer and a detailed hoisting plan must be drawn up. The Owner and or the Engineer should be present during manipulations. However, the responsibility remains fully with the Contractor.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 8 - Page 3 of 6

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The assembling sequence shall be determined in consultation with the Owner and or the Engineer. The work will preferably begin with the laying of below-ground structures such as junctions and collectors. The Contractor shall always take account of the progress of the other works to be carried out, such as Civil Engineering works, Electricity and Instrumentation so that no hazardous situations can occur. To this end, the representative of the Contractor shall have regular contacts with the representatives of the other contractors through the representative of the Owner.

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The Contractor shall as far as possible place the prefabricated elements at their final destination when they are unloaded. Assembling the below-ground section is carried out at a slight slope so that the test water can be completely removed after the resistance test. The Contractor shall ensure that the below-ground pipe parts are clad at the support points before placing them on their support blocks. A neoprene sheet with a minimum thickness of 10 mm shall always be laid between the concrete blocks and the pipe.

If the possibility exists of a gas/air mixture when assembling or disassembling equipment, an equipotential connection shall be placed between the apparatus and the adjacent parts to avoid sparking. Furthermore, spark-free tools shall be used.

Flange and weld joints where the danger of a gas/air mixture exists shall be carried out by a well trained team with a recognised experience.

The work will be carried out accordingly to the work procedure approved by the Owner and the recognised inspection organisation and under the supervision of the latter.

For works at a height, the Contractor shall provide scaffolding that complies with the conditions of the local relevant laws and codes.

The Contractor shall give a detailed description of all the steps during the construction in the execution file (all work procedures) that he submits to the Owner and or the Engineer prior to the start of the works.

8.2. ��&��

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� Check that there is no pressure or gas whatsoever in the pipe.

� Clean the flange surfaces.

� Check that the bolts are clean and coated with Molycote 1000 or equivalent.

� If the tolerance is too small, press the flanges apart with the flange splitter.

� Slip the seal between the flanges (without damaging the graphite in the case of flexible seals) and centre the seal.

� Tighten all bolts hand-tight.

� Check that the bolts used are sufficient and not too long (min. 3 threads visible).

� Number the bolts crosswise ( see appendix ) and tighten the bolts in sequence.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 8 - Page 4 of 6

� Set the torque value to 2/3 of the torque value and tighten the nuts in accordance with the illustration in Appendix 1.

� Set the torque value to the full nominal torque value according to the table in Appendix 1 and tighten the nuts in accordance with the illustration in Appendix 1.

� Repeat the tightening to the full nominal torque value so that each pair of flanges is tightened at least 3 times in total.

� After the resistance test, all flange splices shall be retightened to full nominal torque value.

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See Part 13.

8.3. ��./��

The summary below is not exhaustive.

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All openings must be carefully sealed as long as process instrument pipelines are not connected.

All equipment must be carefully preserved, as per manufacturer instruction book and Owner/Engineer instructions, during the storage and erection of them up to the start up of the installation. Particularly attention shall be given to the internal cleanness (no corrosion or dust and other debris) of all these equipment.

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When assembling filters, the direction of the gas flow must be respected. During the strength test, the filter cartridge may not be present in the filter. The filter cartridge must, however, be placed before the regulators and meters are mounted. The filters shall already have undergone a strength test at the manufacturer workshop and do not therefore have to undergo such a test again.

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When mounting the regulators, the direction of the gas flow must also be respected. Regulator may not be positioned during the strength test with water. These devices shall already have been subjected to a strength test by the supplier. The regulator may only be positioned after the pipe are completely free of dirt and humidity.

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When mounting the turbine meter, the direction of gas flow should be respected. For the strength test, the meters must be replaced by blind flanges or spool pieces. These devices shall have been subjected to a strength test by the supplier.

The turbine meter are very sensitive to dust, corrosion, dirt and humidity and may only be positioned after the pipe has been completely free of dust, corrosion, dirt and humidity and after the filters have been fitted with filter cartridge. Air or gas may only be allowed to flow through the meter lines after the permission of

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 8 - Page 5 of 6

the Owner has been obtained and only after the installation of the conical filters and after the placing of the filter cartridge in the filters. Care must still be taken to ensure that there are no sudden fluctuations in flow.

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When mounting the safety valves, the direction of gas flow should be respected.

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Welded ends valves must be mounted in the open position. The inspection plans shall be completed under the supervision of the Owner and or the Engineer.

8.4. ��&��7��

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During the assembly of the up-grade parts the support plates will be laid on the concrete blocks.

The support will be fixed by means of expanding bolts approved by the Owner and/or the Engineer.

The bolt threads must be greased (molycote 1000 or equivalent).

The supports must be set up and secured so that they can always be removed without the pipelines or apparatus having to be dismantled or moved.

8.5. ��

Platforms shall be positioned after mounting the up-grade parts on the concrete blocks. They shall be fixed by means of expanding bolts approved by the Owner. The platforms must be set up and secured so that they can always be removed without the pipelines or apparatus having to be dismantled or moved.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 8 - Page 6 of 6

Procedure for tightening 1° Lubricate the studbolts with Molycote 1000 (or equivalent). Same for contact face of nuts with the flange. 2° Tighten all nuts manually. 3° Tighten the nuts at maximum torque according to the sequential order of exactly opposite studbolts. 4° Repeat the action under 3.

Sequential RotationalOrder Order

1-2 13-4 55-6 37-8 7

2648

1-2 1 23-4 5 65-6 9 107-8 3 4

9-10 7 811-12 11 12

1-2 1 23-4 9 10

5-6 5 67-8 13 14

9-10 3 411-12 11 1213-14 7 815-16 15 16 ATTACHMENT 1

16-Bolts

12-Bolts

1

5

3

7

2

8

6

4 8-Bolts

15

3

9

10 7

112

8

6

4

12

1

5

1

3

9

107

11

152

8

14

6

4

12

1

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

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GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502


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GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 10 - Page 1 of 16

10. ��

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As a general rule, the trench is excavated on the basis of the lengthwise profile. With specific soil types (rocks, solid blocks, etc.), it may nevertheless occur that the Owner and/or the Engineer require the excavation of the trench wholly or partially before the length profile has been drawn up and therefore before the changes of direction of the pipe have been carried out.

If this method is not prescribed, it may nevertheless be implemented at the suggestion of the Contractor who will then present to the Owner and/or the Engineer the necessary argumentation based on his surveys and soundings. In any case the permission of the Owner and/or the Engineer is required.

If the Owner and/or the Engineer requires or accepts this method, the Contractor shall draw up the lengthwise profile on the basis of the trench actually excavated. After the Owner and/or the Engineer has approved the lengthwise profile thus drawn up, the Contractor shall once more carry out the changes of direction of the pipe on the basis of this profile.

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Before commencing excavations, the Contractor must in every case submit the work procedure and the material for the approval of the Owner and the Administrations concerned. For the work undertaken near existing buildings, the rules as described in part 16 art. 16.7.1 shall be applied.

If the Contractor wishes to use explosives, he automatically undertakes to keep and use them in accordance with the regulations currently in force and with the approval of the Authorities concerned and of the Owner or the Engineer. The supply of the explosives is the responsibility the Contractor as is the procurement of the required permits from the authorised official bodies.

If due to local circumstances the Owner and/or the Engineer deems it necessary, the Contractor shall carry out the excavation work manually without entitlement to any further payment.

In particular, the Contractor must detect all the cables, pipelines, services, etc. of the concessionary companies by means of a sufficient number of inspection holes before any pipes and cables etc. are exposed. Uncovering them will be carried out manually and according to the rules set out in the Building Site Regulations. The capacity of the excavator is specified on the basis of the following tables:

• Using an excavator bucket is not allowed

Values can be obtained in these tables to limit the maximum force capacity of excavating machines working in the vicinity of the utility services to a certain maximum value in accordance with the practical possibilities. Two values are given in the tables, i.e. a force capacity (Fcap.) and a weight (W) derived from it based on average experimental values, and a force capacity (Fsafe) and a weight (Wsafe) derived from this based on a statistical lower limit for these experimental values. In the first instance, it is recommended to choose the values based on the lower limit and, if practically possible, lower still in order to incorporate a certain safety margin.

• Installations operated at a maximum working pressure of 66 bar

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 10 - Page 2 of 16

Diameter mm s mm

Fcap kN

W ton

Fsafe kN

Wsafe ton

114.30 4.37 52.54 2.6 39.25 0.0

168.27 7.1 87.99 10.1 67.81 5.8

219.07 8.2 110.96 15.0 87.34 10.0

273.05 5.6 110.24 14.8 88.31 10.2

323.85 6.3 130.43 19.1 105.92 13.9

355.60 6.3 137.73 20.6 112.69 15.3

406.40 6.3 149.13 23.1 123.32 17.6

508.00 6.9 179.81 29.6 151.38 23.5

609.60 6.8 203.59 34.6 173.91 28.3

914.40 10.1 325.44 60.4 287.17 52.3

1016.00 13.6 409.90 78.1 364.04 68.6

• Installations operated at a maximum working pressure of 80 bar

Diameter mm s mm

Fcap kN

W ton

Fsafe kN

Wsafe ton

114.30 4.37 53.78 2.9 40.18 0.0

168.27 7.1 89.92 10.5 57.11 3.6

219.07 8.2 113.64 15.5 78.39 8.1

273.05 5.6 113.73 15.6 81.61 8.8

323.85 6.3 134.71 20.0 100.45 12.7

355.60 6.3 142.55 21.7 111.30 15.0

406.40 6.3 154.80 24.3 119.75 16.8

508.00 6.9 187.23 31.1 140.98 21.3

609.60 6.8 212.52 36.5 165.73 26.6

914.40 10.1 339.81 63.5 244.82 43.3

1016.00 13.6 425.23 81.6 358.98 67.5

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 10 - Page 3 of 16

If it is deemed necessary for the laying of the pipe that cables, pipelines, poles or pylons have to be shifted or divert temporarily, this should take place in accordance with the directives of the Parties Concerned. If these activities cannot be carried out by the managers or owners concerned, they should be carried out by the Contractor or by a subcontractor in possession of the required professional qualifications or recognition.

If in spite of all safety measures a pipe or cable is nonetheless damaged, the works must immediately be halted and the Owner and/or Eengineer and the concessionary company concerned must be informed without delay. In addition, the Contractor shall provide all the assistance required for the repair work at his own expense.

If unforeseen obstacles appear during excavation work (old foundations, posts, bunkers, etc.), these must be removed in accordance with the indications of and in consultation with the Owner and/or the Engineer and possibly the Authorities concerned to at least 0.50 m below the underside of the pipe to be laid and evacuated from the site. "Good filling soil" should subsequently be used for backfilling.

If the subsoil appears to have several layers, each layer shall be stored separately from the other and later replaced in accordance with the original layering if these layers differ in density, elasticity or hydraulic permeability. If the excavated material is composed of layers of peat, the following rules shall be applied:

• peaty soil in layers with a thickness < 30 cm is not stored separately but mixed into the backfill soil;

• peaty soil in layers with a thickness > 30 cm is stored separately and mixed into the arable soil. The excavated volume, less the volume of the pipeline, shall be replaced by stone-free soil.

In the case of clay or rocky soil, the Contractor shall choose his working method in such a way that the excavated material is sufficiently crushed to ensure correct backfill of the trench. If the Contractor wishes to use a mechanical trencher in areas with different subsoil's, he must submit a study that indicates that the new structure of the subsoil is at least equivalent. In the following areas, the use of a mechanical trencher is forbidden because this causes irreparable structural damage:

• Areas with the presence of thin layers of silt clay (from 20 to 100 µm) and sand or clay layers.

• Areas with sedimentary chalk and peat.

• Areas with peat and clay layers.

• Areas with large presence of basic and carbon-containing material, and layers with a very high iron content.

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When the Contractor comes across buried cables, pipelines and drainage networks during excavation work, he must take the following measures:

• protect and support the cables, pipelines, drainage networks, etc. as the works progress;

• complete the inventory of fixture of the services encountered during excavation with the parties involved and the Owner and/or the Engineer;

• immediately after digging the trench, the Contractor shall survey the existing drainage systems in the presence of the Owner and/or the Engineer.

The drains must be made visible by placing blue-painted posts at the edges of the trench. The drains must be closed off on both sides of the trench if they are not directly included in a drainage system laid out by the Contractor.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 10 - Page 4 of 16

However, this does not diminish the Contractor’s obligation to keep the existing drainage systems in operation and not to affect their functioning. After surveying the drains, the posts shall be positioned on the outside of the working area. These measurements shall immediately be set out by the Contractor in a 1/1000 layout drawing. This drawing shall mention for each Owner plot number:

� the position of each drain measured in relation to a fixed reference point;

� direction of slope;

� type and inner diameter of the drainpipe;

� condition of the drain;

� depth of the drain in relation to the surface.

and one copy of it shall be given to the Owner and/or the Engineer at the latest two working days after the excavation. The Owner and/or the Engineer will carry out the required inspection and if necessary the required corrections will be communicated to the Contractor. Three copies of the accepted drawing will be given to the Owner.

• The “Report of the Presence of Drainage Networks” (see Appendix 1) shall then be filled in together with the tenant/owner and the representative of the Owner;

• In the event of any damage, a proposal for repairs must be submitted for the approval of the Owner and/or the Engineer and the Parties Concerned;

• Observe a clearance of a least 0.20 m between the nearest parts of the cables, pipes and drains at points at which they cross and 0.40 m where they are parallel. These distances should be increased wherever possible especially where they approach large installation. So as to reduce, as far as possible, any risk to neighbouring installation inherent in the Contractor works.

• Adapt the profile design, if necessary.

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The trench shall be dug in such a way that is is symmetrical in relation to the axis of the channel actually market out.

Directrional changes on the trench floor should tally with the draft longitudinal profile perfectly – both horizontally and vertically – and with changes in pipe direction, so that welded pipe sections lie in a continuous and uniform manner along the trench floor.

To ensure that the above changes correspond, the Contractor shall conduct a topographical survey, in the presence of the Owner and/or the Engineer, after the trench has been dug and before laying the pipe in the trench.

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Except other stated in the Particular Technical Specifications the minimum depth should be as follows:

The trench depth should allow a minimum covering of 1.10 m between the upper generatrix of the pipe and the general ground level even if the drawings require a smaller minimum covering. The covering is defined

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 10 - Page 5 of 16

as the vertical distance between the reference levels. The provisions of this article take precedence over the measurements shown on the drawings.

The Contractor is not entitled to increase his price if in local circumstances the pipe has a covering varying between 1.10 m and 1.40 m and/or if the increased depth (greater than 1.40 m) has already been stipulated in the Particular Technical Specifications or detail drawings.

An increase may only be granted if the additional depth is greater than 30 cm over a length exceeding 50 m. If the local additional depth could not be known beforehand and no supplementary storage space for piling up soil was provided on that basis (cf. Part 2), the Contractor should store the supplementary excavated soil on the access road. Such storage should be carried out in conformity with Part 2 of the GTS.

The Contractor shall ensure that when storing another type of soil on the access way it shall be kept separate from any other soil thus stored and that during the works no mixing shall occur due to works traffic. The Contractor shall himself be responsible for the inspection of the covering of the pipe after it has been laid in the trench, independently of the measurements that the Owner and/or the Engineer carries out for drawing up the technical archives.

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Except otherwise stated in the Particular Technical Specifications or the detail drawings and the Authorities concerned, the Contractor shall provide a greater trench depth :

• when the pipeline lies underneath a road or crosses a road;

• In such cases, a covering of 1.2 m is required between the upper generatrix of the pipe and the road surface;

• when the pipeline crosses a watercourse in an open cut. In this case, a covering of minimum 1.3 m is required between the upper generatrix of the pipe and the theoretical profile if this profile is lower than the existing natural profile. If the theoretical profile is higher than the natural profile, a covering of minimum 1.3 m is required between the upper generatrix of the pipe and the natural profile;

• when the pipeline crosses a waterway by means of a borehole. In this case, a covering of minimum 1.3 m is required between the upper generatrix of the casing and the theoretical profile if this profile is lower than the existing natural profile. If the theoretical profile is higher than the natural profile, a covering of minimum 1.3 m is required between the upper generatrix of the casing and the natural profile;

• when the pipeline crosses a ditch. In this case, a covering of 1.1 m is required between the upper generatrix of the pipe and the natural profile of the dredged and deepened ditch, with gauging down to compact ground;

• when the pipe crosses a railway, a minimum covering of 1.6 m is required between the upper generatrix coating of the casing and the bottom of the rail. Except otherwise requested by the railway Authority, the crossing should be perpendicular to the rails.

• when the pipe is located in a casing.

• In this case, a covering of minimum 1.2 m is required between the upper generatrix of the casing and the surface;

• when the pipe has additional equipment (half shells, ballast, anchoring, etc.).

• In such cases, there shall be a minimum covering of 1.1 m measured between the top side of the protection and the surface;

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 10 - Page 6 of 16

N.B.

Concrete slabs are considered as a mechanical protection and not as an additional equipment and are placed 30 cm above the upper generatrix of the pipe;

where under-ground obstacles are encountered, well-defined distances must be maintained.

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If, exceptionally, the minimum depth of the trench cannot be achieve due to local reasons, the Contractor will, provided he has received permission from the Owner and/or the Engineer, provide special protection (binders, half shells, concrete slabs, concrete tiles, etc.). The method of execution must be submitted beforehand for the approval of the Owner and/or the Engineer and the Parties Concerned.

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The foot of the trench must always have a minimum width equal to the outer diameter of the pipe with its coating and any mechanical protection plus at least 20 cm (10 cm on either side). If local circumstances dictate (ballast, anchoring, half shells, etc.), a wider trench shall be provided depending on the space required to ensure proper execution and complete filling up around the pipe.

When using a mechanical trencher, the foot of the trench shall have a width equal to the outer diameter of the pipe with its coating and any mechanical protection plus at least 40 cm (20 cm on either side). The Contractor must take the required precautionary measures to prevent the trench from caving in. In dry, non-cohesive ground, for example, the angle of the bank may at most be equal to the angle of the natural embankment.

In any case, the Contractor must take account of unfavourable factors such as water flowing into the trench, vibrations and excessive loads near the trench, heterogeneity of the ground, the trench remaining open for a long time, etc. Trench side shall under no circumstances be vertical.

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In places where welding must be carried out in the trench, the Contractor shall execute the working pits and/or connecting pits (“Under gas”) so as to facilitate welding as well as the inspection and coating thereof. The working pits must be kept dry. The minimum dimensions of these working pits are :

• length: distance between the welded joints + 2 x 1 m

• width: diameter of the pipe + 2 x 1 m

• the distance between a part fixed (e.g. valve) and the wall of the recess should be 0.60 m min;

• depth: 0.6 m under the pipe.

The minimum dimensions of connecting pits “Under gas” are :

• length: length of the pipe element to be put in place + 2 x 1.5 m.

• width : ∅ of the pipe + 2 x 1 m for a ø smaller than or equal to 300 mm

∅ of the pipe + 2 x 1.5 m for a ø of 300 to 600 mm

∅ of the pipe + 2 x 2 m for a ø larger than 600 mm

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 10 - Page 7 of 16

• depth : free space of at least 0.8 m under the pipe.

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If the type of terrain makes it difficult to obtain a stable trench and in the vicinity of buildings, existing structures, cables and pipelines, the Contractor must, among other things, with a view to safety, use the required means for shoring up the trench walls. As a matter of principle, all temporary timbering sheathing and sharing shall not be left behind in the trenches and/or work pits.

Nevertheless, the Owner and/or the Engineer may, if he judges that the stability of the construction work requires it, oblige the Contractor to leave these struts in place. The Contractor will in this case be reimbursed in accordance with the unit prices of the pricelists. The Contractor shall keep the trench dry and stable until after the topographical measurements and until after the activities of the recognised Inspection Organisation have been completed.

Moreover, the Contractor is obliged to provide the assistance required and to ensure the safety of all personnel working in the trench and/or work pit, even if certain activities take place after normal working hours in the interest of the progress of the site.

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The trench bottom should be evened out depending on the changes of pipeline direction. The bottom of the trench must be completely flat and free of all stones, debris, tree trunks, tree roots, remains of welding electrodes, sharp objects, etc. which would impede the proper execution of the work and damage the pipeline coating.

If the bottom of the trench is rocky or gravely or contains hard objects, the Contractor must apply a layer of sand or light soil to protect the pipeline coating so that any protruding points are covered by at least 20 cm.

The application of top soil instead of sand or light soil is forbidden as is the separation of the subsoil into light soil and stones when this would change the properties of the subsoil in the trench in relation to the surrounding situation. The Contractor may apply a special protection with the approval of the Owner (lathes, neoprene, geo-textile fabric, etc.).

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The trench walls must be free of hard and protruding points to avoid damaging the pipeline coating when it is being lowered in.

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Before starting the drainage operation, the Contractor should apply for the required licences from the administrations concerned. If there is no suitable discharge point to hand in the vicinity (waterway, brook, drain, etc.), closed discharge pipes must be installed to a suitable discharge point. Laying these pipelines, procuring the required licences for this purpose and the right of way and any compensation to be paid are the responsibility of the Agreement. Water from the drainage operation shall only be discharged into a canal, ditch, waterway or drain. The dewatering pipes shall extend to these drainage points laid just outside the working area and buried and protected if they cross the access way. Under no circumstances shall the dewatering pipes discharge onto the adjoining terrain outside the working area.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 10 - Page 8 of 16

The pumps may be placed on the outside of the working strip. Only pumps muffled for sound may be used. Only electrically driven pumps connected to the mains electricity network may be used in the vicinity of houses.

The discharge water may not under any circumstances run freely over the terrain. The removal of discharge water may cause neither damage nor nuisance to third parties. Any pollution, silts, etc. accumulated during the work must be evacuated by the Contractor after completion of the work at his own expense. The Tenderer shall attach to his bid a note in which the different types of dewatering methods are described in detail.

Prior to the start of the works, the Contractor should ascertain the correct height of the water table. He should also carry out some test bore-hole or soundings. The Contractor shall at regular intervals analyse the discharge water at his own expense. The quality thereof should always conform to the standards laid down (inter alia, the content of salt, iron, heavy metals, foreign matter, pH, etc.).

The dewatering operation or horizontal drainage should be carried out in good time so that when excavations start the trench will be sufficiently dry and the Owner and/or the Engineer can check the condition of the trench bottom before lowering in the pipeline.

The dewatering operation should, moreover, be kept in operation if this is necessary for the execution of the works, the topographical measurements, the activities of the Recognised Inspection Organisation, connecting up to the telemetry cable and backfilling.

The dewatering operation should be stopped in such a way that the water table rises slowly and regularly. When the dewatering wells are removed, the bore-holes must be filled in with sand.

In any case, care should be taken to prevent the pipeline from floating the dewatering operation fails or is stopped. The installation of the dewatering operation shall be carried out by an expert subcontractor or by the Contractor himself if he can prove that he is sufficiently competent and experienced in this field.

Any damage to third parties installations, buildings, plantations, crops, etc. as a consequence of drawing off ground water by the dewatering operation should be reported without delay to the Owner and/or Engineer and to the Authorities or private persons concerned. The Contractor, and only the Contractor, will be held responsible for this.

More particularly, the Contractor shall take the required measures if in consequence of the dewatering operation certain water wells run dry or if the course and/or the flow of natural springs are affected by the laying operations.

The Contractor shall bear the consequences of any disruptions to the water discharge system that he causes as a result of works of any kind whatsoever, both within the construction sites and in the vicinity thereof. He must ensure the protection of the construction site continuously against water to prevent any detrimental effect on the execution of the works.

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In rocky soil, the trench must be excavated with a mechanical trencher fitted with suitable teeth which assures maximum fragmentation of the excavated material.

The rocky soil is excavated with a mechanical trencher and backfilled with fine crushed stone. If the use of a mechanical trencher is unfeasible for technical reasons, such as:

• terrain's with a slope greater than 20%

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 10 - Page 9 of 16

• in bends with a bending radius smaller than 40D

• at special points

excavation is carried out with a excavator equipped with a toothed back-hoe which is permitted provided all stones with a diameter greater than 30 mm are crushed prior to backfilling or gathered, transported to a recognised waste disposal site and replaced by stone-free ground.

In such cases, the Contractor is only paid according to pricelist for the cotting, excavation, disposal and replacement by stone-free ground of class 3 rocks in the case of “works in line”.

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The classification of rocks on the basis of their natural cohesion comprises three classes:

� Class 1 Weathered rocks

� Class 2 Uneathered rocks

� Class 3 Compacted rocks

• Class 1 :

All kinds of rocks can appear in this class provided the cohesion of their components are reduced by weathering or crumbling. In this way, small broken pieces occur which are referred to as weathering material. This material can be excavated with an ordinary excavator.

• Class 2 :

These rocks show little or no sign of weathering or crumbling and can be excavated with a normal excavator equipped with a toothed back-hoe.

• Class 3 :

The rocks show no sign of weathering or crumbling and can be considered as the mother rock. This rock can only be excavated with the use of a pneumatic rock breaking hammer mounted on an excavator. When encountering areas with a rocky soil structure, the Owner and/or the Engineer will determine to which class the rocks belong with the help of a geologist.

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Before backfilling the trench, the Contractor must make sure that all the required work has been completed before backfilling (cathodic protection, anchoring, ballast, etc.). In addition, he must take account of the work that has to be carried out during backfilling (teletransmission cable, mechanical protections such as half shells, concrete slabs, warning tape, warning net, etc.).

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Before backfilling the trench, the Contractor will take measurements for drawing up the technical archives.

The measurements relate to :

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 10 - Page 10 of 16

• position of the pipe;

• covering of the pipeline;

• location of the welded joints, concrete slabs, anchorings, ballast, connections of the telemetry cable, cable and connection boxes of the potential measuring points, etc.;

• determination of the angles and the position of each change of direction.

Backfilling may in principle be started after the abovementioned measurements have been completed and the results communicated to the Owner and/or the Engineer.

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The trench shall be backfilled to 10 cm above the pipe with light soil or sand. The light soil or sand must be free of all hard objects (stones, gravels, material that has been broken up, etc.) that might damage the coating. Filling in around the pipe must be carried out in such a way that all voids are filled so that later no subsidence of any kind will occur. As a matter of principle, all the different layers of earth shall be replaced as they were excavated.

If the excavated material contains no light soil or sand that could serve for this first backfill without changing the characteristics of the excavated material in relation to the surrounding subsoil, the Contractor shall provide for the importation of light soil or sand. The use of salty sand, gravel, coal slag, iron slag, etc. is forbidden.

In certain special cases, the Owner and/or the Engineer may stipulate methods of protection during the course of the works that are better suited to the local circumstances (see table). The supply and positioning of such protective items and/or backfilling systems will be paid in accordance with the unit prices of the pricelist as an addition to the price per linear metre of the existing unit price per linear metre for filling in the trench in the relevant pricelist. This price increase will also take account of the removal by transportation of surplus soil depending on the chosen backfilling system. Lump sum prices of the S.P. will always take account of these supplements. Consequently, no additional charge will be made for this.

In hot weather, backfilling may only be carried out if resistance to depressions on the pipeline coating permits it. If this resistance is insufficient, the Contractor shall carry out the backfilling only if the coating and the backfilling material have cooled off sufficiently. Filling in with frozen soil is also forbidden.

• Backfilling systems

TYPE OF FILLING SOIL BACKFILLING SYSTEM

good filling earth backfill with excavated soil

crushed rocky soil

from the trencher

apply geo-textile fabric, min. thickness 8 mm.

Fill in with excavated soil

medium rocky soil

(1) particles < 30 mm

sand bed of 20 cm in trench bottom (2)

apply geo-textile (3) or rock shield (5) fill in with excavated soil max. 0/30

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 10 - Page 11 of 16

rocky soil with (1)

particles > 30 mm

sand bed to 30 cm above and 20 cm under the pipe (2) or non-rotting interlocking wooden lathes, thickness min. 15 mm (4) or geo-textile fabric or rock shield (5) with infill with particles smaller than 30 mm(3) to 30 cm above and 20 cm under the pipe

(1) Filling method to be approved by Owner and/or the Engineer.

Drop height of the filling soil must be limited to the absolute minimum.

(2) Filling with sand-bed only applicable on flat terrain. On sloping terrain, an alternative protection method shall be used.

(3) Geo-textile fabric must be approved by the Owner - and/or the Engineer min. thickness 8 mm.

(4) Non-rotting interlocking wooden lathes, min. thickness 15 mm, must be approved by the Owner and/or the Engineer.

(5) Rock shield protection must be approved by the Owner and/or Engineer.

The Contractor is free to propose to the Owner and/or the Engineer another backfilling method which is taking into account the abovementioned remarks as far as the pipeline coating is well protected from any kind of damages.

Only an approved (by the Owner and/or the Engineer) alternative backfilling method is applicable.

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The thickness of the layers and the frequency of compacting depend on the type of backfilling material. If this backfilling material contains large stones or blocks of rock, these fragments shall be laid in the trench provided the stones are not heavier than 50 kg and the layer of light soil over the pipe must be at least 30 cm.

The upper part of the backfill shall be carried out in consecutive layers. Each layer must be tamped down to avoid hollow spaces which might later lead to subsidence. Each layer shall be put back in such a way that the original layering of the terrain is respected.

Backfilling is carried out with layers max. 30 cm thick. The Contractor must draw up a work procedure for compacting with a description of the compacting equipment that he wishes to use and their functioning. Compacting the filling soil must be carried out continuously by repeated processing of each layer with compacting equipment. The humidity shall be checked before compacting.

After compacting, the soil that has been put back must have the same penetration-resistance characteristics as the soil for the works, and this to a depth of 1m. This may be checked by the Owner and/or the Engineer using a penetrograph.

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In places where the arable soil has been taken away for storage, it shall be replaced and levelled in its original position. The top soil layer, which must be put back at its original height, shall be completely free of foreign objects.

If for one reason or another arable soil must be brought in from outside the working area, it must have the same physical and chemical characteristics as the original soil. The soil brought in should be free of debris or remains and of weed seeds.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 10 - Page 12 of 16

Before placing the soil back on the working way, the subsoil should be raked up to restore the natural hydraulic permeability of the ground. The Contractor shall carry out an inspection in the presence of the Owner and/or the Engineer to determine the extent and depth of the compaction. The rake depth shall be determined by mutual consultation, depending on the results and taking account of the drainage presence.

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The Contractor is responsible for the supply and placing of the reinforced concrete slabs in the places defined in the PTS or in the relevant drawings. The concrete slabs shall meet the specifications of the typical drawing.

The concrete slabs shall be laid in such a way that there is a 30 cm layer of soil or sand between the pipe and the concrete slabs. The slabs must be placed in a dry trench.

Partial backfilling of the trench to 30 cm above the pipe shall be carried out as described before. Prior to lay the concrete slabs, this partial backfilling shall be compacted in a adequate manner.

Before backfilling - necessary for the laying of the concrete slabs the Contractor shall take same measurements as described in para. 10.2.2.

The concrete slabs must be laid in such a way that they are centred on the centre-line of the pipe. The Contractor should take all the measures required to mark out the pipe’s centre-line after partial backfilling to ensure that the concrete slabs are laid correctly. A warning tape (width 6”) shall also be laid on the concrete slabs.

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The Contractor is responsible for the supply and laying of the warning net over the entire length of the pipe.

• Characteristics: Plastified Minimum width: ∅ of the pipe + 2 x 0.2 m.

• The warning net shall be applied horizontally 30 cm above the upper generatrix of the pipeline.

No warning net is laid on the concrete protection slabs.

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The Contractor is responsible for the laying of the warning tape over the entire length of the pipe. Except otherwise specified in the PTS, the Contractor will supply the warning tape.

• Characteristics: Width: 6”

• The warning tape shall be attached horizontally 30 cm above the upper generatrix of the pipeline.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 10 - Page 13 of 16

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In places where the trench meets underground cables or pipelines, the Contractor shall place protective devices in accordance with the requirement of the Public Services and Authorities, owners, tenants and/or operators concerned. Protective items already existing shall be reinstalled by the Contractor and if damaged replaced at his own expense.

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1. General :

For the repair work to the existing drainage system, it shall be assumed that the Contractor or his subcontractor is in possession of the necessary practical knowledge required for drainage work. He is therefore responsible for the repairs and should take all measures required and employ the working methods to supply a repaired drainage system that is free of deposits left behind after the repairs.

