NMDC Limited Hyderabad: Slurry Pipeline, Iron Ore Beneficiation Plant, Pellet Plant and Water Pipeline Project

NMDC LIMITED
HYDERABAD
SLURRY PIPELINE, IRON ORE BENEFICIATION PLANT, PELLET

PLANT AND WATER PIPELINE PROJECT
SLURRY PIPELINE SYSTEM
TECHNICAL SPECIFICATION FOR

EPC CONTRACT FOR LAYING OF SLURRY PIPE LINE AND WATER PIPE LINE
SYSTEM INCLUDING SUPPLY OF COATED PIPE LINES AND ASSOCIATED
FACILITIES
(PACKAGE NO. – SP01)

(VOL - II OF IV)
MECON LIMITED
DELHI
No.MEC/05/28/Q794&Q796/TS/SP01 REV. 04
02/03/2019
SLURRY PIPELINE, IRON ORE BENEFICATION, PELLET
PLANT & WATER PIPELINE PROJECT
EPC Contract for laying of slurry pipe line and water pipe line
NMDC LTD. system including supply of coated pipe lines and associated MECON LIMITED
facilities
Tender Doc. No.: MEC/05/28/Q794&Q796/TS/SP01
CONTENTS
Vol I of IV
Chapter. No. DESCRIPTION Page No.

1.0 Introduction 1-10
2.0 Construction water 11
3.0 Construction power 12-37
4.0 Technological 38-123
4.0B Technological-Procurement 124-187
5.0 Air Conditioning and Ventilation facilities 188-194
6.0 Material handling facilities 195-239
7.0 Civil 240-249
8.0 Steel structure works 250-261
9.0 Power distribution facilities 262-384
10.0 Cathodic Protection, Solar & Corrosion Monitoring system 385-461
11.0 Instrumentation & Control and Communication facilities 462-559
12.0 General layout & Fire Protection facilities 560-584
13.0 Architecture 585-598
14.0 Painting 599
15.0 Packing & Despatch 600
16.0 Erection, site testing & commissioning 601-608
17.0 Project schedule & progress monitoring 609-611
18.0 Performance Guarantee 612-614
19.0 List of drawings and documents to be furnished by the 615-617
tenderer
20.0 Preferred Makes of Equipment 618-629
Annexure I Tender drawings enclosed 630-867
Annexure II Datasheets to be filled by the tenderer & submitted along with 868-1002
the offer
List of Tender Drawings Enclosed (Annexure I)
Sl no Description Drg no. Rev

MECHANICAL DRAWINGS
Schematic route diagram
1. MEC/05/28/Q794/TS/SP01/1001 00
(Bacheli to Nagarnar)
Piping & Instrument diagram
2. symbols & legend abbreviations MEC/05/28/Q794/BE/SP/001 00
& designations
3. symbols & legend equipment & MEC/05/28/Q794/BE/SP/002 00
symbology
4. symbols & legend instrument MEC/05/28/Q794/BE/SP/003 00
identification symbol
5. MEC/05/28/Q794/BE/SP/004 00
symbols & legend instrument
facilities
identification

6. symbols & legend valve & motor MEC/05/28/Q794/BE/SP/005 00
control details
7. MEC/05/28/Q794/BE/SP/006 00
Pump station slurry storage tanks
8. MEC/05/28/Q794/BE/SP/007 00
Pump station slurry storage tanks
9. MEC/05/28/Q794/BE/SP/008 00
Slurry charge pump & test loop
10. Pump station slurry mainline MEC/05/28/Q794/BE/SP/011 00
pump & PIG launcher
11. MEC/05/28/Q794/BE/SP/013 00
Sump & stations
12. MEC/05/28/Q794/BE/SP/014 00
Milk of Lime System
13. Slurry Pipeline Pressure MEC/05/28/Q794/BE/SP/016 00
Monitoring Stations
14. MEC/05/28/Q794/BE/SP/017 00
Pipeline Terminal Choke Station
15. Pipeline Terminal Slurry Storage MEC/05/28/Q794/BE/SP/018 00
Tank
16. Pipeline Terminal Slurry Transfer MEC/05/28/Q794/BE/SP/019 00
Pumps
17. MEC/05/28/Q794/BE/SP/020 00
Gland Seal Pumps
18. MEC/05/28/Q794/BE/SP/021 00
Sump, Pump & Dump Pond
19. Legend for P&ID MEC/05/28/Q794/BE/WP/0000 01
P&ID for Water System at MEC/05/28/Q794/BE/WP/3000