It must be emphasised that the repaired drains must be of the same type and have the same characteristics as the original drains (among other things, with regard to material, thickness, diameter, specific gravity, perforation pattern, resistance to compression, resistance to impact, tension, etc.).

It is in all cases forbidden to replace cut or damaged drainage pipes with drainage pipes of another type or with drainage pipes of a larger diameter slipped over the original pipe. The drainage pipes must be joined axially by means of fitted or threaded earth resist sleeves, so as to resist to axial forces. The sleeve must under no circumstances cover or hinder the perforations over a distance exceeding 300 mm.

2. Investigation before drain repair

Before commencing the drain repair, the Contractor shall investigate with suitable devices whether the drains have been moved, damaged or blocked by earth, mud, etc. If the Contractor proves that the drains on the working strip are not damaged, he may be discharged from responsibility for repair subject to the agreement of the Owner and/or the Engineer.

3. Draft for drain repairing

The materials used and the working procedure must be submitted for approval to the owners and/or the Engineer and the land owner/tenants. The Contractor shall submit a draft plan to the Owner and/or the Engineer at least five working days before repairing the drain. The draft plan shall be drawn up to a scale of 1/1 000 and shall mention the following:

� the position of the existing and new drains

� type and slope of the existing and new drains

� connections and closure points

� outlet point

� depth in relation to ditch bottom and gradient

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 10 - Page 14 of 16

The Owner and/or the Engineer will submit this draft via the Negotiator to the Parties Concerned for the purpose of obtaining prior agreement for the working procedure and for the restoration of the site. If the Party concerned refuses a proposal for repairs with diverted drains, the drainage network must be repaired in the conventional manner.

4. Conventional drain repair

The repair of conventional drains must as a matter of obligation be carried out before the restoration of the site. The drainage systems must be repaired over the complete width of the trench and if necessary over the width of the working strip. Prior to the repairs, the extremities of the drains shall be dug free so that a repair drain can be put in place in accordance with engineering design and the approved procedure.

5. Repair by means of longitudinal drains

If the Contractor decides to repair the drains by means of an open trench technique, this shall be carried out before the restoration of the site. Techniques without trenches can be applied after restoration of the site provided they do not constitute a danger to underground installations. In particular, any mixing of arable soil with subsoil must be avoided and if necessary rectified.

Drainage collectors or drainage pipes laid in parallel with the pipe must discharge into ditches or drains in such a way that their function cannot be reduced due to the block-off of the outlet caused by a build-up of deposits. In particular, the outlet must be located at least 20 cm above the ditch bottom. The Contractor shall hand over to the Owner and/or the Engineer an “as built” drawing (scale 1/1000) with the layout of the longitudinal drains, the connections and closure points, the outlet point with the depth in relation to the ditch bottom and slope, as the case may be.

6. Visiting the site after drain repair

After repairing the drainage, the Contractor will invite the party concerned to come and confirm whether the repair has in his opinion been carried out correctly. The Contractor will complete the “Report of Presence of Drainage Networks” and will submit it to the party concerned for signing. The rest of the backfilling of the trench may only be carried out after acceptance without reservation of the repaired drainage system by the Party concerned.

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The first 30 cm shall be backfilled manually. An endeavour should be made to ensure that the different back-filled layers will have hydraulic permeability equivalent to the original surrounding layers of soil. Outside the first layer of 30 cm, each layer shall then be compacted to prevent any subsidence and to prevent the water finding a course other than through the drainage network after the repair of the drainage system.

New drains and drains to be repaired must be laid according to the rules of the trade and in water-permeable soil (water flow at least 1 cm/hour); this should be sufficiently raked through according to the circumstances.

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At pipeline tie-in joints, backfilling may not be carried out over a distance that is a function of the diameter of the pipeline, on either side of the places in question, to facilitate the tie-in of the elements to be welded.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 10 - Page 15 of 16

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Their lower part shall be carefully filled with sand. The upper part should be filled with arable soil (top soil).

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When the slope requires, the Contractor shall take the necessary measures under his own responsibility to prevent washout of the backfill, such as :

• the immediate re-sowing of sloping terrain (such as road embankments)

• non-removal of tree stumps in the working strip in wooded terrain (except in the trench) subject to the permission of the Owner and/or the Engineer and the Land Owner.

• the placement of a drain at the bottom, next to the pipe. Depending on the slope and the hydraulic permeability, setting of water pit trap, filled with gravel, into which the drain flows (buffer). Each water pit trap shall have minimum dimensions of 1 m x 1 m and a depth to 1 m under the level of the drain. 50 cm of the uppermost soil layers shall be replaced over these drainage pit trap.

• the placing of clay block-off wall.

• the placing of block-off wall composed of sand bags.

• other proposals (in particular situations) made by the Contractor and approved by the Owner/Engineer.

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• After backfilling and before restoration of the site, the Contractor will carry out a supplementary inspection of the coating.

• In order for this inspection to be carried out in the best possible manner, the Contractor shall free the extremities of the sections to be checked and ensure the accessibility and the stability of the trenches (shoring) and ensure that the connection pits are kept dry.

• There must be absolutely no contact of bare metal with the surrounding ground. Bare metal shall be insulated from the ground by means of wooden blocks or equivalent. The sections of pipe to be inspected shall be a maximum of 5000 metres long.

• If the ground is too dry, the Contractor shall dampen the backfill by means of ± 1 000 litres of water per 250 metres of length.

• The Contractor shall immediately unearth all indicated defects and repair them in accordance with an approved procedure (see part 9).

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 10 - Page 16 of 16

APPENDIX 1

REPORT OF PRESENCE OF DRAINAGE NETWORKS (SKETCH IN APPENDIX)

Pipeline : ................................................................................................................................. CDF : ......................................

Owner : ......................................................................................................................................................................................

Negotiator: ................................................................................. Contractor : ..........................................................................

OWNER Name : ............................................. First name : ................ Address : .................................................................................. ..................................................................................................

LAND OWNER/TENANT Name : .......................................... First name : ..........................Address : ........................................................................................ ................................................................................................

PLOTS LOCATED ON THE TERRITORY OF THE MUNICIPALITY :

PLOT no.

Land Register Sect. No.

Quantity Type (collector or secondary)

Type Diam. Depth Present condition

Remarks : .............................................................................................................................................................................

.............................................................................................................................................................................

.............................................................................................................................................................................

............................................................................................................................................................................. The undersigned declare(s) that the above description and appendices are correct and complete. Drawn up in 5 copies on ...................................................................... 20...... Signature of the Owner or operator For agreement

Signature of the member of staff of Owner responsible for

negotiations

Read for agreement the representative of the

Contractor

Read for agreement the expert

Report of restoration to original condition

I, the undersigned, ......................................................................... resident in ..................................................... ............................................................................., Land Owner/Tenant of the plots concerned, hereby acknowledge that the drainage networks have been restored definitively and to my complete satisfaction following the placing of the natural gas pipeline.

Drawn up on ........................................................ 20... Signature

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 502

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GENERAL TECHNICAL

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GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 502

Rev. 1 – 14/09/09 Part 11 - Page 1 of 3

11. ��

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The working method that the Contractor will apply and the material that he will use for laying must :

• be adapted to the local circumstances (site configuration, geological and hydro-geological properties of the ground, diameter of the pipe, etc.);

• be approved by the Owner and/or the Engineer.

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A pipe string section may only be laid if :

• the changes of direction were effected in accordance with the specifications of G.T.S. Part 5.,

• the requirements provided in G.T.S. Part 10 have been met,

• inspections of the welding seams have been carried out and accepted by the recognised inspection organisation,

• the external coating has been checked to see that it is in good condition with holiday detector immediately before laying (see G.T.S. Part 9). The inspection is carried out in the presence of the Owner and/or the Engineer,

• Prior to lowering-in work the recognised inspection organisation may (at the Owner and/or the Engineer request) check the pipeline coating by means of a holiday detector. This random inspection will be carried-out at the same time as the Contractor's inspection work and will not release the Contractor from his responsibility of his own inspection work.

• the temperature is such that the coating will not be damaged.

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Lowering-in must be carried-out in the presence of the Owner representative and/or the Engineer. The Contractor must notify him in time.

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During lowering-in, the Contractor must ensure that :

• the pipe is not subjected to inadmissible stresses;

• The Contractor will submit the required calculation notes in the work procedure;

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 502

Rev. 1 – 14/09/09 Part 11 - Page 2 of 3

• the pipeline is supported over a sufficient surface area to prevent the supports from penetrating the coating;

• a sufficient number of machines with the required capacity will be used for lowering-in the pipeline strings (as per calculation note).

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After lowering-in, the pipeline shall be completely stress free in the trench. Joining the different sections may not cause any inadmissible stresses in the pipeline. Tie-ins joints are only executed on consecutive sections at their definitive level.

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In the absence of concordance between the changes of direction of the pipeline and the trench, both in the horizontal and in the vertical plane, the Owner and/or the Engineer may require the Contractor to make the necessary adjustments, it being understood that this does not entitle the Contractor to any price supplement.

These adjustments comprise :

• widening or deepening the trench,

• backfilling and compaction of the trench bottom,

• cutting out and replacing bends that are not adapted to the profile of the trench,

• if necessary, the complete adaptation of the section concerned.

All material supplied by the Owner and damaged as a result of such activities will be replaced by the Contractor at his own expense.

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The Contractor will carry out all the work required to tie-in the different welded and lowered-in sections together so that a continuous string is produced.

After digging out the working trenches, the Contractor will take all measures necessary to ensure their stability to guarantee the safety of his personnel, the personnel of the Owner and/or the Engineer and that of the recognised Inspection Organisation.

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It is forbidden to shift or move the sections on the trench bottom with lifting gear or other means to bring the pipe ends to be joined closer together. The only method that shall be accepted in this case consists of welding in an additional piece.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 502

Rev. 1 – 14/09/09 Part 11 - Page 3 of 3

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The Contractor should take account of the fact that he may be asked to provide the necessary assistance in this tie-in work after his normal in-line activities have been completed.

These works comprise :

• signposting the construction site

• dewatering of the working pit

• excavations, manual and mechanical

• shoring up

• coating of the pipeline and welded joint

• filling up + compaction

• reinstatement

This work will be charged in the price list.

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In places where the type of ground is such that the pipe might rise as a result of the hydrostatic pressure, ballast should be placed on the pipeline.

The ballast will be applied in places that will be indicated in the P.T.S. and or the relevant drawings.

The Contractor is responsible for the supply and the placement unless otherwise stipulated in the P.T.S..

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The ballast consists of ballast blocks or blocks of prefabricated reinforced concrete, bags of cement, or a continuous coating of reinforced concrete on the most important section.

The reinforcement of the concrete may not come into contact with the pipe. The concrete in contact with the coated pipe should be sufficiently smooth. The cement must be resistant to the earth or the water with which it comes into contact.

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Protection material must be placed between the pipeline coating and the ballast except for those applications where the ballast is applied by guniting. The costs for this should be included in the price for ballast.

The Contractor should indicate in his bid the method(s) of ballasting he intends to use as well as the sizes, the intermediate distances and the ballast materials. The depth of covering mentioned in the P.T.S. Part 10 is calculated between the upper generatrix of the anchoring or ballast fittings and the natural ground level.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

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GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 12 - Page 1 of 10

12. ��

12.1. ��

In certain cases, a teletransmission cable and/or fibre optical cable must be laid alongside the pipeline after lowering-in the pipe in the trench and partially backfilling the pipeline (see Part 10).

The Particular Technical Specifications define the type of cable(s) that must be laid. Except otherwise specified in the P.T.S. and/or the part list the Contractor will deliver the cable(s) and the duct cable for the fibre optical cable(s). The Contractor must carry out all the works and all supplementary deliveries that may be required for lowering-in the cables.

12.2. ��

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See the Particular Technical Specification (P.T.S.).

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The Contractor is responsible for unloading the cable reels, storing them as required and transporting them to the construction sites. The Owner shall be disposed of the test certificates from the factory where the cables were manufactured.

At delivery, the Contractor must check that the reels have not suffered any mechanical damage as a result of transportation. If any damage is detected, the Contractor must draw up a detailed list that must be signed by the carrier and delivered as soon as possible to the Owner and/or the Engineer.

After taking over, the Contractor is responsible for any damage that is noted at a later date.

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The cable reels may only be rolled over short distances. During unreeling, the free cable end must not touch the ground. The collars of the reel must not sink into the ground. For long distance displacements the reels must be lifted from the ground. The protections applied to the cable ends by the cable manufacturer must remain intact until the cable connections are made.

Cable handling must not cause the bending radius to be smaller than 25 cm. Special precautions must be taken to avoid damage to the cable during any welding and/or cladding work on the pipeline. Where necessary, the cable must be temporarily protected.

If there are any obstacles above the lowering-in level of the cable (cables, sewerage, pipelines, etc.), the cable must be drawn manually into the trench and underneath the obstacles. The pulling force on the cable is limited to the value prescribed by the manufacturer. The distance between the workers should allow for the cable to be carried; the cable must not be dragged.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 12 - Page 2 of 10

The ends of two successive cable sections must overlap by 3 m to facilitate subsequent connections. The total length of cable used may not exceed the linear length of the pipe by more than 1 %. The surplus length will be invoiced to the Contractor.

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The cable must be laid accordingly with the relevant standard drawing on the right side of the pipe looking towards the final point of the pipeline.

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If the drainage or dewatering system was put into use before the pipe was laid, they must remain in use until after the cable is laid.

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Lowering-in the cable is forbidden if the ambient temperature is lower then 0°C. If the temperature is lower than 5°C, lowering-in may only be carried out if the cable had been stored at a temperature of at least 15°C for at least 24 hours before starting lowering-in.

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While lowering-in the cable, the sequencing of the reels - as indicated in the connection drawings of the cable factory - must be strictly followed. The Contractor may under no circumstances cut the cable at his own initiative.

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The method and equipment to be used by the Contractor during unreeling must be approved by the Owner and/or the Engineer in advance. During unreeling, the reel must be lifted with a device that raises the reel sufficiently from the ground. The cable must be unreeled by rotating the reel. It is forbidden to pull the cable with mechanical devices.

The cable must be unreeled progressively and immediately into the trench or on the edge of the trench. If the cable has to be unreeled entirely or partially at a specific point of the layout, it must be unrolled and store following an eight figure shape. The part unrolled on the spot must be laid in the trench as soon as possible thereafter in order to avoid damage caused by machinery on the site, etc.

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When the pipeline is laid by boring or drilling at places defined in the drawings or in the construction documents and in places where the method of lowering-in necessitates such action, the Contractor must put a polyethylene encasement (inner diameter - minimum 50 mm) to feed the teletransmission cable through when the pipeline is being laid in line. A pulling cable must be placed in the encasement.

The PE encasement must be located in the place where the teletransmission cable would normally be. In cable ducts, the PE encasement must be fixed to the pipe within the quadrant between 12 o’clock and 3 o’clock.

To feed the cable through the PE encasement, a thimble of steel brushwork must be used, adapted to the diameter of the cable (± 20 mm). This thimble must be pushed for a few metres over the end of the cable.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 12 - Page 3 of 10

The thimble grips the cable as a result of being pulled, allowing it to be pulled right through the PE encasement. The end of the thimble is fitted with a ring to which the pulling cable, laid ready in the PE encasement, can be secured. The tension must be continually checked with a dynamometer fitted with a safety mechanism that cuts out automatically above 440 daN. After feeding the cable, the encasement must be sealed around the cable.

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The light soil or sand that must be applied 10 cm above the pipe during backfill shall be sufficient to protect the cable. In places where the cable could be damaged during mechanical backfill, the backfill must be carried out entirely or partially by hand. During backfilling the Contractor must leave open the pits, after having fixed the cable end to a strong wooden guide stake at least 100 cm above ground level.. Furthermore, the Contractor must provide a small team of labourers to accompany the connection team after its arrival. This team must make the connecting pits accessible and fill them at the various connection points afterwards.

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The Contractor must provide the Owner and/or the Engineer an outline drawing of the connections. The connection of the various cable lengths must be carried out by the Contractor or his recognised sub-contractor specialised staff. The Contractor or his recognised sub-contractor must undertake the necessary activities to install the junction boxes before starting the final works.

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The cable tests must be carried out by the Owner or a specialised company appointed by him. If damage is found during cable tests, all tracking, repair and rectification work shall be borne by the Contractor as will any supplementary supplies.

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The cable factory will place the reels at the disposal of the Owner without cost to the latter and for a certain period agreed by the parties. The Owner will inform the Contractor about the agreement. The Contractor will handle their collection and return to the cable factory within this period.

The address of the cable factory is given in the P.T.S. or confirmed by the Owner.

The fine for delayed return, damage to and/or loss of the reels that will be charged by the cable factory to the Owner will be charged to the account of the Contractor. (Each month or part of month after six months gives entitlement to compensation for one month). The complete cost price and the fines imposed by the cable factory will be charged to the Contractor on each reel not returned to the cable factory after 12 months.

12.3. ��34��

HDPE encasements will be placed at the same time as the gas pipeline. The P.T.S. define whether the encasement should be install.

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See the Particular Technical Specifications (P.T.S.).

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 12 - Page 4 of 10

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The position of the HDPE encasement will depend on the position of the gas pipeline, on the combined lowering-in of a teletransmission cable, on the excavation method used and on the presence of drainage systems.

The position of the cable and or the HDPE encasement regarding the pipeline is specified in the Owner and/or Engineer detail drawings.

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When crossing obstacles, the following cases must be emphasised :

� During directional drilling, sinker and boring laying method for the gas pipeline, the HDPE encasement itself must be placed in a protective steel or PE encasement (at least 80 mm);

� When crossing a road in open trench, the HDPE encasement must be placed under concrete slabs;

� Where an inspection chamber is required, a minimum bending radius of 1 m must be respected and 180° bends must be avoided. A separate bore hole for the HDPE encasement must be made according to the case.

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� All precautions must be taken during loading, transportation and unloading or any other handling operations in order not to damage the encasement. The same applies when moving and placing the encasement in the trench;

� Internal soiling of the encasement must be prevented. The encasement ends must always be sealed with a sealing cap not only during unreeling and lowering-in, but also while the HDPE encasement is still on the reel.

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The HDPE encasement must be placed in pure, stone-free soil that contains no materials that might damage the encasement. Care must be taken to place the encasement as straight as possible without, however, exerting no more pulling power than that obtained through controlled release.

� The encasement must be located in accordance with standard drawing;

� The encasement must be unreeled from the bottom of the coil;

� During unreeling, the outer surface of the encasement must be inspected. Grooves in and damage to the encasement wall must be reported to the Owner and/or the Engineer;

� To prevent damage to the HDPE encasement in the trench, care must be taken to ensure that the bottom is well levelled and free of foreign objects prior to lowering-in;

� Each change in direction must have a bending radius greater than or equal to 1.0 metre;

� Changes in direction may never be incorporated in the connections.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 12 - Page 5 of 10

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1) If the trench can be opened over the entire trajectory between two inspection chambers

� If the trench between two inspection chambers over the entire length has been dug free and if there are no obstacles, the encasement will be unreeled immediately into the trench. To this end, the coil must be placed on a special unrolling vehicle that drives slowly along the trench;

� If obstacles bar the trench in the section where the encasement is to be placed, the unrolling vehicle must wait at the obstacle and the encasement must be pushed underneath the obstacle(s) manually. The encasement must be supported by enough workers to ensure that it is carried and not dragged;

� If the distance over which the HDPE encasement must be carried is too large, rollers may be placed on the bottom of the trench to support the encasement to avoid friction with the soil. In curves, the rollers will be placed in sufficient numbers and in such a way as to allow them to form a track whose bending radius is no less than 1.25 m;

� In this way, the HDPE encasement is free from couplers between 2 inspection chambers unless there are drillings involved;

� The encasement must still be tightened to eliminate the number of “curves” in the encasement (maximum pulling force: 300 daN; to be verified with a dynamometer).

2) If the trench cannot be opened over the entire length between two inspection chambers

� The working method is designed in such a way that the encasement will be cut as little as possible;

� The normal distance between two inspection chambers is 2 000 m or more;

� After the first 250 m of trench starting from the first inspection chamber have been dug out, , the HDPE encasement must be laid or pushed into the trench in the case of obstacles identical to the description in 12.3.4.2.2/1, but for a distance of 250 m;

� The unrolling vehicle must subsequently be moved 250 m further on, and the procedure will be repeated, i.e. a trench is dug for 250 m and the HDPE encasement is laid in it;

� This can only be carried out as long as there are no obstacles on this 250 m section. If there is an obstacle, the HDPE encasement will be cut at the coil, folded back to the obstacle and pushed underneath. The encasement must subsequently be drawn manually;

� In this way, it is possible to lay the 500 metres of HDPE encasement in 250 m trenches without couplers.

The Contractor is free to suggest another method to the Owner and/or the Engineer.

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A distinction is drawn between temporary and permanent sealing.

� Temporary sealing must be carried out with a sealing cap, which must always be set in place while the encasement is being handled, i.e. during transportation, lowering-in, etc;

� Permanent sealing must be carried out with a heat shrinkable sleeve and takes place in the inspection chambers. A leakage test may only be carried out with this sealing present.

The HDPE encasement affixed to the inspection chamber with mechanical anchoring and filofoam must be sawn off at a distance of 40 cm in the inspection chamber. This may only be carried out 30 min. after the filofoam has been applied, i.e. after the polyurethane has hardened. Once the HDPE encasement is laid, it must therefore always be sealed with a permanent seal.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 12 - Page 6 of 10

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Once the encasement is laid, the trench must be filled in accordance with Part 10 of the G.T.S..

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� There should be as few HDPE encasement connections as possible on the trajectory. If, nevertheless, connections are necessary, e.g. if there are too many obstacles or they are too large, the following rules must strictly apply. Any deviation from these rules may subsequently make it difficult or even impossible to “blow in” the optic cable;

� The couplings or connections must be measured by the Contractor relative to the welding seams and, where possible, covered only after the leakage tests to facilitate the diagnosis of any leakage. Prior to starting the tests the Contractor must provide two copies of the lay-out drawings indicating the measured connections or couplings;

� If it is impossible to connect the HDPE encasement immediately after or during lowering-in, the encasement will be placed down in such a way that the ends overlap by 1 m;

� Always seal with a sealing cap.

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� 5 cm must be cut off each encasement end to avoid deformation caused by elongation (plastic flow). The pipes must be cut square using a P.E. pipe-cutter;

� After cutting the HDPE encasement, any internal and external burrs must be removed with a hand scraper;

� The pipe ends must be thoroughly cleaned as follows over a distance of about 10 cm:

� the oxide layer will be removed with a hand scraper; approx. 0.1 mm material will be removed;

� the encasement must be scoured with a rag soaked in methanol.

� The ends are cleaned inside;

� After this treatment, the connection must be made immediately. The treatment must be repeated if this is not possible;

� The inside of the electrofusion coupler must also be cleaned with a rag soaked in methanol.

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The Contractor will apply a mark at 40 mm from the ends on both sections of the HDPE encasement. The electrofusion coupler must be pushed 50 mm by hand over the encasement to the impact edge. The mark must no longer be visible. This procedure must be repeated for the other encasement end. The entire encasement must be tensioned in a welding clamp.

The welding clamp will ensure that there are no other stresses on the coupler during welding. The pipes must be laid perfectly in one line. The screws of the welding clamp must be adjusted to allow only

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 12 - Page 7 of 10

minimum friction while the electrofusion coupler is turning. Subsequently, the welding wires of the welding apparatus will be connected to the electrofusion coupler. The welding apparatus will be set up and the welding started.

After welding, the welding clamp must be kept over the welding sleeve for at least another 20 minutes to divert the torsion of the HDPE encasement to the clamp until complete cooling.

Important note :

The electrofusion coupler must have a barcode.

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The inspection chambers must be indicated on the alignment sheet drawings. The inspection chamber is intended for effecting connections and/or branches. The inspection chambers are paid for according to pricelist.

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� The type of the entire airtight inspection chamber, proposed by the Contractor, must be approved by the Owner and/or Engineer;

� The sealing consists of a concrete slab built into a metal framework and consisting of a sufficient number of partitions to be able to resist the load caused by heavy traffic. The sealing must be fitted with a lock and with a Owner marker;

� The sealing framework includes a system that guarantees airtight sealing (flexible sealing ring, etc.);

� Each side wall has four holes with a diameter of 80 mm.

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� The inspection chambers must be handled carefully and shocks must be avoided that may jeopardise the homogeneity of the structure;

� The inspection chamber must be placed on a gravel bed with a minimum thickness of 10 cm and have a non-woven synthetic sheet as an underlay;

� Stabilised sand must be provided if a non-woven synthetic sheet cannot be placed on undisturbed soil;

� In the event of any difference in level between the HDPE encasement and the inspection chamber, this difference in level must be accommodated in a gradual slope so that the encasement is once again horizontal to the inspection chamber;

� The inspection chamber must be placed in such a way that the top side of the cover coincides with the surface, all fillings and finishings included;

� After placing and fixing the pipes, the empty space between the HDPE encasement and the wall of the inspection chamber must be filled with filofoam (polyurethane foam with closed cells) in order to perfectly seal the entire construction. Pulling may be applied only 30 min after the polyurethane has hardened;

� Unused holes must be sealed with filofoam;

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 12 - Page 8 of 10

� If it is impossible to install a prefabricated inspection chamber, a chamber with the same measurements must be constructed on site;

� The placing of the inspection chamber also encompasses all ground work and restoration of the site, including the excavation, storage and replacing of the soil over the entire working area.

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All inspection chambers and the encasements of the normal trajectory above the pipeline to these inspection chambers must be surveyed by the Contractor’s surveyor.

The Contractor may only fill in the trench after these encasements have been surveyed.

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Connection between the HDPE encasement which follows the pipeline and the inspection chamber

These works include :

� the preparation of the construction site, all works and services according to Part 2 of the Particular Technical Specifications;

� all inspection soundings for the detection of the existing encasement according to the safety standards of the Owner. The inspection soundings are carried out manually under the supervision of the Owner’s representative;

� hand-over and handling of the material according to Part 4 of the Technical Specifications;

� the cutting upwards and downwards and connection of the HDPE encasement of the pipe with the branch to the inspection chamber;

� excavation and execution of the trench according to Part 10, Article 10.1. with the exception of Article 10.1.9. and 10.1.10.2, class 3;

� the placing of the connection with a minimum cover of 80 cm taking into account all underground obstacles as described in Articles 12.1 and 12.3. of the General Technical Specifications with the exception of Articles 12.3.6., 12.3.7. and 12.3.10.;

� the backfilling of the ditch according to Part 10, Article 10.2. of the General Technical Specifications with the exception of Article 10.2.5.2.;

� the restoration of the terrains including the replacing of the soil as described in Part 15, Articles 15.1. to 15.3. or the General Technical Specifications.

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Except otherwise stated in the P.T.S. the HDPE encasement with accessories and the optical fibre cable will be supplied and delivered by the Contractor.

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Before delivery of each section of the HDPE encasement (between two inspection chambers), a continuity test must be carried out followed by a leak test.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 12 - Page 9 of 10

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� A shuttle consisting of a metal centre piece and two semi-flexible disks with a diameter slightly larger than the inner section of the encasement to be tested, must be sent into the encasement;

� The shuttle contains a radio transmitter whose signals can be received by an appropriate receiver at ground level;

� If the shuttle is not equipped with a transmitter, a thin cable must be pulled in with length indications making it possible to establish the distance of any obstacle that might be in the encasement.

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� The end of the section to be tested must be closed off;

� Dry air is drawn in under a pressure of 6 bar;

� At the compressor site the inlet valve will be closed and the inlet pipe closed with a cap;

� A pressure gauge must be connected to the compressed air supply pipe. The test may only start after the pressure in the encasement has stabilised;

� After 24 hours, the internal pressure of the encasement to be tested must be measured. Any drop in pressure must not be greater than 50 %;

� The measurements must be written down in a report containing the identification of the tested section and the pressures recorded(continuous pressure recording);

� All tests must be carried out under constant supervision by the Owner and/or the Engineer. To this end, the Contractor must inform the latter of the planned works in writing two days in advance.

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� Except otherwise stated in the P.T.S. the optical fibre cable and related accessories will be supplied by the Contractor.

� The Contractor will appoint a qualified sub-contractor (approved by Owner/Engineer) for blowing-in work, welding works and testing work.

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See the Particular Technical Specification (P.T.S.).

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The Blowing-in Work, welding work and testing will be supervised by the Owner and/or the Engineer.

The Contractor will have his work teams supervised by qualified professionals. The Owner will delegate a member of his staff to check that the proper procedures are being followed on the site at all times. This

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 12 - Page 10 of 10

delegate will have the power and authority to solve with the Site Manager any problem that might jeopardise the proper procedures on the site.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

PART 13

Cathodic protection








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GENERAL TECHNICAL

SPECIFICATION

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GTS/ 0502


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GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev.1 – 14/09/09 Part 13 - Page 1 of 4

13. ��

13.1. ��

The Contractor must take account of the fact that when laying the pipeline a cathodic protection equipment will have to be set in place as that indicated in the relevant particular drawings. This means that all pipeline parts must have a negative potential measured in relation to a copper sulphate electrode.

Except otherwise stated in the P.T.S. the Contractor will be in charge with the installation of the cathodic protection equipment and, the specific connections, adjustments measurements, etc. will be carried-out by others, means a Company expert in cathodic protection appointed by the Contractor and approved by the Owner and/or Engineer.

The materials that the Owner supplies (if stated in the PTS) for this work are described in the parts lists. The Contractor shall be responsible for all work carried out and supplementary supplies with regard to the equipment. He should take account of the foregoing when choosing the materials.

13.2. ��

The potential control points shall be set up according to the relevant detail drawing.

One end of a grey (approved) electrical cable of minimum 16 mm² shall be secured to the pipe by soft soldering with lead-tin. The procedure for the securing of the cable for cathodic protection shall be submitted by the Contractor to the Owner and/or the Engineer for approval.

The coating of the soldering on the pipeline must be at least equal to that of the pipeline. In particular, no air pocket must remain. Hollow spaces must be filled in with butyl. Once the cable has been secured, it must be wound round the pipe to release tensile stress on the weld.

The other end of the cable shall be brought to the surface and terminates in a control covered trap or P.V.C. attachment post placed in the nearest public open space, footpath or roadside verge or other place as mentioned on drawings..

The control covered trap and P.V.C. posts are supplied by the Contractor. The Contractor introduces the ends of the 16 mm² approved electrical cable in the P.V.C. post or control trap with an excess length of 50 cm at the reinforcement which is carried out by Others.

The Contractor is responsible for all ground work and site restoration according to Parts 10 and 15 of the G.T.S. Above the cable laid in the trench, the Contractor supplies and place protective cable covers and a warning tape. The cable must have a minimum cover of 80 cm.

13.3. ��

To guarantee correct operation of the cathodic protection, a minimum clearance of 20 cm between the structures to be protected (e.g. pipe) and another structure (e.g. concrete element) is absolutely necessary.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev.1 – 14/09/09 Part 13 - Page 2 of 4

13.4. ��

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An interconnection is made according to the relevant detail drawing. In places where the pipe lies in the vicinity of metallic structures, cathodically protected or not, the Contractor shall set up a potential control point, as described in Article 13.2., on the pipeline and on the metallic structure.

Both extremities of the cables brought to the surface shall terminate in the same control covered trap or P.V.C. attachment post. The extremities of the different cables shall be clearly marked and a corresponding plan and description shall be delivered to the Owner and/or the Engineer.

Any potential control points on the installations of third parties shall be set up by the Parties Concerned themselves. The Contractor should in good time contact the Parties Concerned and the Owner. In each case, the Contractor shall comply with the requirements of the Parties Concerned.

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In places where the pipeline lies in the proximity of installations that are not cathodically protected (installations made of cast iron, reinforced concrete, etc.), the Contractor shall isolate electrically the pipeline by inserting an insulating, non-corroding material (e.g. neoprene) with a minimum thickness of 10 mm approved in advance by the Owner and/or the Engineer. The Contractor should obtain the required information from the Parties Concerned. He shall make the necessary arrangements to meet the set requirements.

13.5. ��*��

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A potential control points shall be install on the pipeline at each end of the casing, as described in Article 13.2.

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The pipe in the casing shall be equipped every 8 m with an Mg anode of 17 LBS. The Mg anodes will be supplied by the Contractor. Each Mg anode is provided with a sufficiently long blue approved 10 mm2 electrical cable brought to the surface in a Cathodic Protection control post. The length of the cable shall be adapted by the Contractor in accordance with the length of the casing. The ends of this blue electrical cable shall be numbered and marked in accordance with the anode plan.

The anodes shall be secured on the upper half of the pipe with plastic clamping rings, alternately in the 2 and 10 o’clock positions. The Contractor is responsible for securing the cables to the anodes and for the work described above. The work is carried out according to the relevant detail drawing.

13.6. ��

If a pipeline is laid in a bared metal casing, a white approved electrical cable with a minimum section of 10 mm² shall be soldered on to one end of the casing and a grey approved electrical cable of 16 mm² to the pipe. If the length of the casing exceeds 10 m, the aforementioned fittings will be attached to both sides of the casing.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev.1 – 14/09/09 Part 13 - Page 3 of 4

The soldering of the grey cable will be carried-out in accordance with the procedure in the appendix annexed and the extremity of the cables (white and grey) will be drawn until the potential control point. The Contractor is responsible for supplying all cables and cable covers. The work is carried out according to the relevant detail drawing.

13.7. ��

An inspection of all separate cathodic protection equipment's will be carried-out by the company appointed by the Owner before backfilling. A general inspection of the cathodic protection will be carried out after complete backfilling.

For the purposes of these inspections, the Contractor must notify the Owner and/or the Engineer in good time of when the pipeline will be backfilled. If the results of these inspections are not satisfactory, detection and the elimination of the defects together with supplementary supplies of material shall be borne by the Contractor.

13.8. ��

All flanged joints located in buried piping sections that are cathodically protected must be electrically bonded. This connection consists of a grey approved cable with a min. section of 16 mm² which shall be soldered to each flanges both side of the joint in accordance with the procedure in the appendix attached.

13.9. �� 2�� 3�� 4��3�� 4��4��

During the construction of pipelines, compulsory safety measures must be taken to reduce the capacitive effect of the pipeline if the distance between the pipeline and the overhead HV line is less than :

� 1000m for HV lines of 150, 220 and 400 kV

� 500m for HV lines of 70 kV

� Compulsory safety measures

1) The pipe shall for this purpose be earthed in the working area where contact with the metal of the pipe is possible. During the construction work, the pipeline will be earthed according to the following rules:

� every 50 m max. if the distance to the HV line ≤ 50 m;

� every 100 m max. if the distance to the HV line > 50 m.

N.B.

The earthing of the HV pylons shall never be used as an earthing electrode for the pipe. The earthing electrodes for the pipe shall be at least 20m away from the HV pylon.

2) All direct contact with the metal of the pipe should be avoided by wearing insulated gloves.

3) While raining boots shall be worn.

4) Works to pipelines in the vicinity of HV lines shall be interrupted during a thunderstorm. Defects to HV lines are mainly caused by lightning.

5) The distance between the pipe and the pylons earthing must always be greater than 1 m.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev.1 – 14/09/09 Part 13 - Page 4 of 4

The earthings fitted according to point 1 shall be removed when the pipe is backfilled.

13.10. 5��4��4��3�

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In order to guarantee the safety of the personnel and the pipeline during an incident on an HV line, additional safety measures must be implemented in certain places mentioned in the Particular Technical Specifications or the detail drawings. Certain cathodic protection control posts shall be earthed with a particular reinforced zinc strip and a galvanised steel grid. The Contractor is responsible for the supply and placing of the zinc strip and galvanised steel grids. The Contractor shall attach the necessary specifications and characteristics to his price bid.

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A zinc strip with a steel core (∅ 25 mm) supply by the Contractor is placed at the bottom of the pipe trench as far as possible from the pipe with a well-defined length as defined in the Particular Technical Specifications or the detail drawings. At the terminal strip of the cathodic protection control post, the Contractor provides an excess length of 50 cm. There must be no contact between the pipeline and the zinc strip.

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The Particular Technical Specifications or the detail drawings specify to which cathodic protection post a galvanised steel grid must be install. At the well-defined cathodic protection posts, two galvanised steel grids are buried underneath the surface in order to keep the step voltage within acceptable limits when a technician is working on a cathodic protection post during an incident on an HV line.

The grids must meet the characteristics indicated in the relevant detail drawings. The grids are connected via a 16 mm² approved electrical cable to the terminal box of the cathodic protection measuring post.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev.1 – 14/09/09 Part 13 - Appendix

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PROCEDURE FOR SECURING A CABLE FOR CATHODIC PROTECTION TO THE PIPELINE

This is carried out by means of tin solder and a gas soldering iron.

Working method

The cable must always be soldered above on a horizontal pipeline section. A window of ± 8 x 8 cm shall be cut in the existing coating.

At the place where the cable is to be soldered, the pipe shall be de-greased and sanded or polished clear. It shall then be heated locally by means of a gas-powered soldering iron to a temperature of ± 200°C. It is forbidden to solder with a naked flame. The soldering iron shall be heated with a gas flame.

An area of 4 by 2 cm shall be tinned. The soldering medium to be used is composed of 80 % tin and 20 % lead. The wire shall also be tinned over a distance of 4 cm.

The wire shall be held against the pipe and pressed against it by the soldering iron until the tin on the pipe and the wire melt sufficiently into each other. More tin can be melted on if necessary.

The coating shall be repaired by means of sealing material designed for this purpose.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

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GENERAL TECHNICAL

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GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 14 - Page 1 of 12

14. ��

14.1. ��

Except otherwise stated in the P.T.S., the following statutory acceptance tests shall be carried-out after construction of the pipeline in accordance with the provisions of the ASME code B31.8 latest edition and where applicable, with provisions that may be imposed by the authorities of the concerned country.

At latest 30 days prior to the start of the tests, the Contractor shall submit to the Owner and/or the Engineer a detailed work schedule and a work procedure file for the execution of the testing, cleaning and drying operations. The Contractor shall provide the labour, test medium, temporary supports, ladders and scaffolding, all material including test heads, the measuring apparatus and any spare parts that may be required for the tests and trials.

Such equipment shall be approved in its entirety by the Recognised Inspection Organisation and by the Owner and/or the Engineer. Measuring instruments, such as manometers, manometrographs, manometric scales, barometers, thermometers etc., shall be sufficiently sensitive to give the required degree of precision. Such instruments shall be accompanied by the required valid calibration certificates. The pumps, compressors, etc. should have sufficient capacity and output to permit rapid filling.

The tightness test shall be carried out following the resistance test.

Exception

The following equipment shall not undergo any mechanical test on the worksite:

� gas meters, gas regulator, shut-off valves, safety valves, instruments, thermowells, boilers, pressure vessels, etc., provided such parts have an acceptable pressure certificate;

� discharge lines to the atmosphere such as open vent pipes without noise mufflers and drains;

� (for the testing of instrumentation pipes, see Article 14.9. and Part 17 of the G.T.S.).

14.2. ��

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� Plan of the section to be tested:

a) For pipeline construction:

For the purposes of the resistance test, the Contractor shall submit to the Owner and/or the Engineer and to the recognised inspection organisation a pipeline split up plan ten working days before the test. Due account should be taken in the split up plan of the minimum pressure at the highest point and the maximum pressure at the lowest point. This maximum pressure may under no circumstances exceed the test pressure of the pipes in the factory (i.e. 95 % of the Specified Minimum Yield Strength).

b) For station construction:

For each test section, an overall sketch or isometric drawing shall be submitted to the Owner and/or the Engineer and the recognised inspection organisation. Such documents shall include the following information:

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 14 - Page 2 of 12

� the location of the test inlet pipe, measuring instruments and bleeders;

� the adjustments that will be carried out for the test.

e.g. :

� removal of internal parts of check valves or bridging of the same by means of a bypass or instrumentation bosses;

� bridging carried out for non-tested "in-line" parts (see exceptions above);

� physical limits of the pipe by means of blind plates, blanks, hollow bases, etc.;

� as a general rule, it is not permissible to subject the shut-off valves in the closed position to one side test pressure;

� Copy of the valid calibration certificates of the devices and equipments used for the tests.

� Pressure data of the test apparatus used (manifold) such as valves, test heads, etc.

� Copy of all Non-Destructive Testing documents drawn up by the recognised inspection organisation.

� Copy of the weld log book.

� Form giving :

� date of the test;

� identification of the test equipment;

� test medium and origin;

� the maximum operating pressure;

� test pressure and duration.

� Description of the working method and the material for filling up with water and purging of water from each section.

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� All welds, screw and flange joints must be clean (free of rust, paint, etc.);

� All welds must be accessible for visual inspection:

� no temporary supports on the welds or flange connections;

� provide all necessary ladders or scaffolding for the safe inspection of the welds.

� All heat treatments shall be carried out prior to the tests;

� All reinforcement plates shall already be tested;

� All welds for the preparation of the testing work shall be subjected to the same non-destructive tests as those which are required for the piping to be tested;

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 14 - Page 3 of 12

� Inspection of conformity with the isometric drawing;

� Inspection of the half-open position of the valves;

� All spring supports and expansion joints shall be anchored in good time according to the manufacturer’s instructions;

� All precision instruments or regulators which may be damaged shall be temporarily removed by the Contractor;

� Orifice plates which may hinder correct filling up and drying shall only be mounted once the testing, cleaning and drying operations have been completed;

� Inspection of the connection of the filler pipe, manometer and pressure recording device;

� Cut-off valves which are used to close the testing system (e.g. test equipment) shall have a nominal pressure higher than or equal to the test pressure;

� The valves of drainage and bleeding points shall remain open during the tests and the ends must be fitted either with a flange with a blind flange or a screwed cover;

� For gas filters, check that the filter elements are removed;

� Inspection of marking-off of the test zone;

� When testing with nitrogen in a closed space, the Contractor shall assure constant ventilation. Furthermore, oxygen measurements shall be taken regularly;

� During the tests, the recording and testing devices shall be at least 10 m away from the tested pipe.

Exceptions

� If the trenches hinder the further construction of the station, at the request of the Owner and/or the Engineer and subject to the agreement of the recognised inspection organisation, the pipe shall be clad and the trench shall be backfilled before the mechanical resistance test and tightness test are carried out. The tightness test (with dry air or nitrogen only) must then be carried out with a manometric scale (see Article 14.4).

� If the scraper trap station is connected to a pipe, everything must be backfilled before the start of the resistance test (in conformity with the stress calculations).

� If exceptionally some parts of the pipeline sections under testing are not backfilled, those parts, will be covered by means of thermal insulation sheet.

14.3. )��*��

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� The test medium and the necessary accessory apparatus shall be supplied by the Contractor;

� For the pipeline, the pressure test shall be submitted to the recognised inspection organisation for approval on the basis of the split up plan. The maximum length per section is 30 km;

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 14 - Page 4 of 12

� The backfilling of the trench must be completed before starting the mechanical resistance test. During the resistance test, all traffic over the pipeline is forbidden;

� All reinforcement plates should preferably be tested in advance in the prefabrication workshop with nitrogen at 3.4 bar. The air bleed opening shall remain open until after the mechanical resistance test unless the trench is backfilled before the execution of the mechanical resistance test and tightness test (with dry air or nitrogen only) with a manometric scale;

� The choice of the test medium shall be made according to the following overview table.

Overview table - Resistance test for pipelines and mains to operate at less than 30% of the specified minimum yield strength of the pipe, but in excess of 100 PSI.

Situation Test medium

Test pressure

Test time Safety measures *

Backfill Dry air, nitrogen or water

As specified in ASME CODE B31.8

6 hours

Around intersections and non-buried parts

Above-ground or under ground (but not backfilled) on supports

Everywhere

Overview table - Resistance test for pipelines and mains to operate at hoop stresses of 30 % or more of the specified minimum yield strength of the pipe.


Test pressure

Test time Conditions Safety measures *

Backfill Water Min : 1.4 x MOP

Max : testing pressure of factory

6 hours

Around intersections and non-buried parts

Above-ground or underground (but not backfilled) on supports and stations

everywhere

Gas supplied actuators and stations

Dry air or nitrogen

1.25 x MOP 6 hours only for ND ≤ 3” pipe sections with max. volume ≤ 2m³ and if pipes have no low points where water can be drawn off (drains)

Overview table - Resistance test for stainless steel control and instrumentation piping or tubing.


Test pressure

Test time Conditions Safety measures *

Control and instrumentation piping

Dry air or nitrogen

1.1 x MOP soaping time

see Article 14.9. everywhere

* safety measures :

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 14 - Page 5 of 12

During the pressurisation of the installation and up to one hour after the test pressure has been reached, there is a general safety zone of 10 metres which all personnel and persons are forbidden to enter. Subsequently, until the installation is free of pressure, a safety zone of 5 metres must be observed. All valves and flange connections shall be marked with a sticker bearing the warning “Danger: under pressure”. The zone in which the test is carried out must be marked out and indicated with pictograms and a rotating light.

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� General

When the outside temperature is below + 4 °C, no hydraulic tests shall be carried out with water unless the water is mixed with glycol.

a) Pipeline construction

A caliper plate or-pig shall be used to check that there are no unacceptable deformations in the pipeline before starting the resistance test. Sections with unacceptable deformations shall be cut out and replaced before any resistance test shall start.

For pipelines construction, a bi-di pig or scraper is used to fill the pipe. A quantity of clean water should be pumped in front of the scraper (i.e. approx. 150 m of pipeline volume depending with the pipeline routing).

The scraper and the test heads shall be supplied by the Contractor. The type of scraper must be approved by the Owner and/or the Engineer. The test heads must have the necessary approval certificates (non destructive testing and hydraulic tests. After filling up the pipeline, the valves must be in the half-open position.

Any pressure fluctuations noted during the passage of the scraper should not indicate the presence of obstacles which hinder the free passage of the section.

The pressure increase shall be effected under the supervision of the Owner and/or the Engineer and shall be monitored by the recognised inspection organisation.

Once these operations have started, it is strictly forbidden to cross the pipeline with heavy equipment.

b) Station construction

For station construction, all high points of the pipe section to be tested must be vented. The system must then be pressurised.

� Test water

The test water shall be supplied by the Contractor. It must be clean (eventually after filtering), not silty, with a pH between 6 and 8 and non-corrosive. For stainless steel pipes, the test water shall contain max. 5 ppm of chlorides.

The water shall be sand-free. A compulsory analysis shall be carried out by a recognised inspection organisation at the expense of the Contractor (with the exception of potable tape water). If, after analysis of the water, any doubt persists, a corrosion inhibitor - supplied by the Contractor and submitted to the Owner and/or the Engineer for approval - may be added to it, or another water supply source shall be sought.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 14 - Page 6 of 12

If for any reason the test water has to remain in the pipeline for an unusually long period of time, it should have corrosion inhibitors added to it (supplied by the Contractor and submitted to the Owner and/or the Engineer for approval). In the case of longer storage periods, the Owner and/or the Engineer reserves the right to have a titration test carried out at the expense of the Contractor.

� De-watering

a) Pipeline construction

The Contractor shall under the supervision of the Owner and/or the Engineer inspect the complete open position of the valves before starting de-watering de pipeline.

The type of pigs and foam pigs shall be approved by the Owner and/or the Engineer.

The discharge of the test water shall be carried out in such a way that there is no damage to installations or adjacent plots of land. The Contractor shall request the necessary discharge permit from the competent authorities.

Conventional pigs and foam pigs shall be run through the pipeline as many times as necessary to de-water and clean satisfactorily the pipeline sections. This is subject to the judgement of the Owner and/or the Engineer who must be present at the installation when removing the pigs from the pipeline.


If water is the test medium, the water may be drained through the bleeders and drains provided. During assembly, the Contractor shall check whether any additional drains and bleeders must be provided.

The valves shall be drained as much as possible in the half-open position under air pressure through the bleeder pipes under the supervision of and in consultation with the Owner and/or the Engineer. The discharge of the test water shall be carried out in such a way that there is no damage to installations or adjacent installations. The Contractor shall request the necessary discharge permit from the competent authorities.

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a) Pipe construction

(Only applicable if approved by the Owner and/or the Engineer.)

For pipe construction, the pipe shall be completely buried. Only applicable for pipelines and mains to operate at less than 30 % of the specified minimum yield strength of the pipe, but in excess of 6.9 bar (100 P.S.I.) and within the limits set in the ASME CODE B31.8.


General safety regulations

� For the pneumatic test (air excluded) in enclosed spaces, the premises must be constantly ventilated if any personnel are present. Furthermore, oxygen measurements shall be taken regularly;

� Care must be taken to ensure that the pressure in the test system does not exceed the permissible limit (e.g. under the influence of heat from the sun);

� It is forbidden to hammer the piping;

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 14 - Page 7 of 12

� Weld, screw and flange connections found to be leak-free shall be marked with an indelible colour code on the piping;

� The paint or coloured markers used must not damage the material of the installation.

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� Pressure measurement

The pressure measurement shall be carried out by at least three devices:

� at least one manometer, which must be mounted on one of the piping of the test system;

� a pressure recording device and at least one manometer, mounted near to the pressure recording device.

Such measuring devices shall have an identification number and be accompanied by a calibration certificate. The two types of devices shall have a suitable scale position and range (preferably 1.5 x the pressure to be measured).

When the difference between the readings of two of these devices is greater than 4 % of the arithmetic average of the readings on these 2 devices, the two measuring devices must be recalibrated. The recorded test pressure diagram shall be marked with the test system number and the identification number of the recording device and shall be appended to the test file.

� Pressure loss

In the event of pressure loss, the cause must be investigated. If it is due to any defect in materials supplied by the Owner, any costs arising from any reworking and test re-runs shall be borne by the Owner. In all other cases, the Contractor undertakes to bear the consequences and the costs.

14.4. � �*��1��23��

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Overview table of tightness test for pipeline sections with maximum operating pressure (M.O.P) ≤ 6.9 bar.

Situation Test medium Test pressure Test time Safety measures*

Buried

Dry air or nitrogen Min. 6 bar

6 hours around intersections and non-buried parts

Above-ground or underground (not backfilled) on definitive supports

soaping time everywhere

* Safety measures :

During the pressurisation of the installation and up to one hour after the test pressure has been reached, there is a general safety zone of 10 metres which all personnel and persons are forbidden to enter. Subsequently, until the installation is free of pressure, a safety zone of 5 metres must be observed. All valves and flange connections shall be marked with a sticker bearing the warning “Danger: under pressure”. The zone in which the test is carried out must be marked out and indicated with pictograms and a rotating light.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 14 - Page 8 of 12

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� Buried pipes

Except if otherwise specified in the P.T.S., tightness test shall be performed with water.

The tightness test may be combined with the strength test.

The tightness test pressure shall not be higher than the Resistance test pressure. The test pressure shall not be less than D.P. (Design Pressure).

The test duration shall be determined on the basis of the characteristics of the structure and the accuracy of the measuring instruments. It shall not be less than 24 hours. For volumes of less than 20 m³ or for uncovered sections which can be fully inspected visually, this duration may be reduced for so far duly approved by the Owner and/or the Engineer.

Before carrying out the tightness test, it shall be ascertained that the quantity of air in the pipe is sufficiently small not to affect the test results.

The pipe is considered leak-tight if the temperature and pressure measurements show that the volume of test medium is maintained throughout the test.

If the test reveals that the pipe is not perfectly leak-tight, the Contractor may only be indemnified for the cost of finding the fault if he can prove that the leak was the result of a defect in the Owner’s supplies and that in any case this fault could not have been detected at the time when the pipe sections were received.

� For the installations which have been (resistance) tested with dry air or nitrogen as test medium

The installation shall be brought to 6 bar air pressure and all welds and joints shall be soaped (bubble test) after 24 hours in the presence of the recognised inspection organisation.

14.5. �� ,�,�: ��

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For pipeline construction once the tests (resistance and leak test) results have been declared satisfactory, the cleaning and drying operations shall be carried out. The pipeline section to be cleaned and dried is sealed at the ends by means of welded testing pig traps. These end stations are equipped with instruments for permanent measurement of the temperature, pressure and dew point. After de-watering, conventional pigs and foam pigs shall be run through the pipelines as many times as necessary until internal surface is free of dirt, such as welding slags, rust, oil and dust particles.

The compressors used to draw the pigs shall have an absorption drying units with adequate dew point outlet. After having measured a constant dew point of - 8°C during the last run, the pipeline is closed for at least 24 h.

Except otherwise specified in the P.T.S. the dew point is fixed at -8°C. During this time, the dew point is measured every 4 h. If the dew point has not increased after 24 h, the pipeline is considered dry. It is left at 0.2 bar overpressure dry air or under nitrogen. Dew point measurements are carried out under the supervision of and in consultation with the Owner and/or the Engineer or the recognised inspection organisation at the other end from the drying installation. The Contractor shall only use oil-free and soundproofed compressors for supply to the drying units. When venting the pipeline sections, there shall

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 14 - Page 9 of 12

always be a Contractor's staff present and the public authorities concerned shall be informed by the Contractor.

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During the works, the Contractor shall take the utmost care to keep the inside of the piping clean. He shall carry out the necessary inspections and fit protective covers where necessary.

During de-watering through the purges and drains, the necessary samples shall be taken in glass bottles to check the cleanliness of the pipelines. If it is discovered that these samples have an excess of dirt, the piping shall be cleaned again.

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� Compressed air

After drying, the piping system shall be pressurised with pure, dry and oil-free air or nitrogen which shall subsequently be blown out with sufficient force through the specially designed valves. For the noise pollution caused by the venting, the Contractor shall as a general rule comply with the legislation on work and the environment of the Country concerned.

If the cleanliness is insufficient, the blowing operation shall be continued. For low-pressure pipes, the pressure of blowing used shall under no circumstances be higher than ¾ of the max. operating pressure. For cryogenic pipelines, following cleaning and drying only the upper flanges of the valves shall be dismantled to check the cleanliness of the pipes.

� Flushing (only applicable for small diameters)

The water speed (m/s), depending on the impurities in the case of construction in horizontal pipes (welding slags, rust and loose particles) can be calculated on the basis of the following experimental formula:

U = [0.225(R)0.12 X (H)0.48]

x 1.251

where :

� U = flushing water velocity (m/s)

� R = inner radius of pipe (mm)

� H = dimension of the impurity (mm)

The flushing shall be continued until the desired cleanliness is achieved.

� High-pressure cleaning

1 Bron : The institution of mechanical engineers proceedings, 1973, volume 18763/73. Pipework purging by water

flushing, RR Cranfield, J. Lawrence

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 14 - Page 10 of 12

Can be applied when :

� the injected water can be removed;

� the pipe diameter ≥ 3”;

� the pipe has no inner coating;

� there are no obstacles such as purges or valves with soft joints.

� Chemical cleaning (Pickling)

Only applicable for certain piping processes (e.g. oil cooling circuit of compressors). If pickling is desired, it must be carried out by a specialised firm. When selecting, care must be taken to ensure that the proposed method will not damage the basic material and the welds.

Immediately after this treatment, the pipes shall be thoroughly rinsed and dried. If possible, they should be passivated. As a protection, the pipe should be brought to a slight overpressure with dry air or nitrogen (0.2 bar).

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Unless otherwise stipulated in the Particular Technical Specifications (P.T.S.), the piping shall be dried with compressed air. The compressors used for drying shall have an absorption drying units with adequate dew point outlet.

Valves shall be drained as much as possible in the half-open position under air pressure through the vent pipes under the supervision of and in consultation with the Owner and /or the Engineer. Manipulations of the valves without the supervision of the Owner and/or the Engineer is strictly forbidden. The blowing shall be continued until a constant dew point of -8°C (or other dew point as per PTS) is measured. Subsequently, the pipe shall be closed for 24 hours. If the dew point has not increased after 24 h, the installation is considered dry.

If lower dew points are required, they shall be stipulated in the Particular Technical Specifications (e.g. cryogenic pipes, pipes for piston compressors, etc.).

� The piping to be dried must have the necessary measuring devices to measure constantly the temperature, pressure and dew point;

� The piping is considered dry if following several measurements in 24 h and at several branches of the pipe the dew point measurements are constant and the desired value is not exceeded.

For faster drying, the Contractor may propose drying with heated nitrogen. The temperature shall be limited to +50 °C.

14.6. �� ;��,�� . �� <��,��1��,�<��,�3�

The connection spool piece to be welded must already have successfully undergone a resistance test. The recognised inspection organisation must be informed at least 4 working days before the execution of the tie-in connection welds. Tie-in connection welds which do not undergo the resistance and tightness tests must :

� undergo all the necessary NDT inspections,

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 14 - Page 11 of 12

� be soaped (bubble test) when the pipe is brought into service at a pressure of 6 bar and at operating pressure.

These inspections shall be carried out in the presence of the recognised inspection organisation and the Owner and/or the Engineer. Certain gold welds determined by the Owner and/or the Engineer may only be soaped (bubble test) at a later stage. Consequently, these must be temporarily coated. The terrains shall be temporarily restored to their original condition.

Subsequently, the welds shall be uncovered once again in order to carry out the necessary inspections and to carry out definitive coating and backfill. If this work must be carried out outside the contractual period, they shall be paid for on the basis of pricelists.

14.7. �� = ��

� All above-ground flange and screw connections shall be soaped (bubble test) at operating pressure (including instrumentation);

� The Contractor shall provide the necessary material and labour for this purpose.

14.8. ��

The Contractor shall hand over the final dossier to the Owner and/or the Engineer. The final dossier includes :

� a split-up plan or isometric drawing of each tested section;

� a copy of the calibration certificates for the tested devices;

� a duly completed test form mentioning :

� the date of the test;

� the identification of the test system;

� the test medium;

� the test pressure;

� the test temperature (the ambient and pipe temperature);

� the differences of any Nonconformity Reports and derogations with regard to the test, signed by the recognised inspection organisation and the Owner and/or the Engineer.

� the recording disks or pressure level diagrams of the resistance tests that have been interpreted and completed by the recognised inspection organisation;

� the QRN of the recognised inspection organisation;

� the NDT inspection reports.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 14 - Page 12 of 12

14.9. ��;)�� ,��;�� ; ��>��?�

� Instrumentation and regulation circuits smaller than 2” (instruments, coupling, control line and accessories), insofar as these parts (e.g. thermowell) have not been included in a resistance test of a section of piping, shall be tested for their respective operating pressure during the precommissioning (carried out by the Owner and/or the Engineer). The instrumentation contractor shall include in his assembly price the necessary material and personnel, test medium and accessories (i.e. regulators flexible tubes, etc.);

� These tests need not be submitted to the recognised inspection organisation for approval;

� The instrumentation contractor shall submit the necessary proof that the materials supplied by him withstand the required operating pressure;

� The instrumentation connection pipes between the mini-cabins, the regulator, etc. and the gas pipe shall be tested with nitrogen at 1.1 x MOP.

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Rev. 1 – 14/09/09 Part 15 - Page 1 of 8

15. ��

15.1. �� !��

The Contractor will restore the Construction Site and any other places that have been damaged as a result of the Works to their original condition and this to the entire satisfaction of the Parties concerned.

These works must be carried out within the shortest possible time and at least within 8 weeks following the opening of the working area. In unfavourable weather conditions, the Owner may halt the schedule of the reinstatement work if no effective work can be carried out under these circumstances.

15.2. ��#��$��

The reinstatement of the terrain consists, among other things, of the works summarised in the following non-exhaustive list:

� The works arising out of the conditions, requirements and wishes of the public authorities and administrations;

� Removal of all remaining and surplus material and equipment;

� Reinstatement of drainage and outflow systems, canals, streams, waterways, dikes, road metal, roads, paths, etc;

� Removal of all debris of whatever type as well as stones or broken pieces that might hinder the farming of the land;

� Before replacing the topsoil, the Contractor will even out, level, and break down the subsoil in the working strip to the agreed depth (cf. Part 10, Article 10.2.3.3);

� The machines used for this purpose must be adapted to the different types of ground strata and the depth of the drains; these layers must each be break down without mixing them. The processing of the soil must finally result in a ground structure that shows properties in the areas of texture, permeability, fertility, etc. comparable with those that existed prior to the work operations;

� Replacing the topsoil in its original condition;

� After replacing the top soil, it will be evened out and levelled and thereafter made ready for sowing by raking and hoeing over the entire width of the working area;

� Placement of banks consolidation devices, concrete slabs or posts, wooden posts and sleepers, water fascines, blocks and/or sections of lawn. Wooden materials will be treated against rotting to guarantee a lifetime of 15 years;

� Repair of closures, access ways, walls, slopes, embankments, retainings walls and installations;

� Replacement of removed and/or damaged hedges, closures etc. to the entire satisfaction of the Parties concerned;

� Positioning and/or re-positioning of displaced or removed markers, beacons, property markers etc. with the aid of a surveyor;

� Dismantling and removal of provisional installations. See also part 2 art. 2.2.3.2a.;

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 15 - Page 2 of 8

� Clearing of the constructions sites;

� Any other special point mentioned in the inventory of fixtures.

15.3. ��&��&��

The reinstatement of site report will be drawn up by the Owner’s representative. All remarks in connection with the reinstatement will be reported therein. The representatives of the Contractor and the Owner will together:

� measure and estimation of the off-working Strip area;

� state whether the terrain has been restored to its original condition (cf. Article 15.2). The Contractor will draw up a “List of plots of land for release” on the basis of this assessment. The Contractor undertakes to finish off the reinstatement of the terrain completely, including the markings and accessories, before the evaluation can be made.

On the basis of the “List of plots of land”, a site visit will be organised within 15 days between the representative of the Owner (the Negotiator), the representative of the Contractor and the Parties concerned. They will together complete the “Declaration of release of plot”, see Appendix 1.

If there are no reservations about the reinstatement of the site:

� the Contractor may no longer have access to the plot;

� the “Declaration of release of plot” will be signed by all parties;

� the Party concerned may have the use of his land;

� the Owner’s Negotiator will make an arrangement with the Party concerned for the subsequent administrative settlement and payment joint assessment of the damage/satisfaction, see Appendix 2.

However, if there are any reservations:

� the reservations will be noted in the “Declaration of release of plot” together with a deadline for these to be made good. The Contractor undertakes to adhere to the agreed deadline;

� it will be mentioned whether the Party concerned may or may not have the use of his land;

� the “Declaration of release of plot” will be signed by all parties;

� a date will be specified for a new site visit.

If during the second visit to the site it is noticed that the works cannot be carried out or if the works yet to be carried out on the terrain are so inextensive, compensation can be awarded and the “Settlement” document will be completed (see appendix 3). These cases must be kept to a strict minimum by the Contractor and clearly justified before he requests permission from the Owner.

The Owner reserves the right to pay the Parties concerned directly for any damage caused by the Contractor during the course of the works and not repaired in the appropriate time by the latter, at the expense of the Contractor.

This will include the damage that might result from poorly executed reinstatement, in particular with regard to composition of the topsoil and the soil backfilled above the drainage pipes. This also includes abnormal damage, all damage arising or exacerbated by the non-observance of the contractual obligations including those relating to deadlines and working strip.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 15 - Page 3 of 8

15.4. ��

The purpose of the definitive markings is :

� to indicate the correct location of the pipeline;

� to indicate the position of the pipeline for the purpose of survey with a helicopter.

The pipeline must be marked out during site reinstatement and before the terrain release. Positioning and placing the markers is carried out by the Contractor in accordance with the relevant drawings. Except otherwise specified the aerial beacons will be supplied by the Contractor. They will be in accordance with the relevant drawing and approved by the Owner and/or Engineer.

The Contractor will place the markers and attach the marker plates thereto in accordance with the instructions of the Owner and/or the Engineer. The Contractor will be paid in accordance with the quantities actually supplied and the work actually carried out and on the basis of the price given in the bid in pricelist.

15.5. ��$��!��(��)��

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The positioning of the marker posts is carried out by the Contractor in consultation with the Owner’s Negotiator if the marker posts are located on private land and with the authorities concerned for the public domain in accordance with the relevant drawings and before the terrain release.

The concrete marker posts will be supplied by the Contractor. The Contractor will submit to the Owner and/or the Engineer (for approval) the type of marker he intends to use. The Contractor will place the marker posts, attach the Owner identification signs and fix the information on them. Immediately after the placing of the marker posts by the Contractor these will be checked by the Owner’s surveyor for their correct positioning.

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The positioning of the marker tiles is carried out by the Contractor in consultation with the Owner’s Negotiator if the marker tiles are to be located on private land and with the authorities concerned for the public domain according to the relevant drawing and before the terrain release.