20. 03
bacheli
P&ID for PMS Installed Enroute
MEC/05/28/Q794/BE/WP/2000
21. Cross Country Water P/L from 03
Nagarnar to bacheli
P&ID for Water System at MEC/05/28/Q794/BE/WP/1000
22. 03
Nagarnar
MEC/05/28/Q794 &
23. General Layout of Bacheli 00
Q796/TS/SP01/1000
Equipment Location Plan Mine MEC/05/28/Q794 &
24. 00
Site Pump Station Q796/TS/SP01/1001
facilities
Equipment Location Plan Mine MEC/05/28/Q794 &

25. 00
Site Pump Station Section-A Q796/TS/SP01/1002
Piping layout Mine Site Pump MEC/05/28/Q794 &
26. 00
Station overall piping plan Q796/TS/SP01/1003
Piping layout Mine Site Pump
MEC/05/28/Q794 &
27. Station slurry storage tank area 00
Q796/TS/SP01/1004
upper plan
MEC/05/28/Q794 &
Q796/TS/SP01/1005
lower plan
MEC/05/28/Q794 &
Q796/TS/SP01/1006
Sht-4
30. 00
Station slurry pipeline Q796/TS/SP01/1014
31. 00
Station tank area lower Section-B Q796/TS/SP01/1015
32. 00
Station tank area - Section-C Q796/TS/SP01/1016
GA of Water Pump House at MEC/05/28/Q796/SP/15/BE/100
33. 00
Bacheli 2
MEC/05/28/Q794 &
34. General Layout of Nagarnar 00
Q796/TS/SP01/3000
Equipment Location pipeline MEC/05/28/Q794 &
35. 00
terminal plan view Q796/TS/SP01/3003
Equipment Location pipeline MEC/05/28/Q794 &
36. 00
terminal section A&B Q796/TS/SP01/3002
Piping Layout Pipeline Terminal MEC/05/28/Q794 &
37. 00
Overall piping plan Q796/TS/SP01/3001
38. 00
Choke area plan view sheet -1 Q796/TS/SP01/3004
39. 00
Choke area plan view sheet -2 Q796/TS/SP01/3005
40. 00
tank area plan view sheet -1 Q796/TS/SP01/3006
41. 00
42. 00
43. 00
tank area upper plan view Q796/TS/SP01/3009
44. 00
45. 00
facilities

46. 00
47. 00
48. 00
piping to and from ponds Q796/TS/SP01/3014
49. 00
Choke Loop Sections Q796/TS/SP01/3015
50. 00
tank drains & overflows Q796/TS/SP01/3016
51. 00
sections F,G,H & J Q796/TS/SP01/3017
52. 00
Section-K Q796/TS/SP01/3018
Main water pump house at
53. MEC/Q796/05/28/M/000/001 00
Nagarnar Area
GA Layout of NISP Reservoir MEC/05/28/Q796/SP01/SP/15/B
54. 00
Water Pump House E/2002
Route scheme showing raw
water pipeline from NISP to pellet
plant & slurry pipeline & water
55. pipeline pertaining to bacheli MEC/11/14/Q79A/BA-NA/001 02
Plant and location of culverts
below NISP Railway track and
road
Typical Plot Plan for pressure
56. MEC/05/28/Q796/TS/SP01/2001 00
monitoring station (PMS) (4 Nos.)
Railway CASED Crossing
57. MEC/05/28/Q796/TS/SP01/2002 00
Drawing at Chainage : 36.865 km
58. Drawing at Chainage : 107.101 MEC/05/28/Q796/TS/SP01/2003 00
km
59. Drawing at Chainage : 124.483 MEC/05/28/Q796/TS/SP01/2004 00
km
MEC/TYP/05/21/01A/001
60. Typical Right of use for Pipeline 00
(Page 1 of 3)
Typical Trench Dimensions for MEC/TYP/05/21/01A/002
61. 00
pipe lines
Typical Trench Dimensions for
MEC/TYP/05/21/01A/003
62. two or more pipelines in common 00
trench
Detail of trench dimension &
MEC/TYP/05/21/01A/004
63. back filling for U/G Pipe Lines In 00
Seismic Zone
facilities
Select Backfill for station

MEC/TYP/05/21/01A/005
64. approach and buoyancy control 00
measures for pipelines
65. Slope Stabilization in Hilly Areas MEC/TYP/05/21/01A/006 00
66. Typical Slope Breaker Details MEC/TYP/05/21/01A/007 00
Minimum Elastic Bend Radius for

67. MEC/TYP/05/21/01A/009 00
Pipe
Detail and casing vent and drain
68. MEC/TYP/05/21/01A/010 00
off
69. Pipeline Symbols MEC/TYP/05/21/01A/011 00
70. Topographic Symbols MEC/TYP/05/21/01A/012 00

Location of specimens for weld
MEC/TYP/05/21/02/001
71. procedure qualification for pipe 00
diameter < 12 ¾
Location of specimens for weld
MEC/TYP/05/21/02/002
72. procedure qualification for pipe 00
diameter < 12 ¾
MEC/TYP/05/21/02/003
73. ISO Tensile Test Specimen 00
Hardness Testing of weld Joints

74. MEC/TYP/05/21/02/004 00
– Schematic
75. Charpy V- Notch Test Specimen MEC/TYP/05/21/02/005 00
Calibration piece for ultrasonic

76. MEC/TYP/05/21/02/006 00
equipment
Required IQI Sensitivity Source
77. MEC/TYP/05/21/02/007 00
Side Pentameter
78. Typical Stream Crossing MEC/TYP/05/21/04/001 00
Pipeline road / highway CASED

79. MEC/TYP/05/21/05/001 00
Crossing
80. Typical Detail of railway crossing MEC/TYP/05/21/05/002 00
Typical lined Canal incased

81. MEC/TYP/05/21/05/003 00
crossing detail
Typical lined Canal cased
82. MEC/TYP/05/21/05/004 00
crossing detail
Existing underground pipe
83. MEC/TYP/05/21/05/006 00
crossing type-I
Existing underground pipe
84. MEC/TYP/05/21/05/007 00
crossing type-II
facilities
85. Underground cable crossing MEC/TYP/05/21/05/008 00
86. Overhead power line crossing MEC/TYP/05/21/05/009 00
87. Typical ROW boundary marker MEC/TYP/05/21/10/001 00
88. K.M. Post MEC/TYP/05/21/10/002 00
89. Pipeline Warning sign MEC/TYP/05/21/10/003 00
Navigable water way pipeline

90. MEC/TYP/05/21/10/004 00
crossing warning sign.
91. Aerial Marker MEC/TYP/05/21/10/005 00
92. Direction Marker MEC/TYP/05/21/10/006 00
93. Tolerances for fabrication MEC/TYP/05/21/06/001 00
Pipe Clamp for Bare Pipe Size

94. MEC/TYP/05/21/06/028 00
½” thru 24” Type – C1
Pipe Clamp for Bare Pipe Size
95. MEC/TYP/05/21/06/029 00
½” thru 24” Type – C16
U Bolt for Bare Line Size ½” thru
96. MEC/TYP/05/21/06/031 00
24” type – C4
97. Butt Weld Details MEC/TYP/05/21/06/034 00
Welding of pipe with different

98. MEC/TYP/05/21/06/035 00
Thickness
99. Fillet weld details MEC/TYP/05/21/06/036 00
100. Gasket thickness MEC/TYP/05/21/06/037 00
Stud Bolts RF 150# Dimensions