The marker tiles will be supplied by the Contractor. The Contractor will submit to the Owner and/or the Engineer (for approval) the type of marker he intends to use. The Contractor will be responsible for the positioning and placing of the marker tiles in places indicated on the relevant drawing. Immediately after the placement of the marker tiles by the Contractor these will be checked by the Owner’s surveyor for their correct positioning.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 15 - Page 4 of 8

APPENDIX 1

DECLARATION OF RELEASE OF PLOT CDF OPSRA Pipeline : Owner :

Contractor : Terrain manager : Negotiator : Minimum depth : Width of the working strip :

PLOTS OF LAND LOCATED ON THE TERRITORY OF THE MUNICIPALITY: NIS :

DS no.

Land Register

Div. Sect. No.

Surface

ha a ca


Nature and cultivation Length of the working strip

(m)

OWNER CRS :

Name : First name :

Address :

Account :

OPERATOR CRS :

Name : First name :

Address :

Account :

A)

The undersigned hereby declares that the aforementioned plot(s) of land has/have been restored to their original condition following the works by the responsible contractor, in particular as regards:

1. cleaning of the terrain and discharge of waste, stones, material, etc.; 2. raking of the earth on the surface and depthwise; 3. evening of the terrain and REINSTATEMENT of the soil to its original condition; 4. REINSTATEMENT of canals, dikes, streams, gates, enclosures, drinking troughs, shelters; 5. REINSTATEMENT of drainage, irrigation and dewatering networks; 6. replacement of property posts; 7. REINSTATEMENT of roads and access roads used by the contractor; 8. any other particular point included in the site description.

The owner or operator may restore the plot(s) to use from ... / ... / 20...

From this onwards, the owner and/or operator can make no other claims vis-a-vis Owner and/or its Contractor as regards the REINSTATEMENT of the plot(s) within the framework of the works outlined above.

1/2

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Rev. 1 – 14/09/09 Part 15 - Page 5 of 8

B)

The owner and/or the operator may restore the plot(s) to use from .. / .. / 20..

However, the following “minor works” will be carried out :

1. 2. 3.

B.1.) by the contractor .............................................................................. at the latest by ....... / ....... / .... The owner and/or the operator, Owner and the Contractor will meet once again at the latest on ..... / ....... / .... to ascertain whether the aforementioned works have been carried out and to draw up the definitive description of the damage with a view to compensation.

B.2.) by the owner / operator (*) ..................................................................................................................... The latter hereby declares that he agrees with the definitive description of the damage caused by the works carried out by Owner and/its contractor.

From this onwards, the owner and/or operator can make no other claims vis-a-vis Owner and/or its contractor as regards the REINSTATEMENT of the plot(s) within the framework of the works outlined above.

C)

The owner or the operator may not bring the plot(s) back into use.

Description of the works Deadline Contractor

1.

2.

3.

4.

5.

The owner and/or the operator, the contractor and Owner will meet once again on ....... / ....... / 20.... to release the plot(s) concerned and to draw up the definitive description of the damage with a view to compensation. Drawn up in ......... copies, in.......................................................... , on ....... / ....... / 20....

Signature of the owner or operator (*) Signature of the representative of the contractor

Signature of the representative of

For agreement

with point A/B.1./B.2./C(*)

(*) delete where inappropriate 2/2

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 15 - Page 6 of 8

APPENDIX 2

JOINT ESTIMATE OF DAMAGE / DECLARATION OF SATISFACTORY EXECUTION CDF IMP OPSRA Pipeline : Owner : Width of the working strip : m. Contractor : Negotiator : Date :

PLOTS OF LAND LOCATED ON THE TERRITORY OF THE MUNICIPALITY : NIS :

DS no.

Land Register

Div. Sect. No.

Surface

ha a ca


Nature and cultivation Length of the working strip (m)

OWNER CRS : Name : First name : Address : Account no. :

OPERATOR CRS : Name : First name : Address : Account no. :

ESTIMATE OF THE DAMAGE

Damage for which OWNER is liable Damage for which contractor is liable

TOTAL : TOTAL :

TOTAL :

TO BE DEDUCTED: PREPAID AMOUNTS:

BALANCE TO BE PAID :

Agreement with the above amounts and signing of the certificate of the declaration of Site release on ... / ... / 20... is valid as declaration of satisfactory execution.

The payment of the latter amount is valid as the definitive settlement for the damage, inconvenience and losses caused by the works.

Signature of the owner or operator

Signature of the representative in the negotiations of OWNER

Read for agreement by the representative of the contractor

Read for agreement by the expert

For agreement

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 15 - Page 7 of 8

APPENDIX 3

SETTLEMENT BETWEEN OWNER N.V., represented by its mandatary ..............................................................................., hereinafter referred to as OWNER AND Mr, Mrs.(*) ........................................................................................................................................, hereinafter referred to as THE OWNER or OPERATOR (*) The following agreement has been reached : The OWNER or OPERATOR (*) exploits the following plot(s) in the municipality of .................................................................................................................................................................

DS NO. LAND REGISTER

DIV. SECT. NO.

As it has been jointly established that within the framework of the laying of (the works carried out on) the pipe ................................................................................ the rectification of the following damage : 1.

2.

3.

cannot reasonably be technically effected by the contractor or has not been effected by the contractor by the agreed deadline (*) ; With the understanding that the extent of the damage has been jointly estimated at ..............................................……, taking account of possible future damage ; OWNER will from now, by way of settlement, pay the above amount to the OWNER or the OPERATOR (*) − by transfer to account no.. ........................................................ or − by postal order This definitive lump-sum compensatory payment settles all existing or future damage caused by the works carried out in 20... on the aforementioned plot(s). Consequently, the OWNER or else OPERATOR (*) definitively waives any claim, legal or otherwise, which he could lodge in future on account of the aforementioned works and undertakes to have any successor(s) comply with the provisions of the present agreement. If necessary, he will also inform the owner of the plot(s) of this. Drawn up in ..... copies, in ................................................................., on ......... / ........... / 20.... .

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 15 - Page 8 of 8

Signature of the owner or operator (*)

Signature of the representative of the contractor

Signature of the representative of Owner

(*) delete where inappropriate

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Rev. 1 – 14/09/09 Part 16 - Page 1 of 25

16. PARTICULAR CONSTRUCTION TECHNIQUES

16.1. GENERAL

The Particular Technical Specifications define the specific construction method to be used.

In his bid, the Contractor may suggest a different construction method. The Owner and/or the Engineer and the Recognised Inspection Organisation must approve of this method.

16.2. TRENCHLESS CROSSINGS

16.2.1. Boring

16.2.1.1. Geo technical survey report

If the Owner possesses a Geo technical report, he shall inform the Contractor of the results and mention them in the Particular Special Specifications for his interpretation. The Contractor must carry out the required supplementary tests himself if he deems that the information given to him is not sufficient.

The results will be brought to the attention of the Owner and/or the Engineer. The soil depths described in the drawings are estimated depths. Before starting the works, soundings must be carried out in order to ascertain the correct profile of the watercourse, or other obstacles to be crossed.

16.2.1.2. Working pits and shoring works

The supporting sheet piles of the working pits must always be higher than the highest possible level of the water course to be crossed so that if water breaks through there will be no danger of flooding the surrounding areas.

The calculation notes, including the design and construction method for supporting of the working pits, must be submitted by the Contractor to the Owner and/or the Engineer. However, the Contractor remains responsible for any damage or accident.

The Owner and/or the Engineer must be informed of any changes to the shorings during the works. No material may be left behind on the site. The works comprise, among other things, delivery, placing, maintenance, dismantling and removal of the provisional shorings, including driving unit parts, scaffoldings and all attendant obligations.

16.2.1.3. Casings

The casing elements to be used must be delivered by the Contractor. These pipes may be of the following types:

� approved reinforced concrete pipes;

� approved reinforced concrete pipes with steel plate core;

� approved concrete pipes reinforced with steel fibres.

Any other types are not approved by the Owner and/or Engineer.

GENERAL TECHNICAL

SPECIFICATION

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GTS/ 0502

Rev. 1 – 14/09/09 Part 16 - Page 2 of 25

If the Owner and/or Engineer prescribes a special type of casing, this shall be mentioned in the Particular Special Specifications. The section of the casing to be drive must be specified in the Particular Special Specifications or the relevant drawings. The casing elements used must comply with the following requirements :

a) They must comply with all the external loads during construction and after completion of the work. To this end, the Contractor will submit with his bid a detailed calculation note and detailed drawing for the casing mentioning all technical characteristics;

b) The casing elements (reinforced concrete or asbestos concrete pipes) must be fitted with a watertight joint able to resist at least the maximum prevailing water pressure;

c) Required tolerances of the casing elements :

� on the length of the segment : + 30 mm;

� on the inner side ∅ : + 1 cm;

� on the total thickness of the casing wall : +4 % and -2 % of the theoretical wall thickness;

� on the straightness of the casing : the straightness of the casing may deviate from the theoretical center-line at most 2.5 mm per metre.

d) Where necessary, the casing is provided with injection openings to enable lubrication of the casing during driving between the soil and the outside wall with thixotropic or equivalent fluids in order to reduce the friction between the outside wall and the soil as well as the driving force to be used. Following the driving, the lubricant must be pushed aside, stabilised or bound through injection of a mortar based on trass, lime or cement, after which the remaining cavities must be filled (blocking injection). Finally, the injection openings must be sealed with a durable air and watertight seal (e.g. a screw-cap);

e) Unless otherwise mentioned in the Particular Special Specifications, the following external pressures apply :

� soil pressure : volume weight = 2 t/m3

� dry weight = 1.6 t/m3;

� water pressure : water table level = ground level;

� traffic load : heavy convoy in accordance with relevant standard.

As far as soil covering and water levels are concerned, refer to the applicable drawings. Account must also be taken of the local soil characteristics in the soil analysis. The easing must be resistant to the various influences that may occur during transportation, handling and the driving operation itself.

16.2.1.4. The driving

If the Contractor deems that carrying out the driving is difficult or even impossible because of special circumstances (geographical situation, geology, special conditions imposed by the Particular Special Specifications, etc.), the Contractor must accordingly inform the Owner in his price bid. Otherwise, he is obliged to use all means to carry out the driving works to full completion.

The choice of the driving unit to be used for the driving of the casing as well as the method for excavation at the leading edge come under the responsibilities of the Contractor. However, he must take into account the construction requirements set by the Owner and/or the Engineer. The methodology suggested by the Contractor must guarantee reliable construction within the set timescale. The operating principle must be

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/ 0502

Rev. 1 – 14/09/09 Part 16 - Page 3 of 25

specified by the Tenderer in his bid. In his work procedure file, the Contractor must submit to the Owner and/or Engineer a complete and detailed description of his operating method supported by calculations.

The proposed method must comply with the following conditions :

� The driving may start only after the working pits has been constructed and finished completely and the assembly between the wall and the driving unit has been carried out to the satisfaction of the Owner and/or the Engineer;

� An adapted device must guarantee sufficient pressure distribution over the walls of the working pit and the circumference of the casing;

� During construction of the bore holes for the entry and exit working pits, the Contractor must take into account all legal safety measures. He must submit for approval to the Owner a detailed description of the method of construction of these access ways;

� Approval of this method does not discharge the Contractor of any responsibility;

� During the driving process, a cutting head must be pushed gradually into the virgin soil. As the driving progresses, the soil excavated by the cutting head must be removed using a soil transportation device. The excavation face must under no circumstances go beyond the cutting head. Consequently, the excavation must always be fully lined along the sides;

� Where necessary, the works must be carried out by exercising a counter-pressure at the excavation face to prevent any water from bursting through;

� Depending on the nature of the soil, the groundwater level and the drilling shield used, this face support may consist of:

� air pressure;

� mechanical support;

� drilling fluid or equivalent;

� a combination of the above techniques.

� The front face must at all times be sealed tight against water and soil and separated from the area in which the labourers are operating the drilling shield. The cutting head must be manageable by itself and provided with the necessary guiding jacks which must be able to be driven independently;

� In case of driving with pressurised air as front support, the air pressure must be constantly maintained where there is a danger of water seepage and/or collapse. The Contractor must submit a calculation note illustrating that, under all circumstances, the front face support air pressure will preserve the equilibrium of the soil;

� The Contractor must provide all deliveries and works for the filling of any cavities that may arise at the front face;

� The casing must have a sufficient number of injection openings to enable lubrication of the casing, during driving, between the soil and the outside wall with thixotropic or equivalent fluids in order to reduce soil friction;

� After the driving operations, the injection openings must be sealed to air- and water-tightness;

� The maximum capacity of the entire driving unit must be specified by the Contractor. If this capacity is insufficient to drive the entire casing from the entry pit to the exit pit or if the driving pressure on the casing is too high, the Contractor must, where necessary, provide for intermediate driving stations;

GENERAL TECHNICAL

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Rev. 1 – 14/09/09 Part 16 - Page 4 of 25

� During the driving operation, the Contractor must take the following measurements:

a) measurement of the number of metres drived in, including the cutting head in each work shift of 8 hours;

b) measurement of the peak pressure of the main jacks and that of any intermediate driving stations required to start moving the casing at the commencement of the work of each work shift;

c) measurement of the centre of the cutting head in x, y and z co-ordinates after driving each pipe with an accuracy of 5 mm and comparison with a fixed center-line system independent of the driving wall and casing train;

d) the automatic recording of the front face support pressures (drilling fluid, air, soil, water).

� If the measurement reveals that the center-line of the cutting head deviates by more than 10 cm from the theoretical center-line, the Contractor must stop the work and determine with the Owner and/or the Engineer what measures must be taken to improve the manageability of the driving;

� The maximum permitted deviation throughout the entire duration of the driving process is 10 cm both vertically and horizontally measured in relation to the connection line of the centres of the boreholes in the entry and exit working pit walls. If, following the termination of the driving the deviations are greater at any point than permitted, the works will not be accepted by the Owner and/or the Engineer;

� The Contractor must submit the layout of his safety installation;

� A permanent guard must be present (on ground level) when work is carried out by workers in the casing;

� If work is being carried out with the front face supported by air pressure, the air pressure installation must be able to provide sufficient flow and pressure to turn back the groundwater; stand-by compressor unit must be provided;

� A backup electric generator must also be present to take over automatically the supply the power in case of electric power failure;

� The Contractor must take into account that the pipes used (for the casing) must be able to withstand all loads during driving without showing damages or cracks;

� Special attention must be given to the contact materials between two pipes element during the driving operation;

� The Contractor must provide for the finishing of the joints on the inside of the casing in such a way that they do not damage the pipeline and/or its accessories while being driving through.

16.2.1.5. Spacer collars

The spacer collars must be placed at 2.50 m from each other. At the extremities of the casing, two spacer collars must be placed whereby the outer spacer collars must be located at least 30 cm inside the casing.

The support points of the successive spacer collars may not be located in one line, but must be regularly staggered. The spacer collars must be supplied by the Contractor. They will be made completely of PEHD material with a minimum height of 10 cm and must be submitted to the Owner and/or the Engineer for approval.

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Rev. 1 – 14/09/09 Part 16 - Page 5 of 25

16.2.1.6. Driving the pipeline through the casing

When the pipe is insert into the casing, the presence of the Owner and/or the Engineer is required. The insertion must be carried out with a sufficient number of suitable machines.

The pipeline must be kept completely in line with the casing. Damage to the coating must be excluded altogether. The progress of the pipeline in the casing must be gradual and under control. The front end of the pipe must be equipped with a slider-shoe and drawn by a cable through the casing.

16.2.1.7. Description of the works

The execution of an intersection by means of boring includes, in addition to the abovementioned works :

� The drafting of a length profile as described in Part 2, Article 2.2.4.3.;

� The preparation of the site, entry as well as exit working pit;

� The installation of appropriate road signs;

� The placement of work site warning signs in Part 2, Article 2.2.3.;

� The excavation and piling-up of the arable soil;

� The provision of thoroughfare for worksite traffic;

� The exact location and the accessibility of the complete drilling facilities;

� The excavation of the working pits up to a sufficient depth for the driving of the casing including the temporary piling-up of the soil, the necessary excavation supports, keeping the working pits and the installation dry, manipulation and removal of all necessary materials;

� The execution of all the works stipulated in the foregoing articles;

� The clearing of all excess excavation soil to a recognised waste disposal site;

� The temporary sealing of the casing ends after execution of the driving operation;

� The maintenance of the entry and exit working pits until after the tie-in with the line;

� The insertion of a PE encasement for the passage of a teletransmission cable and, where appropriate, the insertion of a HDPE encasement for the optic fibre cable if the pipe is equipped accordingly;

� The backfilling and compacting in layers of 30 cm of all excavations according to part 10.2;

� The restoration of the site according to part 15.

16.2.1.8. Filling the casing with sand and sealing the extremities of the casing

The working methods of filling and sealing the ends of the casing as proposed by the Contractor must guarantee sufficiently against subsequent subsidence at the extremities of the conduit. In any case, the method must guarantee that at least 95% of the casing will be filled with sand after filling.

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16.2.1.9. Information to be provided by the tenderer

The Tenderer must include in his bid an outline and description of the excavation and working methods that he wishes to use as well as of the materials used both for the excavation and transportation of the excavated soil.

� Driving method: He will construct the required entry and exit working pits in accordance with his own working method. He must respect the minimum length measurements of the casing as indicated in the attached basic drawings;

� Level at the upper generatrix of the casing;

� Evaluation of the maximum driving force considered that must be taken into account;

� Number of possible intermediate driving unit;

� Planning and progress in metres per day of the casing. The Tenderer will also take the following into account while drafting his bid:

a) The drafting of:

� a driving report in which progress and any deviations must be noted daily;

� a diagram of the works showing:

� the driving forces; � progress, delays, break down, etc.; � the measured deviations.

b) The supply of:

� a (continuous) calibrated recording manometer on the main driving unit and any intermediate driving unit(s).

c) The supply of :

� the required testing and manufacturing certificates of the casing as well as the date of manufacture;

� The concrete casing must have at least six weeks of drying before they can be used; if they must be used earlier, they must at least have the strength guaranteed by the manufacturer.

d) The tolerances relating to the results.

If the Tenderer cannot adhere to the required tolerances he must mention this in his bid and must indicate and guarantee the tolerances of his driving method - all of which taking into account his experience as well as the examination of any soil tests attached to the Particular Special Specifications.

e) Before starting the works, the Contractor must have his calculations and working methods approved by the Parties concerned and by the Owner and/or the Engineeer. Furthermore, all these documents must be accompanied by the required certificates that confirm the basic data used by the Contractor;

These documents must include :

� Technical notes that define the characteristics of the Contractor’s supplies, for example: casing pipes, sheet piles, etc.;

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� Calculations notes accompanied by sufficient justification, mainly referring to the following elements of the project:

1) The distance between the upper generatrix of the casing and the bottom of the water course, the foundations of railways and roads;

2) The sheet piles, coffer dams, supports, anchorings that form the entry and exit working pits;

3) The calculations of the settings as a result of the driving;

4) The provisions relating to injection, the use of lubricants, the construction details of the joints;

5) The casing elements during the following stages:

� during driving and over the largest possible driving length, i.e. before reaching the exit pit;

� termination of the driving, empty casing;

� during the insertion of the gas pipeline;

� the completed installation, i.e. the remaining space filled with sand.

f) For the driving of casing underneath roads and railways, the working pits are located completely outside the area bordered by a line at an angle of 45° with the horizontal starting from the outermost edge of the road or rail construction (unless otherwise indicated in the drawings);

g) The driving of the sheet piles may not start until such time as the Contractor has obtained the approval referred to above;

h) The Contractor must consider the construction of the working pits in such a way that, following driving, all provisional sheet piles can be removed. If some sheet piles cannot be pulled out and as a consequence must remain in the ground, there must be explicit agreement on this between the Parties concerned. The working floor (gravel, concrete, steel plates, etc.) must also be removed completely.

This list is not exhaustive.

16.2.2. Ramming of product-carrier pipe

The intersection to be constructed must be limited to 2 complete pipe lengths (approx. 26 m) and the pipe must be clad with adequate PE.

16.2.2.1. Description

The construction of a crossing by means of ramming with the product-carrier pipe comprises :

� The setting-up of a length profile as described in part 2, Article 2.2.4.3;

� The preparation of the construction site, both entry and exit working pits;

� The placement of appropriate road signs;

� The placement of work site warning signs as described in Part 2, Article 2.2.3;

� Excavating and storage of the arable soil;

� Provision of an access way for worksite traffic;

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� The exact location and the accessibility of the entire ramming installation;

� The excavation of the working pits to a sufficient depth for driving by ramming the pipeline, including provisional storage of the soil, the required support, keeping the working pits and the installation dry, manipulation and removal of all required equipment (compressors, driving unit installation, cleaning installation, etc.);

� The execution of the welding joint in accordance with approved welding procedure. The crossing may contain at most 1 welding joint. The welding joint must be milled flat prior to carrying out the welding checks;

� The preparation and coating of the welding joint with previously approved coating products for ramming. The approved products in Article 9.1. are not valid for ramming method;

� The ramming of the product-carrier pipe. The removal of the soil in the product-carrier pipe may under no circumstances be carried out by compressed air. The pipe must be absolutely clean inside;

� The transportation of the surplus excavated soil;

� The temporary sealing of the pipe ends after carrying out the ramming;

� The maintenance of the entry and exit working pits until after tie-in with the line;

� The insertion of a PE encasement for the passage of a teletransmission cable and the insertion - if any - of a HDPE-encasement for the optical fibre cable if the pipe is equipped accordingly;

� The backfilling and compacting in layers of 30 cm of all excavations according to part 10.2;

� The restoration of the site according to part 15.

16.2.2.2. Working method

The working method must be described in the bid. Before starting the works, the Contractor will submit a complete and detailed description of his working method to the Owner and/or the Engineer and the recognised Inspection Organisation.

The detailed description includes :

� The working method description and illustrations of the power transfer system on the product-carrier pipe;

� The description of the Working method for the insertion of the PE/HDPE encasements;

� The static calculation of entry and exit working pits;

� A sketch on which the entry and the exit working pits are indicated, among other things;

� The welding procedures to be used;

� The coating products for the welded joints;

� The dynamic force of the driving unit, percussion frequency and duration of the operation.

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16.2.2.3. Inspections

The ramming of product-carrier pipes must be subjected to a number of technical tests:

� The preceding technical tests for the materials;

� Radiographic and US examination of the welded joints;

� Inspection of the coating of the welded joints and the pipe with a holiday detector prior to position the driving unit;

� Systematic checks, as the progress of the pipes demands, to verify whether the work is conform to the instructions in the drawings and to the specifications;

In this regard, the following must be checked in particular:

� The prescribed profile, direction lines and level markers;

� The condition of the pipes;

� The cutting of 30 cm of pipe at the pneumatic hammer side and US (ultrasonic test) or liquid penetrant test inspection of about 30 cm of the product-carrier pipe after removal of the 30 cm pipe section;

� Inspection of the coating by the cathodic protection company after the driving of the product-carrier pipes prior to tie-in with the line. For this purpose, the uncoated extremities of the pipe must be clean and lie completely free and dry. The cathodic protection current in the not yet coupled pipeline section must not exceed 1 µA per m².

16.2.3. Micro-tunnelling

16.2.3.1. General

This construction method is limited to a maximum of 2 entire pipe lengths (approx. 26 m) and the pipe must be coated with adequate PE.


The construction of a crossing by means of dry-excavating and directly driving of the product-carrier pipe includes :


� The preparation of the construction site, both entry and exit working pits;

� The placement of worksite signs as described in Part 2, Article 2.2.3;


� Excavation and storage of the arable soil;

� Provision of an access way for worksite traffic;

� Exact location and the accessibility of the entire micro-tunnelling installation;

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� The excavation of the working pits, to a sufficient depth, necessary for driving the pipe through, including temporary storage of the excavated soil, the required support, keeping working pits and installation dry, manipulation and removal of all required equipment (including guiding and driving unit, jacks, drilling head, electrical generator, hydraulic sets, vacuum installation, soil transport system, drilling fluid, installation, etc.);

� Execution of the welding joint in accordance with an approved welding procedure with a maximum of one welded joint in the crossing;

� The preparation and coating of the welding joint with coating products that have been approved for micro-tunnelling. The approved products in Part 9 are not valid for micro-tunnelling;

� The driving of the pipes in loose or compact soil and the removal of the excavation soil to be carried away through the pipe which has been drived in;

� This may under no circumstances be carried out by means of compressed air;

� The transportation of surplus excavated soil;

� The works arising from and accompanying the foregoing works:

� the injection of thixotropic or equivalent fluids to reduce friction;

� the temporary sealing of the pipe ends after the driving;

� the maintenance of the entry and exit working pits until after tie-in to the line;

� the insertion of a PE encasement for the passage of the teletransmission cable and the insertion of an HDPE encasement to the optical fibre cable if the pipe is equipped accordingly.

16.2.3.3. Construction method

The construction method must be described in the bid. Before starting the works, the Contractor must submit a complete and detailed description of his working method to the Owner and/or the Engineer and Parties concerned. The detailed description comprises the following, among other things :

� A description and illustrations of the power transfer system on the product-carrier pipe;

� The description of the working method for the insertion of the PE/HDPE encasements;

� The static calculation of entry and exit working pits;

� The provisions relating to the injection and use of lubricant;

� A sketch in which the entry and exit working pits are indicated;

� The welding procedure to be used;

� The coating products for the welded joints.

16.2.3.4. Inspections

The drived pipes must be subjected to a number of technical tests:

� The previous technical tests of the materials;

� Radiographic and US examination of the welded joints;

� Inspection of the coating of the welded joints and the pipe with a holiday detector prior to driving;

� Systematic checks, according to the progress the pipes, in order to verify whether the works are conform to the instructions in the drawings and/or the specifications.

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In this regard, the following will be checked in particular:

� The described profile, direction lines and level markers;

� The condition of the pipes;

� The coating by the cathodic protection company after driving of the pipe. For this purpose, the extremities of the pipe must lie completely free and dry. The cathodic protection current in the pipe not yet coupled pipeline section must not exceed 1 µA per m².

16.2.4. Horizontal directional drillings

Refer to GTS 740/001.

16.3. OPEN TRENCH CROSSING

16.3.1. Casing in open trench

16.3.1.1. Materials

The casing elements to be used for the works must be supplied by the Contractor. They may be of the following types :

� approved reinforced concrete pipes, open trench type

� approved fibre-cement conduits, sewage type

� any other types of conduits approved by the Owner

The inner diameter of the pipe must be at least 300 mm larger than the pipe diameter.


The construction of a crossing by means of a casing includes :


� The preparation of the construction site;

� The placement of worksite warning signs as described in Part 2, Article 2.2.3;


� Location of underground obstacles by means of sounding pits;

� Excavation of the trench including temporary storage (temporary transportation where necessary) of the soil, the required support, keeping the trench dry;

� The placing of casing element on a bed of 15 cm of stabilised sand;

� The backfilling and compaction of the trench;

� The transportation of the surplus soil to an approved waste disposal site;

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� The temporary or final repair works of the roads;

� The insertion of the pipe into the casing;

� The placement of a HDPE encasement for the optical fibre cable if the pipe is equipped accordingly for the teletransmission cable if any;

� The placement of a 2” ø PE encasement with pulling cable;

� The placement of Mg anodes, supplied by the Owner, for casing longer than 40 m.;

� The filling of the casing with sand.

16.3.1.3. Spacer collars

See Article 16.2.2.5.

16.3.1.4. Insertion of the pipe in the casing


16.3.1.5. Filling the casing with sand


16.4. SINKERS/SYPHONS

16.4.1. Temporary assembly and construction sites

Moving already existing structures must be the subject of a special permit issued by the Parties concerned. The Contractor must carry out or have these works carried out in accordance with the instructions and requirements of the Owner and/or the Engineer and the Parties concerned. Permanent access must always be ensured along both banks of waterway.

The constructions of dikes and support dikes, provisional access roads, coffer dams, encasement sheet piles, excavation works, protections as well as reinstatement of existing installations, more particularly banks and dikes, construction of a slipway (where necessary), may only take place after having obtained the necessary permissions of the Parties concerned.

16.4.2. sheet piles and coffer dams

The Contractor must carry out the required supplementary tests or measurements if he deems that the information (relating to currents, tides, sediment movement, soil characteristics, etc.) provided for in the Particular Special Specifications is inadequate to guarantee professional work.

The Contractor must mention this in his bid. The results of any supplementary tests must be communicated to the Owner. The top level of the temporary sheet pile screens must always be higher than the highest possible water level of the waterway to be crossed to ensure that there is no danger of flooding of the surrounding areas if water should break through. For carrying out the excavation works, the Contractor must provide for coffer dams and/or sheet piles in accordance with the soil stability.

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The sheet piles must be constructed over both dikes in such a way as to provide for maximum safety against water break-through. For instance, at no time when the works are being carried may free passage exist between the waterway and the surrounding land, even while the sinker is being put in place. The Contractor will be held fully responsible for any damage caused by the infiltration of water through the sheet piles or coffer dams.

Important note:

The coffer dams must be designed and constructed in the area specially provided for this purpose and indicated on the basic drawing in order not to obstruct any shipping activities. In his bid, the Contractor will provide a description of:

� measurements and installation of these coffer dams and/or sheet piles;

� type and characteristics of the sheet piles provided.

The installation as well as the measurements of coffer dams and sheet piles will be subject to an implementation drawing and a calculation to be submitted to the Owner and/or the Engineer as well as to the Parties concerned for approval. This approval does not in any way diminish the responsibility of the Contractor. The ramming of the sheet piles may not commence until the Contractor has obtained the approval mentioned above.

The specifications of Article 10.1. are also applicable to the realisation of the sinker trench. For this purpose tolerances of ±10 cm apply. The proposed working method must be selected in such a way that this method is in accordance with the planning, safety and stability of the entire works.

16.4.3. Anchoring, ballasting, mechanical protection of the sinker

Weight of the sinker per linear metre prior to application of a protection :

� GL = 14

π (∅ coated steel pipe)2 x weight of displaced water.

Weight of the coated pipe :

� GB = Weight 1 (steel pipe + P.E. coating) + Weight 2 protection.

� G1 = see manufacturer

� G2 = π

4 (∅2

B - ∅2

L) x specific gravity of concrete.

∅B= average outer diameter of the pipe after application of the protection (based on at least 5 measurements)

∅L= ∅ coated steel pipe.

� GB/GL > 1.3 unless otherwise specified in the Particular Special Specifications

The form work used for the application of the concrete protection must be removed. The concrete protection must be at least 10 cm tick everywhere. The application there of may not damage the coating anywhere. The concrete must be reinforced. In the case of injected concrete, the Contractor must guarantee the specific gravity of the concrete.

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16.4.3.1. Specifications relating to shipping

All floating material to be used (dredging vessels, floating derricks, pontoons, containers, tugs, etc.) must be provided with the required lighting, signalling devices, transmitter and transceiver equipment, in conformity with the requirements of the Parties concerned. In particular, during the sinking manoeuvre proper communications with the shore must be assured. The relevant instructions and requirements of the Parties concerned must be followed promptly and strictly.

The Contractor must submit the characteristics of his floating equipment for approval to the Owner and/or the Engineer and the Parties concerned in good time. In particular, all floating equipment or the accompanying support vessel must have sufficient motor capacity in order to ensure adequate manoeuvrability. Shipping may not be hindered during the dredging works; the shipping route must therefore always be freed in good time and provided with beacons according to the instructions of the Parties concerned. Non-operational floating equipment must always be moored alongside the shores according to regulations.

All work activities (profile narrowing, presence of floating equipment, etc.) must be announced through “Messages for Shipping” to the Parties concerned within the stipulated timescale. The date of the sinking works must also be announced in good time; this date may not be changed afterwards except in the case of unforeseen weather circumstances (ice-drift, fog, etc.).

16.4.3.2. Dredging

The characteristics of the soil to be dredged may be mentioned for information in the soil analysis attached to the Particular Special Specifications. If this information is not available, the Contractor himself must carry out the necessary investigations and present the results to the Owner and/or the Engineer and the Parties concerned before starting the works.

The minimum covering described on the drawings must be adhered to everywhere. The transversal banks of the temporary trench must be made in such a way as to avoid any danger of shearing and/or earth depletions that may affect the stability of constructions in the vicinity. Furthermore, the Contractor must adapt his working method to the speed of silting of the trench to be dredged.

If the Particular Special Specifications do not mention a waste disposal site, the Contractor himself must take the necessary steps. The waste disposal site must comply with the applicable legislation.