101. MEC/TYP/05/21/06/038 00
(ASME B16.5)
102. MEC/TYP/05/21/06/039 00
(ASME B16.5)
103. MEC/TYP/05/21/06/040 00
(ASME B16.5)
ARCHITECTURE DRAWINGS
Control Room Building for NISP MEC/05/48/Q794/SP01/TD/ARC 0
Reservoir pump house /001
1.
Ground floor plan & schedule of
finishes and openings
facilities
Control Room Building for NISP MEC/05/48/Q794/SP01/TD/ARC 0

2. Reservoir pump house /002
Elevation and section
Electrical & Control Room MEC/05/48/Q794/SP01/TD/ARC 0
Building at Nagarnar /003
3.
Ground floor plan, elevation &
schedule of openings
Electrical & Control Room MEC/05/48/Q794/SP01/TD/ARC 0
Building at Nagarnar /004
4.
First floor plan & schedule of
openings
Pressure Monitoring Station MEC/05/48/Q794/SP01/TD/ARC 0
Plan, elevation, section & /005
5.
schedule of finishes and
openings
CIVIL DRAWINGS
MEC/05/11/Q794& Q796/TS/SP-
1. Detail of Boundary Wall 00
01/0001
MEC/05/11/Q794& Q796/TS/SP-
2. Typical Detail of Valve Pit 00
01/0002
MEC/05/11/Q794& Q796/TS/SP-
3. Typical Detail of RCC Pavement 00
01/0003
Typical Details Of RCC MEC/05/11/Q794& Q796/TS/SP-
4. 00
Pavement & Pedestals 01/0004
MEC/05/11/Q794& Q796/TS/SP-
5. Typ. Details Of Sleeper Support 00
01/0005
Layout Plan & Section Of Slurry MEC/05/11/Q794& Q796/TS/SP-
6. 00
Dump Pond (Sheet 2 Nos.) 01/0006
Layout Plan & Section Of Culvert MEC/05/11/Q794& Q796/TS/SP-
7. 00
01/0007
Over Head Water Tank For 450 MEC/05/11/Q794& Q796/TS/SP-
8. 00
Cum, 35 M. Staging 01/0008
Bituminous Road Typical Cross MEC/05/11/Q794& Q796/TS/SP-
9. 00
Section 01/0009
MEC/01/14/Q77J/TS/PP-
10. Site levelling at Nagarnar 00
01/0001
Site levelling at Nagarnar, Details MEC/01/14/Q77J/TS/PP-
11. 00
of section A-A & B-B 01/0002
MEC/11/14/Q79A/BP01/BP/50/D
12. Site Levelling Plan Bacheli 00
E/0001
Layout and section of slurry MEC/05/11/Q794&
13. 00
dump pond at Nagarnar Q796/SP01/SP/35/CM/0005
General arrangement and details MEC/05/11/Q794&
14. 00
of earthen reservoir compartment Q796/SP01/SP/35/CM/0006
facilities
STRUCTURAL DRAWINGS
Water pump house at Bacheli
Plan of columns at base, typical
MEC/05/12/Q794/TS/SP-
1. cross section, base plate detail, 0
01/0001
DET A, B, C longitudinal
elevation of column
Gable end walling for axis 1 & 4, MEC/05/12/Q794/TS/SP-
2. 0
walling along rows, plan of roof 01/0002
bracing and plan of purlins
Plan elevation of U/S crane
MEC/05/12/Q794/TS/SP-
3. beam, plan of end P/F EPF-1, 0
01/0003
BKT-1, Detail of HR-1, CAT
ladder, louvre
DG shed at Bacheli
Plan of columns at base, typical MEC/05/12/Q794/TS/SP-
4. 0
cross section, & plan of roof, 01/0004
base plate detail
DG shed at Bacheli
Plan and detail of monorail
MEC/05/12/Q794/TS/SP-
5. beam, walling and longitudinal 0
01/0005
elevation rows A, B , plan of
purlin and gable end walling
Nagarnar
Plan of column at base, typical MEC/05/12/Q794/TS/SP-
6. 0
cross section, base plate detail, 01/0008
detail A, B, C, longitudinal
elevation of column
Nagarnar MEC/05/12/Q794/TS/SP-
7. 0
Gable and walling for axis 1 & 01/0009
10, walling along rows
Nagarnar MEC/05/12/Q794/TS/SP-
8. 0
Plan of roof bracing and plan of 01/0010
purlins
Nagarnar
Plan elevation of U/S crane MEC/05/12/Q794/TS/SP-
9. 0
beam, plan of end P/F EPF-1, 01/0011
BKT-1, Detail of HR-1, cat
ladder, louvre
Typical Detail of steel gate for
10. MEC/05/12/Q794/TS/SP01/1001 0
boundary wall (4.0m wide)
INSTRUMENTATION DRAWINGS
facilities
System Architechture For