If during the dredging works it becomes clear that there are unforeseen and bulky obstacles at the bottom of the sinker trench, such obstacles must be removed to a minimum of 1 metre below the lowest generatrix line of the protected pipe. The resulting cavities must be filled with soil of which the characteristics are roughly equivalent to those of the soil from the dredging trench.

Before starting the works the Contractor must carry out a detailed sounding of the waterway to be crossed. This sounding must be repeated before the sinker is placed and after the backfilling has been carried out. In his bid, the Contractor must mention which method will be used for this sounding (determination of depth - positioning).

16.4.3.3. Sinking

The Contractor is free to suggest an alternative method of launching and sinking. He must submit this method, supported by the required calculations, for approval to the Owner and/or the Engineer and the Parties concerned. To his bid, the Contractor must attach a theoretical drawing and a detailed description that must provide clear insight into the various stages from prefabrication of the sinker on the land up to and including the process of laying it in the trench.

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This work schedule must clearly show, among other things, which temporary measures are considered by the Contractor (including the application of temporary sheet pile constructions, coffer dams, dikes, bridge constructions, etc.) that will reduce the free profile of the waterway. If the Parties concerned do not agree with a certain working method, the Contractor must work out an acceptable working method at his own expense. The approval of a working method by the Owner and/or the Engineer and the Parties concerned, however, in no way discharges the Contractor of his responsibility in this matter.

In particular, special attention must be paid to the hoisting plan drawn up by the Contractor. It must be designed in such a way that during the entire operation no inadmissible stresses may occur in the pipeline and that there will be no danger of lateral kinking or folding. The hoisting belts may not damage either the pipe or the cladding around it.

During the sinking works, the Contractor must have sufficiently trained staff and equipment at his disposal. If necessary, the sinker must be ballasted evenly during launching, proportionate to the water displacement of the pipe during sinking. The filling of the trench may only start after measuring the correct position of the sinker and after explicit agreement by the Owner and/or the Engineer. This must be carried out with filling material that complies with the instructions of the Parties concerned and guarantees sufficient safety against floating. This must be submitted for approval to the Owner and/or the Engineer.

The filling must be carried out carefully to 1 metre above the pipe. In each case the filling soil must be free of stones, fragments or sharp objects that could damage the pipeline and its protection. The soil remaining after filling the trench and the rising banks becomes the property of the Contractor and must be transported away from the site or from the temporary waste disposal site to a recognised waste disposal site.

16.4.3.4. Crossing of bank reinforcements, sheet pile supports coffer dams, embankments, etc.

The demolition works at the crossing must be limited to a minimum area, compatible with the implementation of the work in accordance with the code of good practices. In order to render the sinker compatible in terms of stability and form with existing constructions, the Contractor must request the relevant drawings, calculations and working methods of the constructions to be crossed from the Parties concerned in good time.

If these are not available and/or provide insufficient information, the Contractor must carry out the necessary supplementary surveys (excavating test trenches, taking soundings, measuring, soil analysis, etc.). Based on the information thus obtained, the Contractor must draw up his design and construction drawings and submit them to the Owner and/or the Engineer and the Parties concerned for approval. The instructions of the latter must be strictly followed, and during reconstruction special attention must be given to the connection between old and new parts in order to avoid water seepage around and under the construction.

If certain demolition material are, in the opinion of the Parties concerned, fit to be reused after cleaning, they must be stored temporarily. Removed piles, asphalt concrete, rush mats, filter cloth, fascine mattresses, concrete, masonry, etc., however, become the property of the Contractor and must be carried away to a recognised waste disposal site.

16.4.4. Description of the works

The placement of a sinker also includes, in addition to the abovementioned works:

� The drafting of a length profile as described in Part 2, Article 2.2.4.3;

� The preparation of the worksite, for any working pits;

� The placement of appropriate road and waterway signs;

� The placement of worksite signs as described in Part 2, Article 2.2.3;

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� The excavation and piling-up of arable soil;

� The provision of a access for worksite traffic;

� The excavation up to a sufficient depth for the placement of the sinker, including the temporary piling-up of the soil, the necessary support, keeping the work pit and the installation dry, manipulation and removal of all necessary materials;

� The execution of all works stipulated in the foregoing articles;

� The removal of all excess excavation soil to a recognised waste disposal site;

� The temporary sealing of the pipe ends after the placement of the sinker;

� The maintenance of the tie-in work pits until after the connection with the line;

� The insertion of a PE encasement for the passage of a teletransmission cable and, where appropriate, the insertion of an HDPE encasement for the optic fibre cable if the pipe is equipped accordingly;

� Backfilling according to Part 10, Article 10.2.;

� The restoration of the site according to the aforementioned articles and Part 15 of the General Technical Specifications.

16.5. ABOVEGROUND PIPELINE WORK

FOR INFORMATION ONLY.

16.5.1. General

To guarantee maximum security during Works near existing structures with underground access ways for persons, the following measures shall be taken:

• the demolition materials shall be removed immediately;

• the excavation shall be backfilled or removed the same day;

• the trenches may not remain open after 5 p.m.

16.5.2. Ground level transition protection

16.5.2.1. General note

The brand names of products used in this article are the result of a procedure approved by the Owner for treating the pipeline at above/underground transition point. It is not the intention to promote these products in one way or another. Consequently, the Contractor is free to suggest to the Owner equivalent products from other suppliers or with other brand names. The working method described here below are approved recommended method only. The Contractor must submit for approval his working method to the Owner and/or the Engineer.

16.5.2.2. Method 1 - In accordance relevant drawing

Application of Fibaroll; see part 18 article 18.5

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16.5.2.3. Method 2 - In accordance with relevant drawing

Placing and filling of protection casing.

16.5.2.3.1. Required materials:

� Casings: these consist of concrete or fibre cement with an internal diameter that is 100 mm larger than the outer diameter of the pipe to be protected and a length of 1 metre + the nominal outer diameter. For the protection of existing pipelines two half-shells must be used. For new pipelines casings made out of one piece must be used;

� Centring collars must be placed in the middle of the part of the pipe to be protected;

� Closing device : to be placed on each end of the conduit. On new pipelines these rubber closing devices must be of the closed type;

� Other materials:

1) PU paint Voss Chemie type K6 S.

2) Liquid polyurethane, 2 components.

3) Special glue for gluing the 2 half-shells: Mono-component polyurethane-based glue, PU type Glue 10.

16.5.2.3.2. Working procedure

1) Treating the pipe

a) Existing pipe (one part painted, the other part coated):

� Remove the pipe coating in accordance with a working method recognised by the Owner and/or the Engineer;

� Cleaning the unclad part by means of a solvent;

� The coating must not be removed further than point A of the below-ground section. Point A is located at 600 mm + nominal diameter of the casing below the surface;

� Sand-blasting SA 3 or mechanical brushing ST3;

� Application of a first layer of Voss Chemie PU paint type K6 S diluted with 20% trichloroethylene;

� Application of a sufficient number of undiluted layers of K6 S to obtain a dry layer 250 microns in depth. The surface to be treated with K6 S extends from point A, below-ground section, to 50 mm past the location where the closing device is to be fixed to the above ground section, to ensure a good connection with the paint.

b) New coated pipelines:

� Pipes coated with extruded polyurethane : the placement and filling of the casing may be carried out without removing the coating;

� Pipes coated with tapes or with a damaged coating: identical treatment as for existing pipelines.

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2) Filling the casing

a) Existing pipe:

� The casing consists of 2 half-shells that are glued on site with PU glue 10;

� The closing device must be of the open type and glued on site (Special glue for vulcanising the rubber).

� 1. In vertical position:

� placing the centring collars in the middle of the part to be protected;

� placing and gluing the 2 half-shells, centring the casing;

� placing the bottom closing device;

� filling the conduit with polyurethane in order to ensure the adhesion of the coating at point A;

� repairing the painted part of the pipe above ground level;

� securing the upper closing device after polymerisation of the polyurethane;

� repairing the layers of paint according to code 01 of the Owner.

� 2 In horizontal position:

� placing the centring collars in the middle of the casing to be protected;

� fixing and securing the 2 half-shells, centring the glued casing to connect the coating point A with polyurethane;

� placing the rubber closing devices at the extremities of the casing (to be glued by means of vulcanistion);

� filling the casing with polyurethane;

� removing the closing devices after polymerisation and examining the surfaces injected;

� retouching the layers of paint on the side where the pipe is unclad.

b) New pipe:

The filling of the casing is performed in the workshop. The conduit is filled with polyurethane in accordance with the procedure under 1.b) or 1.a) according to whether they are pipes with PE coating or not. A casing made out of one piece will be used. Further steps are according to 2. (vertical position).

The products must be applied according to the specifications of the manufacturer.

16.5.3. Placing stainless steel clamping rings that serve as sliding sleeves on in service pipelines

In accordance with relevant drawing.

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16.5.3.1. General

Clamping rings may only be applied to pipelines that are protected with paint against corrosion in accordance with code 01.

16.5.3.2. Materials

� 2 clamping ring halves made of stainless steel 304 or 304 L, 3 mm thick;

� neoprene mat 5 mm thick;

� silicone-based sealing product;

� stainless screws.

16.5.3.3. Inspection and examination before applying the clamping rings

a) Make sure that the pipe has already been treated with anti-corrosion paint (complete 01 system) at the location of the clamping rings. The paint must be dry and hard;

b) The indicated locations must be cleaned with cloths soaked well in trichloro-ethane, solvetane or chlorothene. There may be no grease or oil, humidity, scale, etc. on the contact surfaces between the neoprene sheet and the pipe. Where a new layer of paint must be applied at the locations of the clamping rings, this layer must be dry and hard before the clamping rings can be placed (24 to 48 hours);

c) Where necessary, dry the surface prior to application;

d) Check the length and width of the neoprene sheet; its width must be 5 to 10 mm less than the width of the clamping rings, and the circumference of the neoprene sheet must be ± 1 mm less than the circumference of the pipe;

16.5.3.4. Placing the clamping rings

a) Indicate with chalk the final position of the clamping ring on the pipe taking into account that the axis of the clamping ring must lie in the axis of the support;

b) Place the neoprene sheet close to the pipe, taking into account that the seam is located on the bottom line of the pipe at the same level as the seam of the stainless steel clamping rings. For fixing the seam, adhesive tape or glue paper may be used, to be applied crosswise to the pipeline;

c) Moisten the outside of the neoprene sheet slightly with soapy water in order to facilitate the sliding of the clamping ring halves when securing;

d) Place the uppermost half of the clamping ring;

e) Place the lower half of the clamping ring;

f) Connect the two clamping ring halves with stainless steel bolts without applying excessive force to prevent the neoprene creeping between the clamping rings. The bolts must be fixed with one of the following products:

� PERMA BOND no. 118;

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� LOCTITE Stud Loc. no. 270.

g) Filling of the space between the clamping rings and the pipe by means of silicone jointing compound that must be properly smoothed in such a way that no rainwater or condensation can infiltrate between the clamping rings and the pipe.

16.5.4. Placing of PVC half-shells as protection against discharge water at expansion joints of bridges and structures

In accordance with relevant drawing.

16.5.4.1. Materials

� Casing halves made of PVC with an inner diameter equal to the outer diameter of the pipe + 20 mm and a minimum length of 1.5 m;

� Rubber tape 20 mm thick;

� Special glue for rubber tapes;

� PVC fixing tape, “Colson” type or equivalent.

16.5.4.2. Inspection and examination prior to placing the half-shells

� The half-shells may only be placed around the pipe after being covered with a complete anti-corrosion paint treatment and after cleaning the surface to be treated;

� The rubber bands may not be glued to the pipeline.

16.5.4.3. Placing the half-shells

� Gluing the rubber bands on the PVC casing halves;

� Placing the casing halves on the pipe at the fixed locations;

� Placing the ring connection around the pipe.

N.B. : To secure the PVC casing halves only fixing clasps made of PVC may be used.

16.5.5. Replacing existing supports by new supports

16.5.5.1. Preparatory precautions

Prior to starting the works, the Contractor must:

a) Measure the position of the pipe - both vertically and horizontally - at the level of the existing support and the ground exits. The measurements must by carried out by the Contractor in the presence of the Owner’s representative. The markers must be indicated on the installation and set out in the drawing by the Contractor. One or more copies of this drawing must be permanently present on the Construction site;

b) Take all required measures to prevent stresses in the pipe;

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c) Start by dismantling the fire protection taking into account the approved procedure. The elements of the fire protection may only be reassembled at their definitive location when the new supports have been set in place;

d) The different parts of the supports must be delivered, finished and painted. Consequently, the Contractor must take all necessary precautions to avoid damage to the paintwork during unloading at the construction site and during assembly operations.

16.5.5.2. Working method for dismantling a support

a) Check that all preparatory measures have been taken;

b) Remove sliding supports or rollers below the pipe;

c) Grind away all metal parts that will no longer be used for the mounting of the new support;

d) Sand-blast all places where welding will be carried out.

16.5.5.3. Procedure for mounting the new supports

Except otherwise stated in the Particular Technical Specification the mounting and welding of the gliders or stainless steel shells shall be made by the Contractor under the express supervision of the Owner's representative.

16.5.5.3.1. Preparatory works and precautionary measures

a) Before placing the supports the Contractor must have the Teflon plates (gliders) already mounted on the supports;

b) All new supporting parts to be welded to the structure or the already existing support must be welded over the entire circumference in order to ensure complete tightness;

c) After welding new parts to the existing support, the support must be painted completely.

16.5.5.3.2. Mounting

a) Presenting, placing, adjusting and welding of the basic parts of the support to the existing structure;

b) Presenting, placing, adjusting and welding of the lateral guides;

c) Presenting, placing, adjusting and welding of the base plate or cross beam of the support. Painting of the entire assembly after welding;

d) Assembly and adjustment of the lowest sliding plate taking account of the time necessary for the paint previously applied to dry;

e) Assembly and adjustment of the base plate or uppermost transverse plate. A clearance of 0.2 mm must be provided between the pipe and the Teflon plate;

f) After the final adjustment, paint the entire support.

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16.5.6. Removal, repair and replacing of the fire-resistant screens

16.5.6.1. Description of the fire-resistant screen

The fire-resistant screen consists of a [-shaped plate of galvanised metal painted prior to mounting and protected on the side of the pipe with a plate of asbestos cement with natural mineral fibres.

All fire-resistant elements must be mounted on the pipe support between the pipe and the structure of the bridge over the entire length of the construction. The elements of the fire-resistant screens will nearly always be used as support for the teletransmission cables.

16.5.6.2. Procedure

Before starting the works, the Contractor, in cooperation with the Owner, must make a site description to evaluate the scope of the works to be carried out and of the materials to be replaced. To this end, each fire-resistant part will be checked for distortion as well as the asbestos-cement plates, the connections, the paintwork, etc.

16.5.6.3. Scope of the works

a) Before dismantling the fire-resistant elements, the Contractor must determine the correct location of these elements because the distances between the supports may vary. The reinforcement steel plates (150 x 6 mm) will be prepared;

b) Dismantling the fire-resistant elements;

c) Remove the existing reinforcement steel plates from the supports by grinding;

d) Repair the damaged elements, where necessary replacing the plates of asbestos-cement, retouch the paintwork;

e) Mount the reinforcement steel plates on the elements of the fire-resistant equipment (steel bars 150 x 6 mm). The holes for fixing may be drilled in the steel plates beforehand (see detailed drawing). The last two elements on the upstream side of the bridge will be shortened to allow expansion (see detailed plan);

f) The new reinforcement steel plates on the support must be mounted and welded by means of continuous welding beads;

g) After the welding of the new reinforcement plates, retouch the paintwork;

h) Assembly and adjustment of the fire-resistant elements. The corner irons must be welded free of stress so that the axes can slide easily. Furthermore, they must be lubricated when they are mounted;

i) The new parts will be painted before delivery. Consequently, the Contractor must take all the necessary precautions to avoid any damage to the paintwork.

16.5.7. Welding of stainless steel shells to pipelines

The work must be carried out according to relevant drawing.

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16.5.7.1. Preparation

a) The marking of locations of the shells, in accordance with the instructions in the drawing and specifications, taking into account the expansion of the pipe, in such a way that the welding of the shells remains at a distance of at least 300 mm from the welded joints of the pipes. If this distance is unfeasible, it may be reduced provided that supplementary checks are made of the round seam weld of the pipe;

b) Cleaning by sandblasting (Sa 3) or mechanical brushing (St 2.5) of the area(s) before placing and welding the stainless steel shells;

c) U.S. and E.M. inspection of the area concerned of the pipe before welding the shells;

d) Inspection of the outer diameter of the pipe at places where the stainless steel shells will be welded;

e) Apply the shells to the pipe and tighten them using a special tool intended for this purpose (clamping ring or chain) after, where necessary, grinding away the surplus thickness of the existing lengthwise weld on the pipe leaving a surplus thickness of 0.5 mm on the welding joint.

16.5.7.2. Welding procedure for stainless steel shells, stainless steel 304L, on above ground pipes to be laid or on existing pipes which are not in service or under pressure

The procedure is valid for welding on pipes made of steel API. Gr.B up to X60 with wall thicknesses of at least 4.5 mm and with a cooling rate limited to 75ºC/minute with min. temp. of 80ºC at the welding end.

16.5.7.2.1. Electrodes to be used

� Soudochrom L309 L.N.D. 2.5 mm;

� Soudochrom A.D. D.N. 2.5 mm exclusively for downward welding.

16.5.7.2.2. Inspection of the pipe before welding

U.S. inspection according to ASME V, art. 5 and API 1104 assessed according to ASME VIII, Div. 1, App. 12 and E.M. inspection according to ASME V, Art. 7 and acceptance criteria according to ASME VIII, Div. 1, App. 6 and API 1104.

If during inspection an error is discovered, another location must be chosen or if necessary a section of the pipe will be replace. Where necessary, however, the welding joint must be ground with a surplus thickness of approximately 0.5 mm, among other things for helical seam welded pipes or longitudinal seam welded pipes. The pipe must be perfectly cleaned, free of grease, scale, residue of metallisation and humidity.

16.5.7.2.3. Welding sequence

� Press the stainless steel shell solidly against the pipe by means of the appropriate tools;

� Pre-heat.

a) For the lengthwise welding of stainless steel shells:

The entire surface of the shells must be pre-heated with a burner to ± 100º C in order to remove all traces of humidity between the pipe and the shell. Weld in accordance with the indicated sequence 1-2-3-4 on fig. 1 and/or 2.

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b) For round seam welding:

Pre-heat the pipe with a burner to 150 - 200 º C. Try to avoid heating the shell to such an extent that it might come loose from the pipe by expansion. Carry out the entire welding joint A following the sequence of the arrows of fig. 1 and/or 2, after which the same working method must be repeated for welding joint B. After welding, the shell must be neutralised, cleaned and polished with a product approved by the Owner (passivation - Betspastor type, AVESTA-JOHNSON & Co. N.V.).

16.5.7.2.4. Inspection after the welding

The welding seams must be thoroughly checked 100%.

16.5.7.2.5. Welding procedures approved by a recognised inspection organisation

The Contractor shall submit for approval the welding procedure he intends to use.

16.5.7.2.6. Special conditions for painting the round seam welds of the stainless steel shells welded on pipelines

The round seam welds between the stainless steel shells and the steel pipe must be protected against atmospheric influences by painting. To this end, a collar of approx. 20 mm at both ends of the stainless steel shell must be sand-blasted (Sa 3) or mechanically brushed (St 2.5) and painted in accordance with system code 01 approved by the Owner.

During these operations, the central parts of the stainless steel shells must be protected against sand-blasting or stripping. These parts must remain polished in order to facilitate the sliding of the shells on the Teflon sliding supports.

16.6. DISCONNECTING EXISTING PIPELINES

FOR INFORMATION ONLY.

16.6.1. General

The Particular Special Specifications determine which parts of the pipes must be disconnected. The interventions under gas will be carried out by the Contractor well trained team with a recognised experience and the Contractor will also carry out the following work :

� The required excavation works in accordance with the specifications of the G.T.S. Part 10;

� The removal of the existing coating as described in part 9 over the entire length of the working pit except for 0.5 metres along each extremity;

� The supply of all materials and the execution of all work as described in Art. 19.8.2. according to the specific status and service pressure of the pipe;

� The removal of the pipe parts indicated in the P.T.S. (valve station, sample pieces, etc.);

� The restoration of the site in accordance with G.T.S. Part 15;

� The transportation and unloading of the pipeline parts indicated in the P.T.S. to the worksites of the Owner.

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The Contractor will supply all the materials that are not included in the parts lists.

16.6.2. Status of the pipe to be disconnected and special applications

16.6.2.1. Disconnection of pipelines to remain in service

a) Low-pressure pipes (≤ 14,7 bar):

The pipe must be disconnected with a conical terminal plug with a 1” vent. The Owner will supply the end cap and the materials for the 1” pressure release point. The Contractor will carry out all the necessary works in accordance with the relevant drawing.

The 1” pipe Sch.80 of the pressure release point must be bent cold by the Contractor. All welding seams must be tested non-destructively (Rγ for butt welding and liquid penetrant testing for the corner welded seams). The Contractor will deliver and place an approved 16 mm² cable in accordance with G.T.S. Part 13. The welding of the terminal part to the pipeline is carried out by the Contractor well trained team. The Contractor must carry out the required coating works in accordance with G.T.S. Part 9. The tie-in joint must be soaped at 6 bar and at operating pressure.

b) High-pressure pipelines > 14.71 bar:

The pipe must be disconnected with an end-piece in accordance with the relevant drawing. The Contractor will deliver all materials in accordance with the parts list. The Contractor must construct the end-piece in accordance with the drawing mentioned above. All welded joints must be radiographied. The Contractor will carry out a resistance test (1.4 x M.O.P.) and a leak test (soaping at 6 bar). The tie-in joint will be carried out by the Contractor well trained team, radiographied and soaped at 6 bar and operating pressure. The Contractor will supply and place an approved 16 mm² cable in accordance with G.T.S. Part 13 and carry out the coating work in accordance with G.T.S Part 9.

16.6.2.2. Disconnecting pipelines to be left behind permanently

The pipe must be disconnected with a terminal cap in accordance with the relevant drawing. The Contractor will supply all materials in accordance with the parts list. The Contractor will construct the end cap in accordance with the relevant drawing and weld it to the existing pipe after rinsing it with nitrogen and after the Owner and/or the Engineer's approval.

The Contractor will deliver the nitrogen required for rinsing the pipe. The Contractor will deliver and place an approved 50 mm² cable in accordance with G.T.S. Part 13 and will carry out all the coating works in accordance with G.T.S. Part 9. The Contractor will fill the pipe to be left with nitrogen with an over-pressure of 100 gr.

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HORIZONTAL DIRECTIONAL DRILLING

GENERAL TECHNICAL SPECIFICATION



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TABLE OF CONTENTS

1. GLOSSARY ................................................................................................................................ 1

2. GENERALITIES .......................................................................................................................... 1

2.1. SCOPE OF THE GTS .......................................................................................................... 1

2.2. SCOPE OF THE CONTRACTOR ........................................................................................ 1

2.3. SUPPLIES ........................................................................................................................... 2

2.4. SITE LOCATION ................................................................................................................. 3

2.5. GEOGRAPHICAL CO-ORDINATES .................................................................................... 3

3. LAWS - CODES - RULES & STANDARDS ................................................................................ 3

3.1. GENERAL ........................................................................................................................... 3

3.2. PECULIAR CODES & STANDARDS ................................................................................... 3

4. GEOLOGICAL DATA .................................................................................................................. 4

5. RIGHTS OF WAY AND WORK SPACE ...................................................................................... 4

5.1. WORK SPACE .................................................................................................................... 4

5.2. RIGHTS OF WAY ................................................................................................................ 4

6. DRILLING PROFILE ................................................................................................................... 5

7. DOCUMENTS TO BE SUPPLIED BY THE CONTRACTOR ....................................................... 5

8. PIPELINE CALCULATION.......................................................................................................... 7

9. DOCUMENTS TO BE SUPPLIED BY THE CONTACTOR BEFORE AND DURING THE EXECUTION OF THE HDD AND AFTER HIS COMPLETION .................................................... 8

9.1. BEFORE AND DURING THE HDD EXECUTION ................................................................ 8

9.2. AFTER THE HDD EXECUTION .......................................................................................... 8

10. CONTROLS ................................................................................................................................ 9

10.1. GENERAL ........................................................................................................................... 9

10.2. WELD EXAMINATION ......................................................................................................... 9

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10.3. COATING .......................................................................................................................... 10

10.4. CLEANING ........................................................................................................................ 10

10.5. TESTING ........................................................................................................................... 10

10.5.1. General...................................................................................................................... 10

10.5.2. Pre-testing ................................................................................................................. 10

10.5.3. Final Test preparation ................................................................................................ 10

10.5.4. Resistance test .......................................................................................................... 11

10.5.5. Tightness test ............................................................................................................ 11

10.5.6. De-watering - Cleaning - Drying ................................................................................. 11

11. REINSTATEMENT .................................................................................................................... 12

11.1. REINSTATEMENT OF THE WORKING SITE AND ACCESS ROAD ................................ 12

11.2. MARKINGS ....................................................................................................................... 12

11.3. FINAL SITE INSPECTION WITH OWNERS AND USERS................................................. 13

12. ACCEPTANCE .......................................................................................................................... 13

12.1. AS-BUILT RECORDS ........................................................................................................ 13

12.2. PRE-COMMISSIONING & COMMISSIONING ................................................................... 13

12.3. READY FOR "START-UP" ................................................................................................. 13

12.4. PROVISIONAL ACCEPTANCE ......................................................................................... 14

12.5. FINAL ACCEPTANCE ....................................................................................................... 14

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1. GLOSSARY

Consultant the Engineering Company appointed by the Owner for the design of the Project.

Contractor The specialised construction company that will be granted the contract by the Owner to implement the HDD.

DP The Design Pressure as specified in the PTS.

GTS General Technical Specification.

HDD Horizontal Directional Drilling.

MOP The Maximum Operating Pressure as specified in the PTS.

ND The Nominal Diameter of the pipeline as specified in the PTS.

Owner Shall have the meaning as defined in the PTS.

Project Is specified in the PTS

PTS Particular Technical Specifications.

SITE Means the location where the Contractor has to perform the work.

Third Party Inspection Agency specially appointed by the Owner to perform Quality Controls and Certification.

2. GENERALITIES

2.1. SCOPE OF THE GTS

The present GTS intends to define the nature of the works to be performed by a Contractor for the design and the construction of a gas pipeline at particular major obstacle crossing point using the HDD method (Horizontal Directional Drilling).

2.2. SCOPE OF THE CONTRACTOR

Otherwise specified under the PTS the mission of the Contractor shall include all the required tasks necessary to built a gas pipeline string across a major obstacle using the HDD method.

These tasks can be summarised as follow (non-limited)

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� The Contractor shall provide and pay for all labour, materials, tools, equipment machinery, water, electricity, utilities, transportation, installation of other facilities and services necessary for the proper execution and completion of the works. The Contractor shall be fully in charge with the dismantling and eventually the repatriation of the equipment etc…

� The Contractor shall pay any duty tax, load and unload port duties, temporary import taxes etc… for all the equipment mentioned above.

� The Contractor shall be fully responsible for all means, methods, techniques, sequences and procedures and for the co-ordination of all operations of the work under contract.

� Contractor shall verify accurately the data provided and proceed to all additional tests or surveys (Topographic - Hydrological - Geological - etc.) he feels necessary to implement its works.

� The Contractor shall perform all engineering activities that are needed to complete the basic documentation provided by the Owner; in particular, it shall not neglect to proceed to all engineering - detailed engineering - stress calculations - etc. as necessary.

� The Contractor is deemed to have considered and accepted all the risks involved in his task.

� The Contractor shall make all necessary arrangements for the hiring of the labour (local or not) and care for their payment. He will take care of all the expenses relating to accommodation, transportation and subsistence for the staff.

� The work will be supervised by competent staff who speaks at least the official language (specify in the PTS) of the concerned country.

� The Contractor will execute all the required tasks including the welding of the pipeline by qualified welders specified in the contract and the PTS in conformity with the relevant code and standard.

� Traceability Due attention of the Contractor is drawn to the absolute necessity to keep detailed trace of all equipment subjected to pressurised gas.

2.3. SUPPLIES

� Except otherwise stated in the PTS the line pipe elements and fittings will be directly supplied at the work-site by other.

� The Contractor will provide all the necessary consumable to built the pipeline.

� During the works, the Contractor must procure and maintain the installation and equipment which are necessary for the functioning of the workshop and additional equipment.

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� The Contractor shall make all the necessary arrangements to cater for an uninterrupted supply of fuel, lubricant, electricity, water, telephone, etc… during the work.

2.4. SITE LOCATION

The exact location of the work site as well as the access road will be specified in the PTS

2.5. Geographical Co-ordinates

The local official system of co-ordinates that is in force in the concerned country will be used for all activities related to survey, drawings, alignment sheet, geographical information, measurements, etc…

3. LAWS - CODES - RULES & STANDARDS

3.1. GENERAL

Basically, the following is applicable :

� Basic Laws - Codes - Rules & Standards, mandatory by law in the country concerned.

� The present GTS as amended from time to time by attached PTS;

� Peculiar Codes & Standards as per Section 3.2.

� The "Rules of good Practice" commonly used by the world-wide gas industry;

� The "Rules of Art" and "Sound Practices" of the Engineer.

� in general the HDD has to be built in accordance with the best states of Engineering practice.

In case of contradiction, the above shall prevail in descending order of precedence.

3.2. PECULIAR CODES & STANDARDS

The Codes - Rules and Standards applicable in specific cases are listed under a separate PTS.

Except if otherwise specified in the PTS, the following shall serve as basis :

� ASME B.31.8 "Gas Transmission and Distribution Piping Systems" - Last edition and all Codes it refers to.

� Codes - Rules and Standards that are already mandatory at European level.

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� European standards that are still in project but under final clean-up before final approved (referenced "pr EN number") shall be assimilated.

Except if otherwise specified in the PTS, in case of contradiction, the most stringent of the present GTS and the above shall be applied.

4. GEOLOGICAL DATA

The owner has performed hydrological and geological surveys. The final report is appended to the PTS.

These data are given for indicative purpose.

It is the responsibility of Contractor to proceed, at its costs, to any additional surveys that it deems necessary.

5. RIGHTS OF WAY AND WORK SPACE

5.1. WORK SPACE

The minimum temporary working space allocated to Contractor by the Owner is :

� 75 m x 75 m at the drilling site

� 50 m x 50 m at the opposite site.

A working space of 15 m wide will be granted to built and test the pipeline string.

Prior to any HDD activity or pipeline construction work the top soil will be removed and keep in stock apart from the subsoil for reinstatement purpose.

If the drilling points (entry/exit) are located below the highest river water level, the Contractor shall protect the drilling points by creating a dyke 50 cm minimum above the highest recorded water level.

The temporary access road to the work sites will be determine jointly by the Owner and the Contractor and granted by the Owner.

The cost of improvement or execution of temporary accesses will be born by the Contractor.

5.2. RIGHTS OF WAY

The working space and the site location is specified in the PTS.

The right to use the specified working space will be granted by the Owner.

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Should Contractor require more space, it will be Contractor's responsibility to negotiate such additional space in close co-ordination with the Owner. Contractor shall support all relevant costs.

6. DRILLING PROFILE

The Owner will provide (annexed to the PTS) a basic profile drawing and the constraints and particularities of the obstacle to be crossed.

The Contractor shall specify and submit to the Owner for approval his final profile and the different parameters or their limited value which define the location and configuration of the drilled path.

These parameters are:

� entry point

� exit point

� entry angle

� exit angle

� PI elevation

� radius of curvature.

It is acceptable that the entry and exit will vary from the design proposed location. They have to be located inside an area (5 x 10 m) centred around the proposed location, 10 m shall be measured parallel to the HDD alignment.

Except if otherwise specified in the PTS, the minimum radius shall be not less than 1 000 times the Nominal Diameter(ND).

The predetermined theoretical profile shall be closely adhered to when drilling the pilot hole. The permitted deviation shall not exceed 2 m laterally and 1 m vertically from the approved theoretical profile.

7. DOCUMENTS TO BE SUPPLIED BY THE CONTRACTOR

the Contractor will supply with his tender the different documents listed here below.

� Key staff organisation chart.

� curriculum vitae of his key staff

� Project reference list regarding similar HDD works he carried out in the past 5 years.

� A complete description of the anti-corrosion pipe wraps he intends to use for pipeline field joints and repairs.