Instrumentation , Telecom And
1. 00
SCADA System In Pipeline
Control Room, Nagarnar
Installation diagram for Pressure
2. MEC/05/E5/SD/PT/001 00
Transmitter
3. MEC/05/E5/SD/PG/004 00
Gauge
4. Support Details For Junction Box MEC/05/E5/SD/JB/009 00
Instrument Support Single

5. MEC/05/E5/SD/IS/010A 00
Instrument
Instrument Support Two
6. MEC/05/E5/SD/IS/010 B 00
Instrument
Fabricated Canopy for
7. MEC/05/E5/SD/CY/011 00
Instruments
Perforated Tray Supports &
8. MEC/05/E5/SD/CBLY/012 00
Cable Clamping details
9. Transmitter W Remote Seal & MEC/05/E5/SD/PT/015A 00
Isolation Valve for slurry service
Installation diagram for Typ.
Pressure Gauge W Remote Seal
10. MEC/05/E5/SD/PG/018A 00
& Isolation Valve for slurry
service
Installation diagram for Typ.
11. Differential Pressure Transmitter MEC/05/E5/SD/DPT/022 00
for slurry service
Installation diagram for Ultrasonic
MEC/05/E5/SD/ULT/023
12. Level 00
Transmitter
Installation diagram for Flow /
13. MEC/05/E5/SD/IS/024 00
Indicator Switch
Installation diagram for Magnetic
14. Flowmeter (For water & slurry MEC/05/E5/SD/FM/025 00
service)
TELECOMMUNICATION DRAWINGS
Standard drawing optical fiber
1. cable laying (separate trench) MEC/05/E5/T/002 A 00
(OFC through HDPE)
Standard drawing optical fiber
2. cable laying (separate trench) MEC/05/E5/T/005 A 00
(OFC through HDPE)
Optical fiber cable laying (cassed
3. MEC/05/E5/T/008 00
crossing) (2 nos. HDPE Duct)
facilities
Standard sketch OFC joining pit /

4. MEC/05/E5/T/009 00
blowing pit
5. OFC joint marker MEC/05/E5/T/010 00
Standard sketch for optical fiber
6. cable laying (common warning MEC/05/E5/T/02-WM- A 00
mat)
Wiremesh for optical fiber cable
7. MEC/05/E5/T/016 00
termination
ELECTRICAL DRAWINGS
Illumination battery limit diagram MEC/05/E9/Q794/SP01/BL- 01
1.
of slurry pump house at Bacheli SP/29/BE/0009, sheet 1 of 3
Illumination battery limit drawing MEC/05/E9/Q794/SP01/BL- 00
of slurry receipt station and SP/29/BE/0009, sheet 2 of 3
2.
return water pump house at
Nagarnar
Illumination battery limit drawing MEC/05/E9/Q794/SP01/BL- 00
3. of NISP intake water pump SP/29/BE/0009, sheet 3 of 3
house
Cable routing diagram of slurry MEC/05/E9/Q794/SP01/CR- 01
4.
pumping station at Bacheli SP/29/BE/0010, sheet 1 of 3
Cable routing diagram of slurry MEC/05/E9/Q794/SP01/CR- 00
5. receipt station and return water SP/29/BE/0010, sheet 2 of 3
pump house at Nagarnar
Incoming Cable route diagram of MEC/05/E9/Q794/SP01/CR- 00
6. NISP intake water pump house SP/29/BE/0010, sheet 3 of 3
at Nagarnar
Block diagram for UPS System,
7. Rectifier and ACDB / DCDB MEC/SD//05/E9/071/01 00
Legends of Single line diagram MEC/05/E9/Q794/SP02/SP/29 00