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� A description of the major drilling equipment as

� Drill rig specification

� Maximum dynamic torque

� Pull back capacity

� Drilling fluid trailer tank specification

� Control cab

� Pipe racks

� Workshop

� Generators

� Positioning system

� Drilling head

� Ancillary equipment.

� A complete description of the directional drilling working method as:

� The positioning record system and procedure

� Drilling of the pilot hole and wash over pipe.

� Hearing operation (type and size of the reamer)

� Mix compound of the bentonite mud.

� Soil cuttings/Bentonite mud separation and treatment process and reuse of the Bentonite.

� Pipeline pull back operation.

� Alignment and positioning of the pipe string.

� Rollers support used. The support will be designed so as not to damage the pipe coating.

� Detail drawing showing the theoretical profile, the final design profile, the position of the pipe string (with support arrangement) before pull back operation and the location of the bends if any.

� Detailed Time-schedule.

� On site working-time.

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� The method he intends to use for controlling the integrity of the pipeline coating as well as "anti-corrosion" pipe-wraps.

� The method he intends to use for verification of the pipeline final profile after the pull-back operations.

8. PIPELINE CALCULATION

The Contractor will submit for approval to the Owner and Third Party Inspection agency the stress calculation as described in the Deutsche standard NEN 3650 and NEN 3651 or equivalent.

The following phases should be analysed in the pipeline design process :

� predisposition of the launching catenary : Before the pulling operation, the pipeline is outside the bore-hole and has a configuration which allows it to enter the hole. During this phase, the only bending moment is due to the curvature of the catenary and the weight. The pipeline should be designed so that it behaves elastically.

� pull-back operation :

In this phase the pipeline will be pulled back through the bore-hole. The following forces should be considered :

� bending moment due to curvature of the hole;

� friction force between the pipe and drilling mud including the friction due to extra cables/sleeves attached to the string;

� friction force inside the hole, at the location where the soil reaction occurs;

� stress due to soil reaction;

� the Contractor will specify the means he intends to use in order to reduce the friction during the pull-back operation.

The resultant stress should be calculated and the pipeline designed to behave elastically.

� operating conditions :

In this phase the loads acting on the pipeline are :

� bending moment due to curvature of the hole;

� internal pressure of the gas;

� temperature difference of the line between the pipe-laying and operating conditions;

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� dead loads

Vertical soil load at the top of the pipe can be calculated for different pipe laying conditions.

� for pipeline with ND > 500 mm the Contractor shall specify the ballasting method he intends to use to limit the friction during pull-back.

The following effects should be combined for the purposes of calculating the resultant stress :

� calculated longitudinal effects on the entire pipeline system;

� calculated effects on the cross-section of the pipeline.

The stress/strain shall not exceed the relevant allowable stress.

The effects of soil load on the cross-section of the pipe may be analysed. This analysis should be carried out at the deepest point reached in drilling.

9. DOCUMENTS TO BE SUPPLIED BY THE CONTACTOR BEFORE AND DURING THE EXECUTION OF THE HDD AND AFTER HIS COMPLETION

9.1. BEFORE AND DURING THE HDD EXECUTION

� Before the pull-back operation the Contractor will submit for approval to the Owner the final profile of the HDD including any deflexion of the drilling head. The Contractor can start the pull-back operation only after the Owner approval.

This document needs to demonstrate that after completion (operating condition) and under internal pressure (MOP and test pressure), soil load and hydrostatic load the section of the pipeline will not have a radius of curvature smaller than those permitted by the design.

The document shall also indicate the pulling force on the pipe at the beginning, during and at the end of the process and the rate of progress of the pipe.

� During the different execution phases of the HDD the Contractor will record all the information regarding the different operations which includes, among others :

� the measurements of mud pressure, mud flow rate, pulling force, X-Y-Z of the drill head recorded during drilling and any other relevant statistics.

� stand-off during operations and the reasons thereof

9.2. AFTER THE HDD EXECUTION

After completions of the HDD the Contractor will transmit to the Owner the horizontal drilling operation record of the relevant activities which includes.

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� Concerning the drilling mud

� quantity of mud used;

� mud pressure (at the drilling)

� the density of the drilling fluid and soil cuttings;

� the localisation of storage site for the waste from the drilling operation and the measures taken to comply with environmental constraints.

� During drilling operation (per drill pipe element)

� the maximum force applied (push/pull/torque);

� time duration for assembling 2 elements;

� the drilling head position in X-Y-Z- co-ordinates;

� deviation compared to the required position;

� the proposed corrective measures.

� During drill pipe pull-back (per drill pipe element)

� pull-back duration per element;

� maximum pulling force per element.

� An alignment sheet with length profile of the pipeline (scale 1/500) showing the location of each weld joint and their X-Y-Z co-ordinates.

� An official certificate concerning the discharge of the drilling operations tailings approved by the relevant Authorities.

10. CONTROLS

10.1. GENERAL

Prior to any control on site, the overall procedure for weld examination, cleaning, pre-testing, testing, de-watering, etc… shall be submitted to the Owner and the Third Party Agency for approval.

The approved control procedure shall be carried out under the supervision of the Third Party Agency.

10.2. WELD EXAMINATION

All welds shall be inspected non-destructively (Radiographic and ultrasonic testing) in accordance with the requirements of the selected and approved standard for welding.

GENERAL TECHNICAL

SPECIFICATION

GTS 740 501


10.3. COATING

Immediately after the pull-back operation an expert in cathodic protection from the Contractor or his sub-contractor (accepted by the Owner) will control the pipeline external coating. The impressed current needs for the unconnected pipeline string will not exceed 1µA/m².

10.4. CLEANING

Before testing and commissioning, the pipeline section shall be checked for cleanliness and ovalization.

The pipeline section shall be cleaned with a pig or foam sphere.

To clean the pipe and check for ovalization , a pig or a sphere shall be run several times through each underground section.

The pig travel speed shall be controlled and monitored.

To prevent ingress of foreign matter, the sections shall be capped before and after the test.

10.5. TESTING

10.5.1. General

The pressure tests shall prove the resistance and tightness of the pipeline. Testing shall be performed in accordance with applicable standard.

The Contractor will transmit all the records of the tests to the Owner and the third party agency.

10.5.2. Pre-testing

Pipe and fittings shall be pre-tested prior to the pull back operation and weld joint coating a compulsory strength and leak test shall be performed. The minimum duration for strength testing shall be 6 hours (see Resistance test for the test pressure).

The leak test will be carried out using dry air or inert gas of a minimum pressure of 6 bar (see weld points shall be distempered with soapy water and visually examined (soap bubble test).

10.5.3. Final Test preparation

Except if otherwise specified in the PTS, resistance test shall be performed with water.

The water shall be clean, with a corrosion inhibitor added if necessary.

The pipe shall be filled using pigs to prevent the formation of air pockets.

GENERAL TECHNICAL

SPECIFICATION

GTS 740 501


The tests should normally be carried out with trenches adequately back-filled, if any, to avoid the influence of temperature changes. If the ground temperature in the immediate vicinity of the pipes is less than 2°C, antifreeze shall be added.

On completion of filling operations, time should be allowed for the water in the sections to stabilise. The water pressures to be maintained and the location and characteristics of the measuring apparatus (thermometers, dead-weight pressure gauges etc.) shall be defined before testing commences.

The measuring instruments shall have undergone certified periodic calibration. Pressure-recording instruments shall be installed in a sheltered place.

10.5.4. Resistance test

The minimum duration for Resistance testing shall be 6 hours.

Except if otherwise specified in the PTS, Resistance testing shall be carried out at a pressure of at least 1.4 times the DP at the highest point but, at the lowest point, below the pressure at which the line pipes have been tested in factory

The pressure shall be continuously monitored and recorded and shall not show any significant drop during the test.

The test may be performed during the stabilisation period prior to the tightness test.

10.5.5. Tightness test

Except if otherwise specified in the PTS, Tightness test shall be performed with water.

The tightness test may be combined with the strength test.

The tightness test pressure shall not be higher than the Resistance test pressure. The test pressure shall not be less than DP.

The test duration shall be determined on the basis of the characteristics of the structure and the accuracy of the measuring instruments. It shall not be less than 24 hours. For volumes of less than 20 m³ or for uncovered sections which can be fully inspected visually, this duration may be reduced for so far duly approved by the Owner.

Before carrying out the tightness test, it shall be ascertained that the quantity of air in the pipe is sufficiently small not to affect the test results.

The pipe is considered leak-tight if the temperature and pressure measurements show that the volume of test medium is maintained throughout the test.

10.5.6. De-watering - Cleaning - Drying

Once the test results have been declared satisfactory, the pipeline shall be de-watered and properly cleaned and dried.

GENERAL TECHNICAL

SPECIFICATION

GTS 740 501


Conventional pigs and foam pigs shall be run through the pipeline as many times as necessary to de-water and clean it satisfactorily.

Cleaning and drying shall be performed after all tests are finished and certified.

The pigging system shall be equipped with necessary devices to measure temperature - pressure and Dew Point on a continuous way.

After completion of the test, the pipeline is scraped as much as needed by using bi-directional pigs followed by additional runs of foam- en polypigs as needed up to when the pigs do not show any more humidity and all dirt is removed like calamine or other residues from welding, rust, oil, dust, etc..

The compressors used for running the pigs shall be of "oil-free" type and equipped with absorption drying units with adequate Dew Point outlet.

When, during the last run, a constant Dew Point of -8°C is measured, the pipeline is then closed and left quiet for minimum 24 hours.

If, after 24 hours, the Dew Point does not increase any more, the pipeline is then considered dry.

11. REINSTATEMENT

11.1. REINSTATEMENT OF THE WORKING SITE AND ACCESS ROAD

The ground occupied during the work shall be reinstated to its original condition as quickly as possible after completion of the works.

Accesses to property, fences, ditches, retaining walls, irrigation systems and other structures shall be reinstated in compliance with the agreements drawn up at the time of initial survey.

Land register marks moved for the work shall be replaced by a surveyor. Where necessary, devices to prevent erosion of the backfill materials shall be installed when reinstating embankments and slopes.

Reinstatement of footpaths, road surfaces, banks, shoulders etc. shall be performed with the agreement of authorities concerned.

11.2. MARKINGS

The location of the pipe shall be clearly marked by suitable means : conventional yellow markers, overhead markers, sign, etc..

The Marker systems shall be firmly anchored to ensure permanency throughout the time.

GENERAL TECHNICAL

SPECIFICATION

GTS 740 501


11.3. FINAL SITE INSPECTION WITH OWNERS AND USERS

When reinstatement and marking is completed, the site affected by the work shall be subjected to a final inspection by the parties concerned.

12. ACCEPTANCE

12.1. AS-BUILT RECORDS

As work advances, the position of the pipe shall be surveyed and plotted on the drawings.

"As-Built" Documentation containing all documents (drawings, design calculations, welding log etc) which enable location and description of the pipe shall be compiled on completion of the work.

"As-Built" documents shall maximise the use of CAD, computer database (Access 97) and digital records in such a way to allow later integration in a "Geographical Information System" (GIS).

All equipment shall be duly traced with reference to initial supplier Identification Reference (ID) - weld log-book - Certificates - etc..

The exact position "As-build" of these elements shall be accurately located with reference to ID and geographical co-ordinates.

12.2. PRE-COMMISSIONING & COMMISSIONING

Except if otherwise stated in the PTS, Pre-commissioning and Commissioning shall be performed by the Owner after being declared "Ready for Start-up".

Pre-commissioning shall take place prior to the introduction of the gas.

The system may only be commissioned when it is completely installed, tested and cleaned and where applicable, connected to a main network.

If necessary, drying may be completed by vacuum drying, blasting with dry air or any other suitable method in addition to drying by pigging.

If pre-commissioning of the pipeline is not to commence soon after "Ready for Star-up", it shall be filled with a fluid to protect against internal corrosion.

12.3. READY FOR "START-UP"

After "Final Testing" - de-watering - cleaning and drying duly certified by the Third Party Inspection - adequate back-filling of sections adjacent to the HDD itself and completion of all works except those mentioned in a "Punch List" as accepted for later completion, the system may be handed over to Owner as "Ready to Start-up".

GENERAL TECHNICAL

SPECIFICATION

GTS 740 501


12.4. PROVISIONAL ACCEPTANCE

The pipeline system may be proposed for "Provisional Acceptance" after pre-commissioning on final and countersigned inspection of the site and on submission of the construction completion report, including archives, construction drawings, specifications and all documents related to the design and construction.

12.5. FINAL ACCEPTANCE

General criteria for "Final Acceptance" are described in the "Administrative & Commercial Conditions".

In addition to these, "Final Acceptance" shall not be declared before all works are satisfactorily achieved including all points in the "Punch-list" agreed at "Provisional Acceptance" and for so far all certificates are obtained from Authorities - Owners of obstacles - Owner & Tenants of lands - etc. that the reinstatement is achieved properly and to their satisfaction.

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GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

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GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 1 of 45

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The term system will be taken to mean the whole of two or more layers that will be applied consecutively to the base to be protected and which must finally constitute the homogeneous, continuous and sealed protective layer.

The Contractor will consult the paint manufacturer for the technical description of the paint systems stipulated in Article 18.8 of these specifications. The chosen paint systems will be included in the price quotation. The Contractor will indicate the methods of application for the different systems and the environmental conditions.

The Contractor will refer to the paint supplier of his choice to obtain all the guidelines for the addition of additives and solvents to obtain the required finish regardless of the environmental conditions of temperature and wind speed and the method of applying the coats (brush, roller or spray gun).

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FOR INFORMATION ONLY

The Owner has selected complete paint systems with a number of paint manufacturers for different applications. The selected systems along with the conditions for use and application are specified by the paint manufacturer in Article 18.8 of these Specifications.

Article 18.8 defines the systems to be used.

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When a particular part of work is being carried out, the painting system should be chosen in accordance with the environment in which the material to be painted will be located. Indeed, the degree of aggressiveness of the atmosphere that will be encountered in the environment of the work can range from an environment which is not very aggressive to an extremely aggressive environment, depending on whether the location is in a rural area, a non-industrial built-up area, ventilated workshops, in the vicinity of the sea, at chemical plants, in humid rooms or in the vicinity of sources of cold or heat.

Taking account of these uncertainties, different painting systems can be recommended, and it is consequently important to mention at the time of the invitation to tender the degree of aggressiveness in which the material to be painted will be located so that the Contractor can mention this to the supplier of the paint products to determine the system to be applied.

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The composition and quality of the products may not differ from batch to batch. A batch is all of the products of a specified manufacture. If the analyses of products bring to light that the composition does not conform to the specifications of the paint manufacturer, the Owner may refuse to use this batch of products. The paint products must comply with the following conditions:

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 2 of 45

� they must have the viscosity necessary for the described use and the established condition: use of the brush - paint roller (spray gun only for special cases and in the workshop).

Thinning on the building site of paint products with two components will be carried out in accordance with the specifications of the supplier.

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While the works are in progress on the construction site, the Owner and/or the Engineer may carry out sampling on the paint being used for the purpose of checking conformity. The paint products must be made available free of charge to the laboratory or the approved supervisory body in sufficient quantities so that all the tests can be carried out on the same batch.

If the analyses reveal a non-conformity in the composition of the products used (tolerance of + 3 % of the dosage of every component), the Owner and/or the Engineer may refuse application of the product under consideration, halt the work and have the nonconforming product already applied removed.

Before proceeding with the work, a product that does conform will be required. The only purpose of the analyses is to reveal any nonconformity of the composition of the products. Their purpose is therefore not to assess the quality of the different components. The analyses concerned are not acceptance tests of the products supplied and in no way affect the obligations of the Contractor specified in the contract towards the Owner.

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Every recipient will be fitted with a hermetically-sealed lid with an opening that is sufficiently large to allow the contents to be stirred; the outside and inside are protected against oxidation, and, like the lid, are marked with a strip of colour identical to the contents.

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Every recipient will bear the following information:

� name of the manufacturer;

� date and number of manufacture;

� name of the product type;

� net weight of the product or the contents of the recipient.

At the time of delivery, this packaging must be bear labels in conformity with the legal stipulations in force.

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After completion of a job, a general clean-up shall be carried out by the Contractor to remove all debris, materials or irregularities that his work has brought to the site so that it is left tidy.

The restoration work includes, among other things:

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 3 of 45

� the removal of abrasives;

� the removal of the different protective coverings;

� the Contractor will make the required repairs to any damage after refitting the supports;

� the removal of paint and cleaning of the stains on the floor.

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The cases that occur in practice on building sites, with regard to painted surfaces, can be broken down as follows :

� material of which the oxide content disappears by natural oxidation;

� material that has already been covered with a layer of paint in the workshop;

� material that is covered with old paint layers that show different degrees of weathering.

Good preparation of the surface is the best guarantee for good anti-corrosion protection.

Paintwork may never begin until the surface to be treated is dry and is independent of the base coat and cleared of dirt, dust, rust, scale, grease, salt attack, cement powder, cement mud-scale, sand, oil, etc.

The method of preparation of the surface will be implemented in accordance with the preparation methods described below:

� cleaning (bright blast-cleaning);

� mechanical cleaning;

� manual derusting.

The Contractor should have the required material at his disposal to clean the surfaces to be coated thoroughly in accordance with the preparation methods specified in Article 18.2, regardless of the form or the condition of such surfaces. Devices that might be damaged during the preparation will either be taken away by the Owner or screened off by the Contractor. The latter will inquire about this during his exploration of the site for the works.

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Before beginning cleaning by blasting, the person carrying out the work will take the following measures:

� clear the steel surface of oil and/or grease;

� ensure that each flange collar (section where the sealing is applied) is properly screened off against the blasting and the subsequent works;

� check that no blasting grains can get into the pipes during this process. Any openings not sealed off must be screened off;

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 4 of 45

� where there are valves, regulators and other devices, the manufacturer’s identification plate will be dismantled so that all surfaces can be treated. The plate will then be put back again;

� screen off all non-metal structures such as rubber where there is a filter;

� with valves, operators and other devices, care should be taken to ensure that no metal filings or paint get into the apparatus;

� the Owner reserves the right to carry out or all of these works himself.

To prevent rust forming quickly as the result of humidity on the blasted surface, cleaning by blasting may only be carried out when the temperature of the steel surface is at least 3°C higher than the dew-point of the ambient air.

Blasting may not be carried out if the relative degree of humidity exceeds 80 %. The choice of the type of blasting medium used depends on local circumstances such as the possible presence of gas and the material to be blasted - e.g. INOX (stainless steel).

The abrasive to be used must conform to the local low i.e. it may contain no carbon and less than 1 % free silicone dioxide. The Sa 3 will always be requested and must at least reach Sa 2 1/2 during the initial stage of the paintwork. For blasting followed by metallisation, the surface preparation degree to be achieved is always Sa 3. The degree of cleanliness to be obtained will be inspected in accordance with the Swedish standard SVENSK STANDARD ISO 8501-1-1988 SS 05.5900.

� Sa 3 : surface blasted down to the bare metal; when the surface is inspected with a magnifying glass, scale, rust and foreign bodies must be completely removed and it should be possible to raise a metallic shine on the treated surface;

� Sa 2 1/2: blasted very carefully. Scale, rust and foreign bodies must be removed in such a way that anything left behind will only be visible as nuances (shading) or strips.

The blast-cleaning will be carried out by means of compressed air free of water and oil.

After the blasting and before painting, the surface should be completely cleaned of blasting material and so forth with a soft brush, a dry cloth or dry compressed air.

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If sandblasting is not permitted or if the metal structures are not easily accessible for blasting or blasting for one reason or another is technically unfeasible, mechanical derusting can be used instead. With mechanical cleaning by means of chipping, rotating steel brushes and sanding discs, a degree of cleanliness St 3 should be reached.

� St 3 : removal of the old paint layers of which the adhesion leaves something to be desired and/or of which the paint layer no longer fulfils the requirements.

If parts are present that are so corroded that St 3 is difficult to achieve, this should be notified to the Owner’s representative prior to the start of the works.

N.B. :

� St 3 : means removal of every old paint layer. Retouching means local polishing with St 3 or Sa 3 followed by application of the desired painting system.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 5 of 45

After mechanical cleaning, the surface should be made dust-free with a cloth or a soft brush, washed with an organic solvent and thoroughly dried off with a dry cloth (e.g. with 1.1.1. Trichloroethane such as Solvethane, Chlorothene NU).

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Manual derusting with the aid of scrapers, steel brushes, sandpaper etc. shall only be permitted in exceptional cases for local repairs. Any deviation therefrom must be requested from the Owner and/or the Engineer.

With manual derusting, a surface preparation degree St 3 must be obtained. The length of the handles of the equipment used may not exceed 50 cm.

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This layer is in general applied by the manufacturer, for example, on valves, regulators, etc. Layers of this kind will be checked for their proper adhesion in accordance with ASTM D3359, method A. The adhesion should be at least 4A (see APPENDIX 1).

If the paint layer shows less adhesion or is incompatible with the rest of the system, it should be completely removed (see also Article 18.2.6.). If the paint layer is not removed, the Contractor accepts it in the state in which the coating is found and the guarantee remains in force. The adhesion does not have to be examined if system 63 has already been applied in the workshop on behalf of the Owner.

The Contractor, who must provide for the protection on the construction site, must therefore obtain the information regarding the treatment of the surface and the quality of the paint that was used and must, moreover, examine the adhesion of the layer on the construction site, the percentage of damage and weathering as well as the value of the preparation of the surface in the workshop together with the thickness thereof that must be supplemented if necessary.

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Galvanised surfaces, both old and new, will be carefully roughened up. Every foreign body (concrete splatters, chalk marks, grease and oil stains, etc.) will be removed. Thereafter, rub the surfaces with abundant water and, if necessary, with cleaning products.

To this end, nylon brushes will be used for every kind of dirt as well as for removing zinc salt residue. Thereafter, the surfaces will be treated in accordance with system 21. Where the zinc layer is lacking, it will be derusted manually to a degree of cleanliness St 3, after which a primer coat will be applied in accordance with system 22.

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� degrease with the desired degreasing product;

� clean under high pressure or with a product prescribed by the paint supplier.

If the paint layer adheres well and is applied on a clean base, the painting system described may be continued (see Article 18.8). If the percentage of damage and weathering does not exceed 5 %/m, retouching may be considered. These partial repairs will be carried out in accordance with the stipulation in Article 18.8.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 6 of 45

If, on the other hand, the percentage of damage does exceed 5 %/m or if the layer applied in the workshop comes loose, the Contractor must draw the attention of the Owner to this and carry out the complete application system in accordance with Article 18.8.

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If the surfaces do not show deep weathering limited to the spread of rust by small pitted areas or non-penetrative rust in spots, it will very often be sufficient to clean the surfaces with abrasives or with an abrasive disc, then to rub them down with steel wool, remove the dust and wash off. If thick rust appears, in spots, scale rust and active rust canker, this should be removed with needle hammers or stripped away directly by blasting, removing the dust and washing off.

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Remove unsound paint layers and loose components with scrapers, blades or rotating steel brushes. Thoroughly clean the entire surface with water containing ammonia. Thoroughly remove moss, algae and fungal growths. Where these growths have been removed, treat the area with a fungicide in accordance with the instructions for use.

Once the entire area is completely dry, brush off the dead residue of moss, algae and fungus with a hard brush. In the case of reinforcement steel that has been laid bare, remove as much rust, dust and grease as possible and treat it with a primer coat. When painting concrete surfaces, they must first be checked for cracks. Cracks larger than 0.3 mm must be repaired with an appropriate system in accordance with the type and extent of the repairs (e.g. injection with epoxy mortar). Repair damage such as cracks and bursts to concrete parts with a two-component mortar or preferably with micro-mortars. Finally, check the alkalinity of the surface with the aid of litmus paper and neutralise it if necessary.

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It is sometimes necessary to use solvents when the surfaces to be painted are streaked with grease or oil. In this case a suitable organic solvent should be applied. The operation should be carried out with the aid of clean brushes or rags and clean solvent.

All the legal specifications in connection with solvents etc. must be adhered to. The Owner and/or the Engineer will be informed in advance of any toxicity or flammability. All measures must be taken to prevent any risk of fire and to rule out any possibility of poisoning (ventilation). The Contractor will provide drip collectors to keep the environment free of pollution.

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The Contractor must call in a representative of the Owner and/or the Engineer or of the Approved Supervisory Body responsible for checking the condition of the metal during stripping and informing the Owner and/or the Engineer immediately of any damage that he might have noticed:

� deep corrosion of the plates - rivets – bolts;

� faulty welding;

� fittings that appear to be dangerous because of their age

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 7 of 45

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The Contractor must have the equipment necessary for the removal of asphalt from the pipe without damaging the latter (scratching, impact, etc.). The Contractor undertakes to carry out the work in accordance with an approved procedure.

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� Metallisation must be carried out in accordance with ISO 2063;

� Metallisation is carried out as rapidly as possible after blasting in order to limit corrosion of the pipes (max. 3 hours later). With metallisation, a surface preparation degree Sa 3 is compulsory. The roughness of the blasted surfaces should be from 25 to 50 µ Rmax ;

� The metallising is always carried out on dry parts in good weather conditions (maximum relative humidity 80 %);

� For metallisation, a wire composed of 85 % zinc and 15 % aluminium with a minimum guaranteed degree of purity of 99.5 % is used (subject to other specifications). The application thereof is always carried out in accordance with the conditions of the manufacturer and may at all times be submitted to the Owner’s representative;

� The sealant should be applied maximum 3 hours after metallisation;

� The sealant must be thinned and applied in accordance with the tables in Article 18.8 of the present specifications. A visual inspection whereby the sealant completely covers the metallisation will suffice here;

� When evaluating the metallisation, a negative deviation from the minimum coating thickness, as prescribed in the tables in Article 18.8, to 80 µ for 20% of the measurements will be permitted.

N.B.:

For the metallisation of the surfaces that are exposed to high temperatures such as chimneys, ZINACOR 850 (85/ZN/15 AL) will be used of which the systems are defined in Article 18.8 of the present "Specifications for Paintwork" (syst. 51 - 51a).

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Painting may not be carried out in unsuitable conditions.

All preparatory work and painting may only be carried out in dry weather and at a minimum temperature of 10°C, except for special cases requested by the Owner and/or the Engineer.

Unless otherwise stipulated in the specifications of the paint supplier, application of the paint is forbidden if it is forecast that the temperature will fall to below 0°C before the paint is dry. The temperature of the surface to be painted must be at least 3°C higher than the dew point of the ambient air. Application of the paint is also not permitted if there is a danger that the coat of paint will not be dry before dew or condensation sets in.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 8 of 45

The work must be stopped:

� if the temperature of the surface to be painted is higher than that described by the supplier;

� in rain, snow, mist or fog or when the relative humidity is higher than 80 %.

Coats that have not yet dried and have been exposed to frost, mist, snow or rain and might thereby be damaged must be removed after drying and the surfaces must be repainted at the expense of the Contractor.

Working in direct sunlight or in hot weather must be avoided.

The first coat of paint must be applied maximum 3 hours after the preparation of the surface if the relative humidity of the air is between 50 % and 80 %. This time span may be increased to 6 hours if the relative humidity is less than 50 %. In all cases, the preparation of the surface must exhibit degree Sa 3 and at the very least the appearance of degree Sa 2 ½ at the time of painting.

The coats of paint may only be applied on carefully cleaned surfaces that must be dry and free of grease and dust.

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Painting may be carried out when the Contractor can be sure that the instructions of the paint supplier have been scrupulously followed with regard to the parameters in the following (non-exhaustive) list:

� ambient temperature;

� surface temperature;

� relative humidity;

� dew point;

� drying times.

The Contractor must in this respect be able to produce the instructions for the paint on the site. The Owner will guarantee 100% supervision in this regard during the execution of the work.

In addition, the paintwork may only be carried out to a minimum ambient temperature of 5°C and/or to a maximum relative degree of humidity of 85 %. Application of the paint is also not permitted if there is a danger that the coat of paint will not be dry before dew or condensation sets in.

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Neither the environment of the site nor the marking labels of devices may be covered with paint, and they must be kept free of paint splashes. To this end, it is advisable to use removable masking tape.

Paint splashes, leaks, etc. on any adjacent installations such as measuring apparatus, valves, pipes, sources of light, insulation, heat insulators, walls, concrete, etc. must immediately be wiped up and the damage repaired before the paint is dry.

Otherwise, the Owner will be obliged to have the cleaning carried out at the expense of the Contractor. The paint recipient will only be opened at the time of use (unless otherwise specified by the manufacturer).

The product will be mixed in the recipient with the aid of suitable tools and thus homogenised.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 9 of 45

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Normally, three methods of application will be used on the construction site for the paint products - i.e., with a brush, with a roller or with a spray gun.

� The brush method makes it possible to obtain good penetration of the paint over irregularities in the metal;

� Only this method will be used for application of the base coats, for retouching and for protrusions, welded areas, riveted joints or bolted joints;

� The roller method may be used on large flat surfaces for the intermediate and top coats;

� The spray gun method must be used in accordance with the instructions of the manufacturer and carried out by qualified personnel.

The Contractor must guarantee that all safety measures have been taken for such work. The spray gun method may only be used on the site for places that are difficult to reach with the brush. In this case, a request must be made to the Owner and/or the Engineer for a deviation.

All paintwork will be carried out with good brushes or rollers that are suitable for the type of paint being used and for the form of the material to be painted and fitted with short handles. The maximum length of the brush and roller handles will be 50 cm; longer handles may only be used for places that are absolutely inaccessible. The maximum width of a brush will be 13 cm.

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Application of the paint will be carried out in accordance with best practice in order to obtain a homogeneous and continuous layer. The Owner or the Approved Supervisory Body demands that painting of a layer will only be started after acceptance by them of the surface preparation or of the previous layer of paint.

The layers of paint must have a uniform thickness. They must be spread in such a way that all concave parts are dried out and that the surface is completely covered and has a glossy appearance without leaving brush marks and without exhibiting bubbles, foam, wrinkles, drips, craters, skins or gums that arise from weathered paint.

Each layer must have the colour stipulated in the tables in Article 18.8 of the present specifications, which clearly differs from the previous layer, taking account of the colour of the top layer, all of which for the purpose of being able to identify the number of coats and their order of sequence. If the colour of the coats is not mentioned in the tables in Article 18.8 the colour difference in consecutive coats must, if possible, be at least 100 RAL. The colour of the top layer is given in the table in APPENDIX 5.

The coating power should be such that the underlying layer is not visible. Only 1 layer per day may be applied, unless otherwise specified by the Owner or the Approved Supervisory Body.

The drying times prescribed by the paint manufacturer must be strictly observed in relation to the environmental conditions before proceeding with the application of the next layer.

The dry coating thicknesses indicated in the description of the paint systems are minimum thicknesses. In this connection, the Contractor is obliged to contact the paint manufacturer and conform to his guidelines. The Contractor must respect the thicknesses specified by the supplier.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 10 of 45

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In the case of works being carried out in a workshop, the metal structures will be surrounded by ventilated contraction film that prevents damage during transportation. This film may only be applied after complete polymerisation of the paint.

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Between flanges and around neoprene supports, polyurethane gaskets will be provided that will be covered with the last paint layer, except for the support of the above ground crossing. Some thread ends will be lightly sandblasted and protected with system 02 or 33. Stud bolts fitted in the workshop for metallised flanges may not be sandblasted but system St 3 - 01A will be applied.

After the paintwork, the flange will be finished off as follows:

� a foam strip will be placed between the flange on the stud bolt;

� the space will then be filled with an elastic seam in accordance with the chosen paint system (see Article 18.1.2);

� an opening on the underside of at least 8 mm will be kept as a condensation outlet;

� the seam will finally be wiped smooth with white spirit so that a good appearance is obtained. Finally, the seam will be covered with the last coat of paint (see Article 18.4.7).

� Maintenance of the support surfaces

In order to maintain the support surface, the pipe or device support must be lifted up or lowered sufficiently. The existing supports shall be lowered, taken out and/or removed under the supervision of Owner’s teams. They can then be moved by the Contractor in accordance with his needs for the painting operation. The local person in charge will indicate how this work will be carried out. The support surface will be treated in the same manner as the other parts. After the paintwork, the support will be refitted. Between the support and the pipe, there will be a NEOPRENE gasket supplied by the Owner.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 11 of 45

Finally, the whole unit will be sealed with an elastic seam that will finally be covered with the last layer of paint between the support and the pipe. In the case of above-ground crossing , this grouting may not be covered with the last layer of paint (see Article 18.4.7).

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The Contractor will provide system 02 over the entire length of the pipes above ground and below ground and up to a height of 20 cm and a depth of 40 cm, perpendicular to the ground level mark. In each case, he must ensure that the jointing below the asphalt is in good condition and assures faultless adhesion. He will apply the following products over the entire surface area, prepared in accordance with Sa 3:

1) The primer of system 01a

2) Reinforced polyester ± 20 cm above the ground level marker and ± 5 cm on the asphalt cleaned beforehand. (application of reinforced polyester is carried out in accordance with the work method prescribed by the manufacturer - see appendix 2). Moreover, in the case of PE, in contrast to asphalt, he will apply a polyken primer to the PE immediately before applying the reinforced polyester.

3) He will then apply the other coats of system 01a to the surface section and thus cover the reinforced polyester with about 5 cm (see article 18.8 paint systems)

4) For new constructions, the polyken primer will be applied to PE and then subsequently processed as described under point 2.

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The transition point will be treated in accordance with the products and methods described in the G.T.S. Part 16.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 12 of 45

��/� +*��'(�*��(('�7&��

� Mounting, maintenance and dismantling of scaffolding for carrying out adaptation and/or paintwork to surface gas pipes or gas transport installations in use;

� The Contractor will specify the cost of scaffolding in the pricelist;

� The supplementary rental price for delays attributable to the Contractor will be charged to him;

� In his price quotation, the Contractor should present the Owner with diagrams of the scaffolding that he intends to install for carrying out the works of the Owner;

� For certain works, the Owner will provide scaffolding himself to carry out his own works. This scaffolding will be made available to the Contractor;

� A report will be drawn up when the scaffolding is handed over. The duration of the period when this scaffolding is made available free of charge is the number of working days necessary for the paintwork given in the pricelist, plus any delay resulting from bad weather conditions.

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The Contractor is responsible for checking the weather conditions to ascertain whether the paintwork can be carried out within the technical specifications mentioned in the present specifications (see Article 18.4.1 & 18.4.2.).

The Contractor should have the required calibrated monitoring apparatus for this purpose on site (with calibration certificates). The personnel who will have to use this apparatus should have the training required for this purpose.

The Owner or his representative and possibly the Approved Supervisory Body indicated by the Owner will maintain supervision during the works and inspect the works with random checks. A daily report (C45-N) (APPENDIX 3) will be drawn up in relation to the department that maintains supervision of these works.

The supplementary inspection and the supervision by the Owner or the Approved Supervisory Body does not diminish in any way the liability of the Contractor. The proper execution of the work and the materials used may be checked at any time.

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At the start of the works, the Owner or the Approved Supervisory Body will indicate a few surfaces that the Contractor will prepare and cover in accordance with the recognised method of operation under the inspection and to the satisfaction of all parties: the Owner or his representative, the Approved Supervisory Body, the Contractor and possibly the paint manufacturer. These reference surfaces will serve as a point of comparison for the good adhesion of the paint on the installations as a whole. The parties will together work out a system for the identification of these surfaces in order to be able to monitor the condition of the coatings over time. If the paintwork on a section of the installations is in a worse condition than the reference surfaces, the Contractor may be obliged to treat these parts again.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 13 of 45

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If on delivery of the works no agreement can be reached between the Contractor and the Owner regarding the conformity of the works to the requirements of these specifications, an Approved Supervisory Body will be called in. The Approved Supervisory Body will then carry out inspections on site whereby the following assessment criteria will be used:

� The Swedish standards ISO 8501-1 1988 SS 05.5900 concerning the degree of cleanliness of the areas derusted by blasting, by machine or by hand;

� The wet film thickness of the paint will be measured in accordance with ISO 2808 or ASTM D1212;

� The dry layer thickness of the film will be measured electronically, with complete statistical information, in accordance with ISO 2808 or ASTM D 1186;

� The thickness of each layer will be measured in accordance with ISO 2808, ASTM 4138 or DIN 50986;

� Adhesion tests will be carried out in accordance with ISO 2409, ASTM 3359 or DIN 53151;

� Traction tests will be carried out in conformity with ISO 4624 or ASTM D 4541;

� The rugosity will be measured electronically in accordance with DIN 4768;

� The non-porosity will be measured with a test tension depending on the type of coating, the layer thickness and after consultation with the paint manufacturer;

� Any defects in the paint film may be inspected visually by means of a magnifying glass or microscope. If necessary, a photographic report may be drawn up in accordance with ASTM Standard D 4121-82.

The final judgement of the Approved Supervisory Body is irrevocable and binding for the Contractor and the Owner. In the event of non-conformity of the works with the criteria of these specifications, all costs arising from the inspection by the Approved Supervisory Body shall be borne by the Contractor.

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The Contractor declares that he is aware of:

� the maximum operating temperature of the surfaces to be covered;

� the maximum permitted degree of humidity of the bearing surface;

� the properties of the environment to which the surfaces to be covered are subject.

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The Contractor fully guarantees the following without reservation:

� the observance of all stipulations of the specifications for paintwork regarding, among other things :

� the preparation of the surfaces;

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 14 of 45

� the thickness of each layer;

� the total thickness of the covering.

� the uniformity of the materials used;

� the repair of all defects before delivery of the works;

The Contractor will carry out the requested repair work as promptly as possible.

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Every protection system is considered to give satisfaction during the period of guarantee. The Owner requires the conditions as described in the General Terms and Conditions of Purchase.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 15 of 45

�� '7+��*��)'*��;3��)��'4��<('��&�('�-��&'��'��3=�

SUPPLIER : N.V. LAVENNE CODE APPLICATION TYPE NO. OF

LAYERS DESCRIPTION OF SYSTEM COLOUR DRY

LAYER DEPTH IN MICRONS

TOTAL DRY LAYER DEPTH

IN MICRONS MIN MAX

LV01 Surfaces (to 90°C) Sa3

Epoxy + polyurethane (2 components)

1 1 1 1

RUSTOZINC EP 4024 RUSTOCOAT SEALANT 4230 RUSTOCOAT HB FINISH 4448 MURATHANE FINISH 5456

GREY RAL 9007 BEIGE SEE APPENDIX 5

35 70 60 35

60 120 130 50

200

LVO1a Surfaces (to 90°C) Sa3 or St3 Welding seams or repairs in system 01, 63 and stud bolts


1 1 1

RUSTOCOAT HB PRIMER 4048 RUSTOCOAT HB MIOX 4248 MURATHANE FINISH 5456

RED-BROWN GREEN SEE APPENDIX 5

75 100 35

100 150 50

210

LV02 Ground exit (see Art. 18.5) NETWORKS Sa3 INSTALLATIONS St3


1 1 1 (1

see system 01a RUSTOCOAT HB PRIMER 4048 RUSTOCOAT HB MIOX 4248 REINFORCED POLYESTER Polyken primer in case of PE) idem for nets but with St3 (remove all existing paint)

RED-BROWN GREEN

75 100

100 150

75

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1 1

RUSTOCOAT HB MIOX 4248-102 RUSTOCOAT HB MIOX 4248-101

GREEN DARK GREY

75 75

150 150

150

- without insulation (90° - 120° C) Sa 3 or St 3

EPOXY POLYURETHANE (2 components)

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RUSTOCOAT HB PRIMER 4048 RUSTOCOAT HB MIOX 4248 MURATHANE FINISH 5456

RED-BROWN GREEN SEE APPENDIX 5

75 100 35

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GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 17 of 45

SUPPLIER : N.V. LAVENNE CODE APPLICATION TYPE NO. OF

LAYERS DESCRIPTION OF SYSTEM COLOUR DRY


TOTAL DRY LAYER DEPTH IN MICRONS

MIN MAX LV21 New galvanisation in the

workplace Synthetic resin dispersed in water

1 1

Preparation Degreasing with DEGREASER ZS 8014 Rinse off with clean water RUSTOCOAT HB PRIMER 4048 MURATHANE FINISH 5456

CREAM SEE APPENDIX 5

75 35

100 50

110

LV22 Galvanisation still in good condition (max. 10 % rust) St 3 or Sa 3

Synthetic resin dispersed in water

1 1 1

Preparation Rinse with clear water and dry. After removing rust, degrease with DEGREASER ZS 8014. Retouch with RUSTOCOAT EP PRIMER 4054 RUSTOCOAT HB PRIMER 4048 MURATHANE FINISH 5456

GREEN BLUE CREAM SEE APPENDIX 5

40 75 35

60 100 50

110 / 150

LV33 Steel Sa3 or St 3

Vinyl Alkyd and Vinyl

1 1 1 1

RUSTOGALV VA PRIMER 1352 RUSTOGALV UNDERCOAT TC2350 RUSTOGALV MIOX 2351 RUSTOGALV FINISH 3350

30 50 50 30

60 70 70 50

160 LV41 Concrete plinths EPOXY POLY-

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1

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1

1 1

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BEIGE SEE APPENDIX 5

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(90°

- 12

0° C

) Sa

3 o

r St 3

Poly

uret

hane

1

com

pone

nt

1 1 C

RY

LT

AN

E A

C P

rim

er c

oat

CR

YL

TA

NE

AC

Top

coa

t P I

NK

G

REY

80

80

16

0

- w

ithou

t ins

ulat

ion

(90°

- 12

0°

C)

Sa 3

or S

t 3

Poly

uret

hane

(2

com

pone

nts)

1 1 1

OX

YPA

INT

FA

503

Pri

mer

coa

t O

XY

PAIN

T F

F 11

00 M

iddl

e co

at

CR

YL

TA

NE

AC

Top

coa

t

RE

D

BL

UE

SEE

A

PPE

ND

IX 5

40

70

45

75

120

90

20

0

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 21 of 45

L15 Pipelines in cellars Sa 3


1 2

GALVOXY, zinc-rich Primer coat OXYTAR Epoxy tar

GREY SEE APPENDIX 5

40 150

75 200

340

Pipelines in cellars St 3


1 2

OXYPAINT FA 503 Primer coat OXYTAR Epoxy tar

RED SEE APPENDIX 5

60 150

75 200

360

GE

NE

RA

L

TEC

HN

ICA

L

SPE

CIF

ICA

TIO

N

7000

0 74

0 G

TS/

502

R

ev. 1

– 1

4/09

/09

Part

18 -

Page

22

of 4

5 SU

PPL

IER

: L

IBE

RT

C

OD

E

APP

LIC

AT

ION

T

YPE

N

O. O

F

LA

YE

RS

DE

SCR

IPT

ION

OF

TH

E S

YST

EM

C

OL

OU

R

DR

Y L

AY

ER

D

EPT

H IN

M

ICR

ON

S

TO

TA

L D

RY

L

AY

ER

DE

PTH

IN

MIC

RO

NS

MIN

M

AX

L21

N

ew g

alva

nisa

tion

in th

e w

orkp

lace

W

ater

-thi

nned

pai

nt

1 1

Prep

arat

ion

a or

b

a) D

egre

asin

g w

ith tr

ichl

oro-

etha

ne

1.1.

1. a

nd c

lean

with

Lith

ofor

m 2

. Was

h of

f with

cle

an w

ater

+ d

ry

b) v

aria

nt :

With

ste

am d

egre

asin

g (h

igh

pres

sure

) Ste

am D

evil

Typ

e C

RY

LT

AN

E A

C P

rim

er c

oat

CR

YL

TA

NE

AC

Top

coa

t

PIN

K

SEE

APP

EN

DIX

5

60

60

10

0 90

12

0 L

22

Gal

vani

satio

n st

ill in

goo

d co

nditi

on

(max

. 10

% ru

st)

St 3

or S

a 3

Wat

er-t

hinn

ed p

aint

1 1

Prep

arat

ion

a or

b

a) d

egre

asin

g w

ith tr

ichl

oro-

etha

ne

1.1.

1. a

nd c

lean

with

Lith

ofor

m 2

. Was

h of

f with

cle

an w

ater

+ d

ry

b) V

aria

nt :

Stea

m d

egre

asin

g (h

igh

pres

sure

) R

ub d

own

rust

spo

ts, r

etou

ch w

ith

CR

YL

TA

NE

AC

Pri

mer

coa

t C

RY

LT

AN

E A

C P

rim

er c

oat

CR

YL

TA

NE

AC

Top

coa

t

BR

OW

N R

ED

PI

NK

SE

E A

PPE

ND

IX 5

60

60

60

10

0 10

0 90

18

0 / 1

20

L33

St

eel

Sa3

or S

t 3

Vin

yl C

opol

ymer

1 1 1 1

DU

RO

ZIN

C S

A 5

07 P

rim

er c

oat

DU

RO

ZIN

C S

A 8

20 P

rim

er c

oat

SM M

IDD

LE

CO

AT

SM

TO

P C

OA

T

RE

D

GR

EY

P I

NK

S E

E A

PPE

ND

IX 5

50

50

40

180

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 23 of 45

SUPPLIER : LIBERT CODE APPLICATION TYPE NO. OF

LAYERS DESCRIPTION OF THE SYSTEM COLOUR DRY LAYER

DEPTH IN MICRONS


IN MICRONS MIN MAX L41 Concrete plinths Epoxy

(2 components)

1

1

1 1 1

Blast - remove dust Protect uncovered and derusted steel with OXYPAINT FA 503 Impregnate cracks with AQUAPOX DW/FM 1000 Repair the cracks with epoxy FX/SL product AQUAPOX DW/FM 1000, soak CRYLTANE AC, primer coat CRYLTANE AC, top coat

RED WHITE WHITE PINK SEE APPENDIX 5

40-80

45 45

90 90

90 L51 Chimneys

Blast Sa 3 450° C maximum

Silicic acid salt ethyl of zinc (2 components)

2

1 1

On the site SILIKA GALVEX (brush) In the workshop Metallisation Zinacor 85/15 SILIKA GALVEX (Airless)

25

100 60

50

90

50

160 L51a Chimneys up to 600° C Silicone

Aluminium 1 2

Aluminisation (rugosity R.max 50 µ) WP 1110

120 30

180

L63 Metallisation Sa 3 (rugosity : R max. 50 µ)

Polyurethane (2 components)

1

1

1

In the workplace Metallisation ZINACOR 85/15 CRYLTANE AC PRIMER 30 % thinned CRYLTANE AC PRIMER On the site CRYLTANE AC, top coat, gloss

RED PINK SEE APPENDIX 5

100

80

60

100

80

240

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 24 of 45

SUPPLIER : LIBERT CODE APPLICATION TYPE NO. OF

LAYERS DESCRIPTION OF THE SYSTEM COLOUR DRY



IN MICRONS

MIN MAX L70 Non-ferrous metals and special

steel (Alu., Inox...)

Polyurethane (2 components)

1 1 1

Degreasing with trichloro-ethane 1.1.1. and clean Lithoform 2 Rinse off thoroughly and dry Variant: Degreasing with high-pressure steam CRYLTANE AC primer CRYLTANE AC primer CRYLTANE AC, top coat gloss

RED PINK SEE APPENDIX 5

60 60 60

80 80 80

180

L81 Concrete floors Dry blast free of dust and oil

Polyurethane 1 component

1 2

Light sandblasting - remove dust, wash off with warm soda (oil). Rinse and dry POLYFLOOR primer POLYFLOOR finish

0,14-0,15L/m² 2 x 0,15 L/m²

L85 Concrete floors Antislip idem L81

Polyurethane 1 component

1 1 1

Light sandblasting - remove dust, wash off with warm soda (oil). Rinse and dry POLYFLOOR primer POLYFLOOR anti-slip POLYFLOOR finish

0,14-0,15L/m² 2 x 0,15 L/m² 2 x 0,15 L/m²

L90 Indoor Masonry, indoor concrete, bricks

Acrylate 1 1

RESACRYL A.F. thinned 10 % to 20 % RESACRYL A.F. not thinned

±0,15 L/m² ±0,2 L/m²

L91 Outdoor Concrete and bricks

Acrylate 1 1

RESACRYL A.F. thinned 10 % to 20 % RESACRYL A.F. not thinned

±0,15 L/m² ±0,2 L/m²

L92 Outdoor Damaged concrete and bricks

Acrylate 1 1 1

RESACRYL A.F. thinned 10 % to 20 % water LIBOQUARTZ RESACRYL A.F. not thinned

± 0,15 L/m² ± 0,8 L/m² ± 0,2 L/m²

GE

NE

RA

L

TEC

HN

ICA

L

SPE

CIF

ICA

TIO

N

7000

0 74

0 G

TS/

502

R

ev. 1

– 1

4/09

/09

Part

18 -

Page

25

of 4

5 SU

PPL

IER

: R

IPO

LIN

BE

NE

LU

X

CO

DE

A

PPL

ICA

TIO

N

TY

PE

NO

. OF

L

AY

ER

S D

ESC

RIP

TIO

N O

F T

HE

SY

STE

M

CO

LO

UR

D

RY

L

AY

ER

DE

PTH

IN

MIC

RO

NS

TO

TA

L D

RY

L

AY

ER

DE

PTH

IN

MIC

RO

NS

MIN

M

AX

RB

01

Surf

aces

(up

to 9

0°C

) Sa

3 E

poxy

Pol

yure

than

e

(2 c

ompo

nent

s)

1 1 1

VIG

OR

ZN

302

V

IGO

R E

P 23

5 V

IGO

R P

U 8

01 S

T

GR

EY-G

RE

EN

R

ED

-B

RO

WN

SE

E

APP

EN

DIX

5

50

80

80

100

150

150

21

0

RB

01a

Surf

aces

(up

to 9

0°C

) Sa

3 or

St3

W

eldi

ng s

eam

s or

repa

irs

of

syst

em 0

1, 6

3 an

d st

ud b

olts

Epo

xy P

olyu

reth

ane

(2

com

pone

nts)

1 1 1

VIG

OR

EP

235

VIG

OR

EP

235

VIG

OR

PU

801

ST

RE

D-

BR

OW

N

OC

HR

E B

EIG

E

S EE

A

PPE

ND

IX 5

80

80

80

150

150

150

24

0

RB

02

Gro

und

exit

(see

Art

. 18.

5)

NE

TS

Sa

3 IN

STA

LL

ATI

ON

S

St3

Epo

xy +

po

lyur

etha

ne

(2 c

ompo

nent

s)

1 1 1 (1

see

syst

em 0

1a

VIG

OR

EP

235

VIG

OR

EP

235

RE

INFO

RC

ED

PO

LY

EST

ER

Po

lyke

n pr

imer

in c

ase

of P

E)

idem

net

s bu

t with

St 3

(r

emov

al o

f all

exis

ting

pain

t)

OC

HR

E B

EIG

E

RE

D-

BR

OW

N

80

80

15

0 15

0

80

RB

03

War

m s

urfa

ces

- with

insu

latio

n (9

0° -

120°

C)

Sa 3

or S

t 3

Epo

xy

1 1 V

IGO

R E

P 23

5 V

IGO

R E

P 23

5 R

ED

-B

RO

WN

O

CH

RE

BE

IGE

80

80

150

150

16

0

- w

ithou

t ins

ulat

ion

(90°

- 12

0°

C)

Sa 3

or S

t 3

Epo

xy

1 1 1

VIG

OR

EP

235

VIG

OR

EP

235

VIG

OR

PU

801

ST

RE

D-

BR

OW

N

OC

HR

E B

EIG

E

SEE

A

PPE

ND

IX 5

80

80

80

150

150

150

24

0

RB

15

Pipe

lines

in c

ella

rs

Epo

xy

1 V

IGO

R Z

N 3

02

GR

EY-G

RE

EN

50

10

0

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 26 of 45

Sa 3 1 1

VIGOR EP 235 VIGOR EP 235

OCHRE BEIGE GREY

80 80

100 100

210

Pipelines in cellars St 3

Epoxy Epoxy - Tar

1 1 1

VIGOR EP 235 VIGOR EP 235 VIGOR EP 235

RED-BROWN OCHRE BEIGE GREY

80 80 80

100 100 100

240

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 27 of 45

SUPPLIER : RIPOLIN BENELUX CODE APPLICATION TYPE NO. OF




IN MICRONS

MIN MAX RB21 New galvanisation in the

workplace Epoxy

1 1

(see art.2.5.2.) degreasing, clean and rinse with clean water CENTREPOX PZ VIGOR PU 801 ST

WHITE-GREY SEE APPENDIX 5

40 80

60 150

120

RB22 Galvanisation still in good condition (max. 10 % rust) St 3 or Sa 3

Epoxy

1 1 1

After degreasing with trichloro-ethane, clean with P2-Henkel and rinse with clean water CENTREPOX PZ VIGOR EP 235 VIGOR PU 801 ST

WHITE-GREY OCHRE BEIGE SEE APPENDIX 5

40 80 80

60 150 150

200

RB33 Steel Sa3 or St 3

Vinyl Alkyd 1 1 1

FREITANYL HB PRIMER FREITANYL HB MIO FREITANYL HB Top coat

60 60 60

100 100 100

180 RB33 a Repair of system RB33

Sa3 or St 3 Vinyl Alkyd 2 FREITANYL HB Top coat SEE

APPENDIX 5 50 70 100

RB41 Concrete plinths Epoxy + Polyurethane

1

1

1 1

On metal after careful brushing VIGOR EP 235 On concrete after the correct preparation ENDOKOTE 426.20 fill with epoxy mortar FREITAGSOL EP250 VIGOR PU 801 ST

OCHRE BEIGE SEE APPENDIX 5

80

40

5 mm 80

150

50

150

RB51 Chimney up to 400° C Sa 3

Zinc ethyl silicate 1 1

Metallisation ZINACOR 85/15 VIGOR ZN 304, 30% thinned damage: layer of ECOLZINC no. 2 after removal of the zinc salts on the site

100 35

60

135

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 28 of 45



LAYER DEPTH

IN MICRONS

TOTAL DRY LAYER

DEPTH IN MICRONS

MIN MAX RB51a Chimney up to 600° C

Sa 3 - rugosity: Rmax 50 µ Silicone resin aluminium

2 1

Metallisation ALUMINIUM SUPERTHERMOVIT 600 SUPERTHERMOVIT 600

SILVER GREY ALUMINIUM

120 25 20

35 30

190 RB63 Metallisation

Sa 3 (rugosity : R max. 50 µ)

Epoxy + Polyurethane (2 components)

1 1

1

In the workshop, Metallisation ZINACOR 85/15 CENTREPOX PZ VIGOR EP 235 On the site VIGOR PU 801 ST

WHITE-GREY RED-BROWN SEE APPENDIX 5

100 40 80

40

60 100

60

260 RB70 Non-ferrous metals

and special steel (Alu., Inox...) Epoxy + Polyurethane

1 1 1

After degreasing with trichloro-ethane and rinse with clean water CENTREPOX PZ VIGOR EP 235 VIGOR PU 801 ST

WHITE-GREY RED-BROWN SEE APPENDIX 5

40 80 40

50 150 60

160 RB81 Concrete floors

Dry blast free of dust and oil Epoxy-phenol

1 1

For new floors: remove the surface milk-skin of the cement by a mechanical procedure For old floors : degrease and remove dust SOLENDOKOTE 442.40 15% thinned SOLENDOKOTE 442.40

± 250 gr./m² ± 250 gr./m²

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 29 of 45





IN MICRONS MIN MAX RB85 Concrete floors

Antislip idem RB81

Epoxy-phenol

1 1

For new floors: remove the surface milk-skin of the cement by a mechanical procedure For old floors : degrease and remove dust For the use of anti-slip powder SOLENDOKOTE 442.40 15% thinned SOLENDOKOTE 442.40 The anti slip is obtained by anti slip powder min. 5% in the last layer

± 250 gr./m² ± 250 gr./m²

RB90 Indoor masonry, concrete, stones inside buildings

Acrylate

1 1 to 2

Before starting work take humidity measurements Thoroughly clean surface and remove dust Check all joints GUIPRIM adhesive coat, thinned RIPALO Facade

± 8 m²/kg ± 5 m²/kg

RB91 Outdoor concrete and bricks outside

Acrylate

1 1 to 2

Before starting work take humidity measurements Thoroughly clean surface and remove dust Check all joints GUIPRIM adhesive coat, thinned EUCRYL Facade

± 8 m²/kg 11-14 m²/kg

RB92 Outdoor damaged concrete and bricks

Acrylate

1 1 to 2

Before starting work take humidity measurements Thoroughly clean surface and remove dust. Check all joints RIPONOV adhesive coat, thinned RIPONOV

± 3 m²/kg ± 3 m²/kg

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 30 of 45

SUPPLIER : SIGMA COATINGS N.V. CODE APPLICATION TYPE NO. OF




IN MICRONS MIN MAX S01 Surfaces (up to 90°C)

Sa3 Epoxy and polyurethane (2 components)

1 1 1

SIGMACOVER ZN PRIMER SIGMACOVER CM MIOCOAT SIGMADUR HS SEMIGLOSS

CREAM BEIGE SEE APPENDIX 5

60 70 70

80 150 100

200

S01a Surfaces (up to 90°C) Sa3 or St3 Welding seams or repairs of system 01, 63 and stud bolts

Epoxy and polyurethane (2 components)

1 1 1

SIGMACOVER ALU PRIMER SIGMACOVER CM MIOCOAT SIGMADUR HS SEMIGLOSS

GREY BEIGE SEE APPENDIX 5

70 70 70

200 150 100

210

S02 Ground exit (see Art. 18.5) NETWORKS Sa3 INSTALLATIONS St3


1 1 1 (1

see system 01a SIGMACOVER ALU PRIMER SIGMACOVER CM MIOCOAT REINFORCED POLYESTER Polyken primer in case of PE) idem Networks but with St3 (removal of all existing paint)

GREY BEIGE

70 70

200 150

70

S03 Warm surfaces 90° C - 120°C Insulated Sa 3 - St 3

Epoxy 1 1

SIGMACOVER CM MIOCOAT SIGMACOVER CM MIOCOAT 9553

GREEN BEIGE

70 70

100 100

140

Warm surfaces 90° C - 120°C Not insulated Sa 3 - St 3

Epoxy 1 1 1

SIGMACOVER ALU PRIMER SIGMACOVER CM MIOCOAT SIGMADUR HS SEMIGLOSS

GREY BEIGE SEE APPENDIX 5

70 70 70

200 150 100

210

S15 Pipelines in cellars Sa 3

Epoxy (2 components)

1 1 1

SIGMACOVER ZN PRIMER CHEMIKOTE T BROWN CHEMIKOTE T BLACK

CREAM SEE APPENDIX 5

40 100 100

100 180 180

240

GE

NE

RA

L

TEC

HN

ICA

L

SPE

CIF

ICA

TIO

N

7000

0 74

0 G

TS/

502

R

ev. 1

– 1

4/09

/09

Part

18 -

Page

31

of 4

5

Pipe

lines

in c

ella

rs

St 3

E

poxy

(2

com

pone

nts)

1 1 1

SIG

MA

CO

VE

R P

RIM

ER

C

HE

MIK

OT

E T

BR

OW

N

CH

EM

IKO

TE

T B

LA

CK

KH

AK

I SE

E

APP

EN

DIX

5

50

100

100

100

180

180

25

0

S21

New

gal

vani

satio

n E

poxy

1 1

Deg

reas

ing

and

clea

n.

Rin

se w

ith c

lean

wat

er a

nd d

ry.

SIG

MA

CO

VE

R P

RIM

ER

SI

GM

AD

UR

HS

SEM

IGL

OSS

KH

AK

I S E

E

APP

EN

DIX

5

50

70

10

0 10

0

12

0

S22

Gal

vani

satio

n st

ill in

goo

d co

nditi

on

(max

. 10

% ru

st)

St 3

or S

a 3

Epo

xy

1 1 1

Deg

reas

ing

and

clea

n.

Rin

se w

ith c

lean

wat

er a

nd d

ry.

Rem

ove

rust

from

the

rust

ed p

arts

St 3

R

etou

ch th

e de

rust

ed p

arts

SI

GM

AC

OV

ER

PR

IME

R

SIG

MA

CO

VE

R P

RIM

ER

SI

GM

AD

UR

HS

SEM

IGL

OSS

KH

AK

I K

HA

KI

S EE

A

PPE

ND

IX 5

50

50

70

10

0 10

0 10

0

17

0

S33

Stee

l Sa

3 or

St 3

V

inyl

Alk

yd

1 1 2

VIN

YL

AL

KY

D P

RIM

ER

702

3-20

51

SIG

MA

VIN

YL

MIO

702

5-50

51

SIG

MA

VIN

YL

top

coat

702

7

40

40

40

70

70

70

16

0 S4

1 C

oncr

ete

plin

ths

Tw

o co

mpo

nent

s so

lven

t-fr

ee

1 1 1 1

Any

repa

irs

:

abra

de d

own

to c

lean

con

cret

e an

d re

mov

e ru

st fr

om s

teel

to S

t 3

ap

ply

CO

LTU

RA

PR

IME

R M

AC

to

stee

l and

con

cret

e to

be

repa

ired

afte

r app

licat

ion

of th

e st

ill w

et p

rim

er fi

ll w

ith C

OL

TU

RA

PR

IME

R E

PU

SIG

MA

RIT

E W

L P

RIM

ER

30

% th

inne

d w

ith 9

1-92

SI

GM

AC

OV

ER

CM

MIO

CO

AT

SI

GM

AD

UR

HS

SEM

IGL

OSS

WH

ITE

BE

IGE

S EE

A

PPE

ND

IX 5

70

70

10

0 10

0

gr

outin

g la

yer

14

0

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 32 of 45

S51 Chimneys 450° C

Sa3

1

1

In the workshop Metallisation ZN 100 ZINACOR 85/15 SIGMASILGUARD MC, thinned 50% with 90-53 On the site Remove chloride by washing off with water to which a detergent has been added, with a hard brush SIGMASILGUARD MC, 50 % thinned with 90-53

100 35

35

55

55

± 170

S51a Chimneys up to 600° C Sa 3 - rugosity: Rmax 50 µ

Alu silicate 1 1

Metallisation Alu. SIGMATERM SILICAAT ALUMINIUM

120 30

150

S63 Metallisation Sa 3 (rugosity : R max. 50 µ)

Epoxy (2 components) Polyurethane

1 1

1

In the workshop Metallisation ZN 100 ZINACOR 85/15 SIGMARITE SEALANT 20% thinned SIGMACOVER CM MIOCOAT On the site SIGMADUR HS SEMIGLOSS

GREEN BEIGE SEE APPENDIX 5

100 40 70

70

60 150

100

280

S70 Non-ferrous metals (Alu, Inox ...)

Epoxy (2 components) Polyurethane

1 1 1

Preparation Remove the oxidation layer with Deoxidiser 670 solution and. hard nylon brush. Rinse off to remove every trace of Deoxidiser. On the still wet surface, apply Alodine 1200* (ready for use) * Instructions Henkel SIGMACOVER PRIMER SIGMACOVER CM MIOCOAT SIGMADUR HS SEMIGLOSS

KHAKI BEIGE SEE APPENDIX 5

50 70 70

100 150 100

190

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 33 of 45

SUPPLIER : SIGMA COATINGS N.V. CODE APPLICATION TYPE NO. OF

LAYERS DESCRIPTION OF THE SYSTEM DRY


TOTAL DRY LAYER DEPTH IN MICRONS

MIN MAX S81 Concrete floors

Dry blast, free of dust and oil

1

1

Below-ground free of dirt, dust, cement slag and other impurities SIGMARITE GP Finish, 20 % thinned with 91-92 SIGMARITE GP Finish

yield 5 m²/L

yield 5 m²/L

S85 Concrete floors Antislip idem S81

Anti-slip paint

1

1

Below-ground free of dirty, dust, cement slag and other impurities SIGMARITE GP Finish, 20 % thinned with 91-92 SIGMARITE GP Finish + 5 % anti-slip powder

yield 5 m²/L

yield 5 m²/L

S90 Indoor masonry, concrete, bricks

PV acetate 2 to 3 SIGMATEX SUPERLATEX 1st layer 10 % thinned with water 1 or 2 layers unthinned

yield 10m²/L

S91 Outdoor concrete and brick Acrylate 1

2

SIGMAFIX UNIVERSAL 1/4 parts water SIGMACRYL FACADE

yield 10m²/L

S92 Outdoor damaged concrete and brick

Quartz finishing 1

2

SIGMAFIX UNIVERSAL 1/4 parts water KWARTSTONE

400 gr/m²/low

GENERAL TECHNICAL

SPECIFICATION

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GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 35 of 45

��1� *+�(��+��&'�*�

The measurement statement must allow an estimate to be made of the quantities and/or surface area of the work carried out or yet to be carried out.