8.
/TS/001,002 Sheet 1 of 2
Notes for Single line diagram MEC/05/E9/Q794/SP02/SP/29 00
9.
/TS/001,002 Sheet 2 of 2
Single Line Diagram of PMCC-01 MEC/05/E9/Q794/SP02/SP/29/T 01
10. for slurry pumping station at S/002, sheet 1 of 2
Bacheli
Single Line Diagram of PMCC-02 MEC/05/E9/Q794/SP02/SP/29/T 01
11. for slurry pumping station at S/002, sheet 2 of 2
Bacheli
Single line diagram of HT MCC 00
MEC/05/E9/Q794&Q796/SP01/S
12. for slurry & return water pumping
P/29/TS/0004 (2 sheets)
station at Nagarnar
Single line diagram of LTSS for 01
MEC/05/E9/Q794&Q796/SP01/S
13. slurry and return water pumping
P/29/TS/0005
station at Nagarnar
facilities
Single Line Diagram of PMCC for MEC/05/E9/Q794&Q796/SP01/ 01

14. NISP reservoir pump house at WP/29/TS/006
Nagarnar
Single line diagram for power MEC/05/E9/Q794&Q796/SP- 00
15.
distribution board for PMS station 01/SP/29/TS/003, sheet 1 of 2
Single line diagram for lighting MEC/05/E9/Q794&Q796/SP- 00
16.
distribution board for PMS station 01/SP/29/TS/003, sheet 2 of 2
Single line diagram for CSS at MEC/05/E9/Q794&Q796/SP- 00
17. Nagarnar 01/CP-SP/29/TS/0008, sheet 1
of 6
Single line diagram for Feeder MEC/05/E9/Q794&Q796/SP- 00
pillar (Typical) of construction 01/CP-SP/29/TS/0008, sheet 2
18. power for slurry pumping & water of 6
pumping station at Bacheli,
Nagarnar & NISP
Single line diagram for Feeder MEC/05/E9/Q794&Q796/SP- 00
pillar (Typical) of construction 01/CP-SP/29/TS/0008, sheet 3
19. power for slurry pumping & water of 6
pumping station at Bacheli,
Nagarnar & NISP
Single line diagram for LDB MEC/05/E9/Q794&Q796/SP- 00
(Typical) of construction power 01/CP-SP/29/TS/0008, sheet 4
20.
for slurry pumping at Nagarnar & of 6
NISP
Construction power cable routing MEC/05/E9/Q794&Q796/SP- 00
21. drawing for slurry and water 01/CP-SP/29/TS/0008, sheet 5
package at Nagarnar of 6
Construction power cable routing MEC/05/E9/Q794&Q796/SP- 00
22. drawing for intake water package 01/CP-SP/29/TS/0008, sheet 6
at Nagarnar of 6
MEC/05/E9/Q794&Q796/SP01& 00
23. Cable trench detail (Typical)
SP02/SP&WP/29/TS/0011
SOLAR SYSTEM DRAWINGS
Typical block diagram of solar MEC//05/E9/Q794&Q796/SP01/
1. 01
power system with grid charger SPV-SP/29/TS/013
CP SYSTEM DRAWINGS
1. Electrode for Earthing System MEC/SD//05/26/23/01 00
2. Earth Electrode in Test Pit MEC/SD//05/26/23/02 00
3. Pre-packed Zinc Anode MEC/SD/05/E9/E/CP/1601 01
4. Pre-packed Magnesium Anode MEC/SD/05/E9/E/CP/1602 01
Magnesium Ribbon Anode For

5. MEC/SD/05/E9/E/CP/1603 01
Grounding
6. Details of Test Station for TCP MEC/SD/05/E9/E/CP/1604 01
facilities
(2 Sheets)
Test Station Connection MEC/SD/05/E9/E/CP/1605,
7. 01
Schemes (4 Sheets)
8. Galvanic Anode Installation MEC/SD/05/E9/E/CP/1606 01
Zinc Ribbon Anode For Cased
9. Crossings With Coated Casings MEC/SD/05/E9/E/CP/1607 01
Pipeline Grounding Through MEC/SD/05/E9/E/CP/1608

10. Polarisation Cells and Galvanic (2 SHEETS) 01
Anode
11. Detail Of Zinc Grounding Cell MEC/SD/05/E9/E/CP/1609 01
Permanent Copper – Copper
12. Sulphate Reference Cell & MEC/SD/05/62/16/10 00
Installation Details
MEC/SD/05/E9/E/CP/1611
13. Shallow Anode Ground Bed (PCP) 01
(3 SHEETS)
MEC/SD/05/E9/E/CP/1612
14. Anode Lead Junction Box 01
(2 Sheets)
15. Casing Pipe Details MEC/SD/05/E9/E/CP/1613 01
Details of Test Station For MEC/SD/05/E9/E/CP/1614

16. 01
Polarization Cell (2 Sheets)
17. Deep Well Anode Bed MEC/SD/05/E9/E/CP/1615 01

Connection Scheme For Hooking
18. Through CJB / Test Station MEC/SD/05/E9/E/CP/1616 01
Details of Thermit Weld For Cable

19. MEC/SD/05/E9/E/CP/1618 01
To Pipe Joint
MATERIAL HANDLING DRAWINGS

Clearance diagram for hand
MEC/05/P4/Q794&Q796/SP-
1. operated travelling chain pulley 00
01/SP/55/TS/0001
blocks
Clearance diagram for hand
MEC/05/P4/Q794&Q796/SP-
2. operated travelling chain pulley 00
01/SP/55/TS/0002
blocks
Clearance diagram for 7.5 T MEC/05/P4/Q794&Q796/SP-
3. 00
electric hoist 01/SP/55/TS/0003
Clearance diagram for 7.5 T MEC/05/P4/Q794&Q796/SP-
4. 00
electric hoist 01/SP/55/TS/0004
Clearance diagram for 5 T electric MEC/05/P4/Q794&Q796/SP-
5. 00
hoist 01/SP/55/TS/0005
Clearance diagram single girder MEC/05/P4/Q794&Q796/SP-
6. 00
under slung crane CAP.-2T 01/SP/55/TS/0006
facilities

7. 00
under slung crane CAP.-5T 01/SP/55/TS/0007
8. 00
under slung crane CAP.-12.5T 01/SP/55/TS/0008
DATASHEETS TO BE FILLED BY THE TENDERER &

SUBMITTED ALONG WITH THE OFFER Enclosed (Annexure II)
Sl no. Description
Mechanical Datasheets
1. TANK AGITATOR
2. MILK OF LIME PLANT
3. SLURRY BALL VALVES (CLASS 600 DN 600)
4. SLURRY BALL VALVES (CLASS 600 DN 250)
5. KNIFE GATE VALVE
6. SLURRY STORAGE TANK
7. SLURRY TERMINAL TRANSFER PUMP
Instrumentation Datasheets
1. TERMINAL SERVER
2. HOOTER CUM STROBE
3. LEVEL SWITCH
4. JUNCTION BOX AND CABLE GLANDS
5. SIGNAL CABLE (SINGLE PAIR)
6. SIGNAL CABLE (MULTI PAIR) / RTD CABLE
7. CONTROL CABLE (THREE CORE) CABLE
8. CONTROL CABLE (MULTI CORE)
9. POWER CABLE (THREE CORE & MULTI CORE)
10. OPTICAL FIBER CABLE (SMF)
11. PCs
12. LASERJET PRINTER
13. DOT MATRIX PRINTER
14. ETHERNET SWITCH
15. PANELS AND CONSOLES
16. DATASHEET OF PRESSURE TRANSMITTER (DIAPHRAGM SEAL
TYPE)
17. DATASHEET OF PRESSURE TRANSMITTER (DIRECT TYPE)
Electrical Data sheets
1. Data sheet for MOV actuator
2. Data Sheet for UPS
3. 6.6 KV HT Switchboard
4. Circuit Breakers
5. 11kV & 6.6kV MV CABLES - XLPE
6. Power and control cable - XLPE
7. Control cable
8. DC battery bank(SMF/FLOODED)
facilities
9. Battery charger
10. AC/DC distribution board
11. Variable Frequency Drive
12. Electric Motor
13. Convertor Transformer
14. Distribution Transformer
15. Illumination System
16. Diesel Generator Set
Solar System Data sheets
1. SOLAR PHOTO VOLTAIC (SPV) POWER SUPPLY SYSTEM
CP System Data Sheets
1. CATHODIC PROTECTION TRANSFORMER RECTIFIER (TR) UNIT
2. CATHODIC PROTECTION POWER SUPPLY MODULE (CPPSM)
Note: Drawings listed above and contained in Page no. 630-867 are not uploaded
due to large size and interested bidders have to collect the CDs containing
drawings either from the office of MECON or NMDC from the address
mentioned in the NIT.
02.03.19 4 Hitesh Manju, SDE A K Jha, DGM Amit Gangal, DGM