��1�� %��

The surface area per linear metre of the pipes is given in table 1. The equivalent length that must be taken into consideration for the calculation of the surface area of the fittings is given in table 2. Any fittings not mentioned in table 2 will not be considered for the supplementary equivalent length.

Cut-off valves and operators are mentioned in table 2. For a T-piece and a reducer, the largest nominal diameter will be considered. For smaller diameters not mentioned in the tables, the larger diameter will be considered.

��1�� !��

I, L, T, U profiles

� the surface area of the profiles is given in table 3;

� profiles not mentioned will be calculated ;

� openings or off-cuts will be deducted if they exceed 50 % of the part considered.

��1� � *��6��>�, !��

The surface is the length of the screw thread and nut multiplied by a coefficient (see table 4).

TABLE 1

Nominal diameter Nominal diameter Outside diameter Surface area per INCH MM MM linear M-M2

1 25 33.7 0.11 2 50 60.3 0.19 3 80 88.9 0.28 4 100 114.3 0.36 6 150 168.3 0.53 8 200 219.1 0.69

10 250 273 0.86 12 300 323.9 1.02 14 350 353.6 1.12 16 400 406.4 1.28 18 450 457 1.48 20 500 508 1.60

24 600 609.6 1.92 28 700 711.2 2.24 32 800 812.8 2.35

GENERAL TECHNICAL

SPECIFICATION

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GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 36 of 45

36 900 914.4 2.87

40 1000 1016 3.19 42 1050 1066 3.35 48 1200 1220 3.83 56 1400 1420 4.46 64 1600 1620 5.09 72 1800 1820 5.72 80 2000 2020 6.35

TABLE 2

Outside diameter Flange MM T- Piece Blind flange

from - up to

6 - 50 0.30 0.3 65 - 200 0.75 0.5

250 - 2000 1.50 0.7

VALVES :

Outside diameter DS-Surface area (m2)

2" 0.38 3" 0.64 4" 0.83 6" 1.22 8" 1.58 10" 2.24 12" 2.65 14" 2.91 16" 3.33 20" 4.16 24" 4.99 28” 5.84 36" 7.46 40” 8.34

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 37 of 45

OPERATORS

Outside diameter DS-Surface area (m2)

8" 2.64 10" 3.20 12" 3.31 14" 3.38 16" 3.72 20" 4.18 24" 4.65 28” 5.11 36" 6.05 40” 6.51

GENERAL TECHNICAL

SPECIFICATION

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GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 38 of 45

TABLE 3

U-PROFILES SYMMETRICAL T-PROFILES

Name H x W (mm) m² / m m²/ton H x W D m² / m m²/ton 30 x 15 0.103 59.19 15 x 15 3 0.055 84.60

30 x 33 0.174 40.74 20 x 20 3 0.075 85.20

40 x 20 0.142 49.47 25 x 25 3.2 0.094 72.90

40 x 35 0.199 40.86 30 x 30 4 0.114 64.40

50 x 25 0.181 46.89 35 x 35 4.5 0.133 57.10

50 x 38 0.232 41.50 40 x 40 5 0.153 51.70

60 x 30 0.215 42.41 45 x 45 5.5 0.171 46.60

70 x 40 0.276 41.02 50 x 50 6 0.191 43.--

UPN 8 80 x 45 0.312 36.10 60 x 60 7 0.229 36.80

UPN 10 100 x 50 0.372 35.10 70 x 70 8 0.268 32.20

UPN 12 120 x 55 0.434 32.40 80 x 80 9 0.307 28.70

UPN 14 140 x 60 0.489 30.60 90 x 90 10 0.345 25.70

UPN 16 160 x 65 0.546 29.-- 100 x 100 11 0.383 23.40

UPN 18 180 x 70 0.611 27.80 120 x 120 13 0.459 19.80

UPN 20 200 x 75 0.661 26.10 140 x 140 15 0.537 17.20

UPN 22 220 x 80 0.718 24.40 160 x 160 15 0.617 17.20

UPN 24 240 x 85 0.775 23.30 180 x 180 18 0.693 14.30

UPN 26 260 x 90 0.834 22.--

UPN 28 280 x 95 0.890 21.30

UPN 30 300 x 100 0.950 20.60 ASYMMETRICAL T-PROFILES 320 x 100 0.982 16.50

350 x 100 1.047 17.30 H x W mm D m² / m m²/ton 380 x 102 1.110 17.70 30 x 60 5.5 0.171 47.--

400 x 110 1.182 16.50 35 x 70 6 0.201 43.10

40 x 80 7 0.233 37.50

45 x 90 8 0.258 32.20

50 x 100 8.5 0.287 30.50

60 x 120 10 0.345 25.70

70 x 140 11.5 0.402 22.50

80 x 160 13 0.460 19.80

90 x 180 14.5 0.518 17.80

100 x 200 16 0.576 16.20

GENERAL TECHNICAL

SPECIFICATION

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GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 39 of 45

EQUAL-SIDED ANGLE IRONS EUROPEAN SERIES

b x b (x e) P Kg/m

Surface m²/m

b x b (x e) P Kg/m

Surface m²/m

20 x 20 x 3 0.88 0.077 80 x 80 x 6 7.34 0.311 x 4 1.14 x 7 8.49

25 x 25 x 3 1.11 0.097 x 8 9.63 x 4 1.45 x 10 11.90 x 5 1.78 x 12 14.10

30 x 30 x 3 1.36 0.116 90 x 90 x 6 8.31 0.351 x 4 1.78 x 8 10.90 x 5 2.18 x 9 12.20

35 x 35 x 3 1.60 0.136 x 11 14.70 x 4 2.10 x 13 17.10 x 5 2.57 100 x 100 x 6.5 9.98 0.390

40 x 40 x 3 1.84 0.155 x 8 12.20 x 4 2.42 x 10 15.00 x 5 2.97 x 12 17.80 x 6 3.52 x 15 21.90

45 x 45 x 3 2.09 0.174 120 x 120 x 8 14.70 0.469 x 4 2.74 x 10 18.20 x 5 3.38 x 12 21.60 x 6 4.00 ` x 15 26.60

50 x 50 x 3 2.33 0.194 150 x 150 x 10 23.00 0.586 x 4 3.06 x 12 27.30 x 5 3.77 x 15 33.80 x 6 4.47 x 18 40.10 x 7 5.15 180 x 180 x 15 40.90 0.705 x 8 5.82 x 18 48.60

60 x 60 x 4 3.70 0.233 x 20 53.70 x 5 4.57 200 x 200 x 16 48.50 0.785 x 6 5.42 x 18 54.20 x 8 7.09 x 20 59.90

x 10 8.69 x 24 71.10 70 x 70 x 5 5.37 0.272

x 6 6.38 x 7 7.38 x 8 8.36

x 10 10.30

GENERAL TECHNICAL

SPECIFICATION

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Rev. 1 – 14/09/09 Part 18 - Page 40 of 45

UNEQUAL-SIDED ANGLE IRONS EUROPEAN SERIES

b x a (x e) P Kg/m

Surface m²/m

b x a (x e) P Kg/m

Surface m²/m

30 x 20 x 3 1.11 0.097 90 x 65 x 6 7.07 0.300 x 4 1.45 x 7 8.19 x 5 1.78 x 8 9.28

40 x 20 x 3 1.36 0.117 x 10 11.44 x 4 1.77 100 x 50 x 6 6.85 0.292 x 5 2.17 x 7 7.93

40 x 25 x 4 1.93 0.130 x 8 8.99 x 5 2.37 x 10 11.1

45 x 30 x 4 2.25 0.146 100 x 65 x 7 8.77 0.350 x 5 2.77 x 8 9.94

50 x 30 x 4 2.41 0.156 x 9 11.1 x 5 2.96 x 10 12.25 x 6 3.51 100 x 75 x 8 10.6 0.342

60 x 30 x 5 3.37 0.175 x 10 13.0 x 6 3.99 x 12 15.4

60 x 40 x 5 3.76 0.195 120 x 80 x 8 12.2 0.391 x 6 4.46 x 10 15.0 x 7 5.14 x 12 17.8

65 x 50 x 5 4.35 0.224 130 x 65 x 8 11.9 0.381 x 6 5.16 x 10 14.6 x 7 5.97 x 12 17.3

x 8 6.75 150 x 75 x 9 15.36 0.471 70 x 50 x 5 4.56 0.233 x 10 17.0

x 6 5.41 x 12 20.17

x 7 6.25 150 x 90 x 10 18.2 0.469 x 8 7.07 x 12 21.6

75 x 50 x 5 4.74 0.244 x 15 26.6 x 6 5.63 200 x 100 x 10 23.0 0.587 x 7 6.51 x 12 27.3 x 8 7.39 x 14 31.6

80 x 40 x 5 4.55 0.234 x 16 35.9 x 6 5.41 x 7 6.25

x 8 7.07

GENERAL TECHNICAL

SPECIFICATION

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Rev. 1 – 14/09/09 Part 18 - Page 41 of 45

NORMAL I-PROFILES OF 80 MM AND MORE SYMMETRICAL IPE PROFILES EUROPEAN SERIES

Usual name P

Kg/m

H

mm

B

mm

Surface

m²/m Usual name

P

Kg/m

H

mm

B

mm

Surface

m²/m

IPN 8 5.95 80 42 0.30 IPE 80 6.00 80 46 0.33

IPN 10 8.32 100 50 0.37 IPE 100 8.10 100 55 0.40

IPN 12 11.2 120 58 0.44 IPE 120 10.4 120 64 0.48

IPN 14 14.4 140 66 0.50 IPE 140 12.9 140 73 0.55

IPN 16 17.9 160 74 0.58 IPE 160 15.8 160 82 0.62

IPN 18 21.9 180 82 0.64 IPE 180 18.8 180 91 0.70

IPN 20 26.3 200 90 0.71 IPE 200 22.4 200 100 0.77

IPN 22 31.1 220 98 0.78 IPE 220 26.2 220 110 0.85

IPN 24 36.2 240 106 0.84 IPE 240 30.7 240 120 0.92

IPN 26 41.9 260 113 0.91 IPE 270 36.1 270 135 1.04

IPN 28 48.0 280 119 0.97 IPE 300 42.2 300 150 1.16

IPN 30 54.2 300 125 1.03 IPE 330 49.1 330 160 1.25

IPN 32 61.1 320 131 1.09 IPE 360 57.1 360 170 1.35

IPN 34 68.1 340 137 1.15 IPE 400 66.3 400 180 1.47

IPN 36 76.2 360 143 1.21 IPE 450 77.6 450 190 1.61

IPN 38 84.0 380 149 1.27 IPE 500 90.7 500 200 1.74

IPN 40 92.6 400 155 1.33 IPE 550 106 550 210 1.88

IPN 42.5 104 425 163 1.41 IPE 600 122 600 220 2.01

IPN 45 115 450 170 1.48

IPN 47.5 128 475 178 1.55

IPN 50 141 500 185 1.63

IPN 55 167 550 200 1.80

GENERAL TECHNICAL

SPECIFICATION

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GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 42 of 45

PROFILES WITH WIDE PARALLEL EUROPEAN PROFILES: EURONORM 53-62 FLANGES

No. of profile profile Name P Kg/m

H mm

B mm

Surface m²/m

10 HE 100 A 16.7 96 100 0.561 HE 100 B 20.4 100 100 0.567 HE 100 M 41.8 120 106 0.619

12 HE 120 A 19.9 114 120 0.677 HE 120 B 26.7 120 120 0.686 HE 120 M 52.1 140 126 0.738

14 HE 140 A 24.7 133 140 0.794 HE 140 B 33.7 140 140 0.805 HE 140 M 63.2 160 146 0.857

16 HE 160 A 30.4 152 160 0.906 HE 160 B 42.6 160 160 0.918 HE 160 M 76.2 180 166 0.970

18 HE 180 A 35.5 171 180 1.024 HE 180 B 51.2 180 180 1.037 HE 180 M 88.9 200 186 1.089

20 HE 200 A 42.3 190 200 1.136 HE 200 B 61.3 200 200 1.151 HE 200 M 103.0 220 206 1.203

22 HE 220 A 50.5 210 220 1.255 HE 220 B 71.5 220 220 1.270 HE 220 M 117.0 240 226 1.322

24 HE 240 A 60.3 230 240 1.369 HE 240 B 83.2 240 240 1.384 HE 240 M 157.0 270 248 1.460

GENERAL TECHNICAL

SPECIFICATION

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GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 43 of 45

PROFILES WITH WIDE PARALLEL FLANGES SPECIAL PROFILES: COLUMNS

Name P Kg/m

H mm

B mm

Surface m²/m

Name P Kg/m

H m

B mm

Surface m²/m

HD 100 x 15 14.9 96.5 100.0 0.564 HD 260 x 240

240.37 314 273 1.625

x 20 19.6 101.6 100.0 0.573 274 273.76 326 276 1.654 x 24 23.8 103.0 102.0 0.579 333 333.39 346 282 1.707

HD 130 x 20 20.3 124.0 128.0 0.729 HD 310 x 94 93.91 306 305 1.767

x 24 23.8 127.0 127.0 0.737 106 105.92 310 306 1.777 x 28 27.5 130.0 127.6 0.744 118 117.99 314 307 1.787 x 33 33.2 125.0 123.0 0.705 135 135.05 319 309 1.801

155 154.71 325 311 1.817 HD 160 x 30 29.96 157.0 155.0 0.896 177 177.00 332 313 1.835

x 35 34.87 160.0 156.0 0.904 207 207.15 341 316 1.859 x 40 39.82 163.0 157.0 0.912 240 240.23 351 319 1.885 x 46 46.06 167.0 158.0 0.922 274 273.77 361 322 1.912

308 307.79 371 325 1.938 HD 210 x 43 43.45 201.0 204.0 1.174 350 350.43 383 329 1.970

x 50 49.85 204.0 205.0 1.182 435 434.78 407 336 2.032 x 56 56.31 207.0 206.0 1.190 x 63 62.81 210.0 207.0 1.198 HD 360 x

135 135.18 355 369 2.117

x 71 70.99 214.0 208.0 1.208 152 152.49 360 370 2.129 x 83 82.39 219.0 210.0 1.222 176 175.67 366 372 2.145 x 94 94.25 225.0 211.0 1.236 199 199.03 372 374 2.161

x 117 116.59 235.0 213.0 1.256 x 139 139.12 245.0 216.0 1.283 HD 400 x

190 190.04 369 391 2.226

x 162 162.02 255.0 219.0 1.308 214 214.34 375 393 2.242 x 200 200.22 271.0 225.0 1.356 237 237.10 381 394 2.255 x 252 251.53 291.0 232.0 1.410 262 261.74 387 396 2.271

287 286.56 393 398 2.287 HD 260 x 60 59.99 248.0 253.0 1.452 312 311.57 399 400 2.303

x 68 67.92 251.0 254.0 1.460 337 336.77 405 402 2.319 x 78 77.89 255.0 255.0 1.470 370 370.48 413 405 2.342 x 90 89.94 260.0 256.0 1.482 404 403.78 421 407 2.361

x 104 104.15 265.0 258.0 1.496 446 445.88 431 410 2.387 x 121 120.56 271.0 260.0 1.512 488 488.45 441 413 2.413 x 141 141.15 278.0 262.0 1.530 531 531.49 451 416 2.439 x 160 160.15 286.0 264.0 1.550 577 577.37 461 420 2.468

GENERAL TECHNICAL

SPECIFICATION

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GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 44 of 45

x 184 183.66 294.0 267.0 1.573 621 621.43 471 423 2.494 x 209 209.47 302.0 270.0 1.595 679 678.56 481 426 2.510

GENERAL TECHNICAL

SPECIFICATION

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GTS/502

Rev. 1 – 14/09/09 Part 18 - Page 45 of 45

TABLE 4

Diameter of screw thread Diameter of screw thread INCHES MM Coefficient

up to up to

1 25 20

1 1/4 32 25

1 1/2 40 30

2 50 40

S S S

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09

APPENDIX 1 - adhesion tests

ADHESION TEST ON COATINGS BY MEANS OF THE GRID TEST

DIN 53 151 ASTM D3359-B ISO 2409 BS 3900-E6

Description Surface of the gridded area

that is peeling. (Example for 6 grooves)

Classification DIN Classification

ASTM

The sides of the cuts are completely smooth. Not one square in the grid pattern has come loose.

0

5B

Small coating particles have come loose at the cutting points. Less than 5% of the surface is affected.

1

4B

Small coating particles have come loose along the sides and at the corners of the cuts. 5 to 15% of the surface is affected.

2

3B

The coating crumbles away along the sides of the cuts and on parts of the little squares. 15 to 35% of the surface is affected.

3

2B

Much of the coating crumbles away along the sides of the cuts and complete squares have peeled loose. 35 to 65% of the surface is affected.

4

1B

Crumbling and peeling to a greater extent than that of DIN4

More than 65% has peeled.

5

0B

Carrying out the GRID test

� For dry coating layer less than 50 µm, a Cross-Cut blade is used with a distance between blades of 1 mm. For coating layer larger than 50 µ, a Cross-Cut blade should be used with an interspacing of 2 mm.

� The application of incisions is carried out in two stages, each in one continuous movement. First a cut of ± 20 mm is made, followed by a second cut of about the same length but at 90 degrees to the direction of the first incision.

� The grid pattern is then rubbed away with a soft brush or cloth. The result is subsequently compared with the table above.

� If this work is carried out in accordance with ASTM D3359-87, a piece of adhesive tape specified in accordance with that standard will then be applied to the grid pattern and peeled off.

GENERAL TECHNICAL

SPECIFICATION

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GTS/502

Rev. 1 – 14/09/09

TABLE Cross Cut Adhesion Test (acc. to ASTM)

GENERAL TECHNICAL

SPECIFICATION

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GTS/502

Rev. 1 – 14/09/09

APPENDIX 2 WORK METHOD FOR REINFORCED POLYESTER

� Information about the product

� is a polyester coating in rolls;

� is a plastic easy to work with, reinforced with glass fibre (G.R.P.);

� is made in sheets and delivered as standard in 10 m x 2 mm rolls;

� in its untreated form is extremely flexible; it can be cut to any shape or in accordance with the required format; it can then be fashioned, adapted, rolled up, rolled out and/or fitted to practically any object or surface;

� when exposed to UV light, it begins to harden after a few minutes and will become hard over a period of a few hours;

� once hardened is:

� an extremely strong and inalterable material with an exceptional lifetime and good resistance to heat;

� waterproof;

� resistant to a large number of acids, chemical products and solvents;

� offers numerous possibilities:

� clean, safe and extremely easy to use;

� quality always guaranteed;

� maintains its strength, weight and lifetime;

� has a resistance stronger than UV;

� minimum waste.

� Painting firms

Paint appliers :

� must be officially recognised and registered;

� must be known and given a permit by DuPol Benelux;

� once registered and given a permit, they will undergo training by the instructors of DuPol;

� after the training and practical experience, they will be taken on as “recognised appliers of reinforced polyester”;

� every year an assessment will take place regarding the working method used and the knowledge developed with reinforced polyester.

Application

� requires the use of suitable tools and accessories of good quality, such as:

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09

� cutting table;

� ruler;

� universal knife and scissors;

� cutting machine safety bar;

� pressing roll;

� wide transparent adhesive tape;

� thick black polyethylene film.

� the application of reinforced polyester may only be carried out in dry weather with a minimum temperature of ± 5ºc;

� the site must always be protected from direct sunlight;

� it is highly advisable to cut reinforced polyester beforehand to the required sizes (protected from sunlight);

� unused reinforced polyester must immediately be protected from sunlight by means of the thick black polyethylene film.

� On new steel pipes

� clean the steel surface to be treated by sandblasting Sa3;

� protect the site from direct sunlight;

� apply a layer of reinforced polyester having the width of the surface to be treated with a longitudinal and transversal overlap of 100 mm; press hard and/or roll all over these overlaps (see drawing: the dotted section represents the reinforced polyester);

� fix the applied reinforced polyester with wide transparent adhesive tape;

� exposed to sunlight, reinforced polyester will harden in ± 20 min.;

� in the absence of sunlight, UV lamps may be used (min 300 W); the hardening time will then be a little longer;

� after hardening, remove the transparent adhesive tape;

WELDED JOINT

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09

� for increased protection, it is recommended to use UV resin (UVH-100) on the transversal and longitudinal overlaps;

� use UV resin (UVH-100) beforehand for jointing with already hardened reinforced polyester.

� On existing steel pipes (after sandblasting)

� remove the old coating;

� sandblast Sa3 to check the condition of the surface;

� repair or replace the metal, if necessary;

� derust manually to St3;

� apply a layer of ALUTEC and/or PRIMER (D400);

� protect the site against sunlight;

� after drying, apply reinforced polyester over the width of the surface to be treated with an overlap of 100 mm; press hard and/or roll all over these overlaps;

� spread the extremities with UV resin (UVH-100);





� Existing steel pipes (without sandblasting)

� do not remove the old coating, but do remove dust;

� apply 1 layer of PRIMER (D400);


� after drying (± 1 to 1 ½ hours), apply reinforced polyester over the width of the surface to be treated with an overlap of 100 mm; press hard and/or roll all over these overlaps;

� spread the extremities with UV resin (UVH-100);





� Concrete

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09

� clean the surface to be treated and, if necessary, smooth it;

� apply 1 layer of PRIMER (D400);


� after drying (± 1 to 1 ½ hours), apply reinforced polyester over the width of the surface to be treated with an overlap of 50 mm;

� press hard and/or roll over the reinforced polyester;

� it is recommended to use UV resin (UVH-100) and vulcanising on the overlaps for a better seal before applying the next layer of reinforced polyester;




GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09

APPENDIX 3 PAINTWORK - DAILY REPORT

Supervisor _______________________________________ Hours worked: by supervisor ________________________ Activity: _________________________________________ Hours worked on site : ______________________________

General weather conditions: Dry � Humid � Rain �

Site personnel Number Hours Site equipment Number Hours

WEATHER CONDITIONS

TIME Td Th RH DP Tobj ∆T OK NOK

Ts : Temperature dry - Th : Temperature humid - RH :Relative humidity - DP :Dew point - Tobj : Temperature of object - ∆T : Tobj - DP

COMMENTS: The paintwork was only started when the weather conditions were acceptable.

Humidity and temperature were continuously measured during and after execution of the work

R102 C45-N Blad 1/2

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09

OWNER / Material - Paintwork - Daily report

Object Preparation of surface**

Layers & Depths

Paint used Paint system

Pipe � Sa 3 � � µm

Shut-off valve � St 2 � � µm

Filter � Dgr � � µm

.................................... � None � � µm




.................................... � None � � µm




.................................... � None � � µm




.................................... � None � � µm




.................................... � None � � µm

** SA3 = Sand-blasted - St2 = Rust removed manually - Dgr = Degreased

Supplementary notes in appendix (Second page of Daily Report - Form C42N) Yes � No �

SUPERVISOR - DS

Name & Signature OPERATOR

Name & Signature Copies: WHITE : Operator YELLOW : Supervisor PINK: Person in charge of Works

C45-N BLAD 2/2

GENERAL TECHNICAL

SPECIFICATION

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GTS/502

Rev. 1 – 14/09/09

APPENDIX 4. ATMOSPHERIC CONDITIONS

� No paintwork may be carried out if the atmospheric conditions are not suitable.

� To obtain the best results when carrying out paintwork, it is of essential importance that no condensation appears on the cleaned or blasted surface or between the different layers.

For this reason, the temperature of the surface to be painted should be at least 3º higher than the dew point or condensation temperature of the ambient air. In the table below, the dew point of the air is given for a number of conditions of air temperature and relative humidity. Correlation between relative humidity, air temperature and dew point

Air Dew point in ºC with a relative humidity of : temp.

°C 50% 55% 60% 65% 70% 75% 80% 85% 90%

5 -4.1 -2.9 -1.8 -0.9 0.0 0.9 1.8 2.7 3.6 6 -3.2 -2.1 -1.0 -0.1 0.9 1.8 2.8 3.7 4.5 7 -2.4 -1.3 -0.2 0.8 1.8 2.8 3.7 4.6 5.5 8 -1.6 -0.4 0.8 1.8 2.8 3.8 4.7 5.6 6.5 9 -0.8 0.4 1.7 2.7 3.8 4.7 5.7 6.6 7.5 10 0.1 1.3 2.6 3.7 4.7 5.7 6.7 7.6 8.4 11 1.0 2.3 3.5 4.6 5.6 6.7 7.6 8.6 9.4 12 1.9 3.2 4.5 5.6 6.6 7.7 8.6 9.6 10.4 13 2.8 4.2 5.4 6.6 7.6 8.6 9.6 10.6 11.4 14 3.7 5.1 6.4 7.5 8.6 9.6 10.6 11.5 12.4 15 4.7 6.1 7.3 8.5 9.5 10.6 11.5 12.5 13.4 16 5.6 7.0 8.3 9.5 10.5 11.6 12.5 13.5 14.4 17 6.5 7.9 9.2 10.4 11.5 12.5 13.5 14.5 15.3 18 7.4 8.8 10.2 11.4 12.4 13.5 14.5 15.4 16.3 19 8.3 9.7 11.2 12.3 13.4 14.5 15.5 16.4 17.3 20 9.3 10.7 12.0 13.3 14.4 15.4 16.4 17.4 18.4 21 10.2 11.6 12.9 14.2 15.3 16.4 17.4 18.4 19.3 22 11.1 12.5 13.8 15.2 16.3 17.4 18.4 19.4 20.3 23 12.0 13.5 14.8 16.1 17.2 18.4 19.4 20.3 21.3 24 12.9 14.4 15.7 17.0 18.2 19.3 20.3 21.3 22.3 25 13.8 15.3 16.7 17.9 19.1 20.3 21.3 22.3 23.2 26 14.8 16.2 17.6 18.8 20.1 21.2 22.3 23.3 24.2 27 15.7 17.2 18.6 19.8 21.1 22.2 23.2 24.3 25.2 28 16.6 18.1 19.5 20.8 22.0 23.2 24.2 25.2 26.2 29 17.5 19.1 20.5 21.7 22.9 24.1 25.2 26.2 27.2 30 18.4 20.0 21.4 22.7 23.9 25.1 26.2 27.2 28.2

From this table we can deduce that paintwork may not be carried out when the relative humidity of the air is higher than 80% (in theory 82%). With an air humidity of 82% and higher, the temperature of the steel surface should be higher than the air temperature.

Application of the paint is also not permitted if there is a danger that the film of paint will not be dry before dew, condensation or frost sets in.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/502

Rev. 1 – 14/09/09

APPENDIX 5 colour code

COLOUR CODE

COMPRESSION STATIONS

DESCRIPTION COLOUR RAL CODE

High-pressure gas White RAL 9010

Low-pressure gas Orange RAL 2003

Surplus gas burners Yellow RAL 1004

Fire extinguishers Red RAL 3000

Air Blue RAL 5009

Water Green RAL 6010

Oil Brown RAL 8003

Valves - devices Grey RAL 7038

Supports Black RAL 9005

Doors Dark blue RAL 5010

PRESSURE REGULATING

Pipes - valves Supports etc. Grey RAL 7038

Fences, doors Green RAL 6020

High-pressure arrow Red RAL 3000

Low- or medium-pressure arrow Orange RAL 2003

Rev. D M Y Modifications Drawn Checked Approved Validated

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Drawing No. Rev.

Scale SheetSize

SUBJECT

TRACTEBEL Engineering pvt. ltd.

of

TYPICAL RIGHT OF USE FOR PIPELINES

GGNG-D-20707-001 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL TRENCH DETAILS

GGNG-D-20707-002 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL ROAD CROSSING(OPEN CUT/JACKING METHOD)

GGNG-D-20707-003 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL ROAD CASED CROSSING (B+C)

GGNG-D-20707-004 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL WATER WAY CROSSING (OPEN CUT)

GGNG-D-20707-005 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL WATER WAY CASED CROSSING (B+C)

GGNG-D-20707-006 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL MECHANICAL PROTECTIONCONCRETE SLAB DETAILS

GGNG-D-20707-007 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL UNDERGROUNDCABLE CROSSING DETAILS

GGNG-D-20707-008 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL OVERHEAD POWER LINECROSSING DETAILS

GGNG-D-20707-009 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL CONCRETE COATING FORMECHANICAL PROTECTION

GGNG-D-20707-010 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL SADDLE FOR ANTI-BOUYANCY

GGNG-D-20707-011 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL RAILWAY CASED CROSSING (B+C)

GGNG-D-20707-012 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL HDD RIVER CROSSING SHOWING MAX.SCOUR LEVEL & MIN. COVER FOR PIPE

GGNG-D-20707-013 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL EXISTING PIPE LINE CROSSING

GGNG-D-20707-014 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL AERIAL MARKER DETAILS

GGNG-D-20707-015 0

NTS 01A3 01


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Drawing No. Rev.

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SUBJECT


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NAVIGABLE WATERWAY PIPELINECROSSING WARNING SIGN

GGNG-D-20707-016 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


of

TYPICAL DIRECTION MARKER DETAILS

GGNG-D-20707-017 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL K.M. POST DETAILS

GGNG-D-20707-018 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL PIPE LINE WARNING SIGN DETAILS

GGNG-D-20707-019 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


of

TYPICAL ROW BOUNDARY MARKER

GGNG-D-20707-020 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL CREEK CROSSINGAND TRENCH BREAKER DETAILS

GGNG-D-20707-021 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


of

TYPICAL EROSION CONTROL BANK DETAILS

GGNG-D-20707-022 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL WATER BODY BANK PROTECTION DETAILS

GGNG-D-20707-023 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL PRESSURE TAPPINGS(PA, PG, PC, PT, PIC ETC.)

GGNG-D-20707-024 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


of

TYPICAL RAIN CAP FOR VENT PIPES

GGNG-D-20707-026 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL OPEN CUT RIVER CROSSINGFOR ROCKY TERRAIN

GGNG-D-20707-027 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL SUPPORT FOR BARE PIPE(SIZE 1/2" TO 30")

GGNG-D-20707-028 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL TEMPERATURE CONNECTIONS DETAILS

GGNG-D-20707-031 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL PRESSURE CONNECTIONS DETAILS

GGNG-D-20707-032 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL PROTECTION DETAILS AT HILLY TERRAIN

GGNG-D-20707-033 0

NTS 01A3 01


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL SCRAPER STATION JIB CRANE AND FOUNDATION DETAILS

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PART DESCRIPTION

S. NO. DESCRIPTIONS QTY. MATERIAL

64

3

5

7

1

2


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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VALVE PIT TYPE-IIFOR >4"∅ TO <16"∅ VALVE

GGNG-D-20707-036 0

NTS 01A3 01


Th

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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL OPEN CUT RIVER CROSSING FOR SOFT SOIL TERRAIN

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NTS 01A3 01

TYPE-1

TYPICAL OFC INSTALLATION DETAILS FOR OPEN CUT

ROAD CROSSING, NALA & MINOR CANAL CROSSING,

WHERE CONCRETE SLABS ARE PROVIDED

TYPE-2

TYPICAL OFC INSTALLATION DETAILS IN

BORING & CASED CROSSING FOR RAILWAY CROSSING

TYPE-3


BORING + CASING FOR ROAD & LINED CANAL CROSSING

TYPE-4


OPEN CUT CROSSING FOR

RIVER/NALA/UNLINED CANAL/DRAIN

(WITH OR WITHOUT CONCRETE COATED)

TYPE-5

TYPICAL OFC INSTALLATION DETAILS

IN HDD FOR RIVER CROSSING


Th

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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL DETAILS FOR OFC INSTALLATION

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LIFTING HOOK DETAIL - A


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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL OFC JOINTING PIT / BLOWING PIT DETAILS

GGNG-D-20707-051 0

NTS 01A3 01


Th

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Drawing No. Rev.

Scale SheetSize

SUBJECT


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TYPICAL TRENCH DETAILSIN SANDY/SAND DUNES

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NTS 01A3 01

At the helm of the Energy Transition, Tractebel provides a full range of engineering and consulting servicesthroughout the life cycle of its clients’ projects, including design and project management. As one of the world’slargest engineering consultancy companies and with more than 150 years of experience, it's our mission to activelyshape the world of tomorrow. With about 4,400 experts and offices in 33 countries, we are able to offer ourcustomers multidisciplinary solutions in energy, water and infrastructure.

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LAYING AND ASSOCIATED WORKS FOR ONGC …tender.tractebelindia.com/GAIL ARC Project/8000013032/Vol II...

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