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23.03.16 0 Dinesh Kumar Sinha, SDE Sunil Kumar, AGM Amit Gangal, DGM
Date Rev. No. PREPARED BY CHECKED BY APPROVED BY

facilities
CONTENTS
VOLUME-II OF IV
I) TECHNICAL SPECIFICATIONS
A. TECHNICAL SPECIFICATION FOR MECHANICAL WORKS
Sl Description Specification No Page No.

No
1. Specification for Mainline Construction 1-44

MEC/S/05/28/01
(Onshore)
2. Specification for Welding of Onshore MEC/S/05/28/02 45-102

Pipelines and WSC
3. Specification for Hydrostatic Testing of MEC/S/05/28/03 103-123

Onshore Pipeline
4. Specification for major water Crossings 124-137

MEC/S/05/28/04
(Conventional)
5. Specification for Pipeline Crossing Roads, 138-148

MEC/S/05/28/05
Railroads, Minor Water and Other
Crossings
6. Specification for Piping Fabrication and MEC/S/05/28/06 149-212
Erection
7. Specification for Shop and Field MEC/S/05/28/07 213-269

Painting
8. Specification for Repair of Pipeline 270-275

MEC/S/05/28/08
Corrosion Coating
9. Specification for Pipeline Markers 276-281
MEC/S/05/28/10
10. Specification for Flushing and Testing MEC/S/05/28/11 282-292

of Piping Systems
11. Specification for Casing Insulators and End MEC/S/05/28/12 293-299

Seals
12. Specification for Field Joint Coating MEC/S/05/28/13 300-315

(Onshore Pipelines)
13. Specification for Vents, Drains and MEC/S/05/28/15 316-323
Wells
14. Specification for Blasting MEC/S/05/28/18 324-335
15. Specification for Gaskets, Bolts and MEC/S/05/28/19 336-342

Nuts
facilities
16. Specification for Pipeline Information MEC/S/05/28/20 343-350

Management System (PIMS)
17. Specification for Warning Mats MEC/S/05/28/42 351-356
18. Specification for Health, Safety and MEC/S/05/28/65 357-418

Environment Management (HSE)
19. Specification for Quality Assurance MEC/S/05/28/66 419-428

System Requirements
20. Specification for Documentation of MEC/S/05/28/69 429-437

Pipeline Construction
21. Specification for Calliper Pigging MEC/S/05/28/70 A 438-447
22. Specification for Field Joint Coatings of MEC/S/05/28/74 448-463

Pipeline for HDD Crossing
23. Specification for Pipeline Crossings Using MEC/S/05/28/75 464-477

HDD Method
24. Piping Material Specification - Slurry 478-516

pipelines
101176-S-M-014
(M/s Ausenco basic engineering
document on PMS)
25. Piping Material Specification - Water MEC/05/28/ Q794/000/1092 517-532

pipelines
26. Technical Specification for Pre- MEC/05/28/ Q794/000/1093 533-541

Commissioning and Commissioning of
slurry & water of pipelines
27. Specification for Seamless Fittings and MEC/TS/05/21/025A 542-548

Flanges [Size up to DN 400mm (16")
NB]
28. Specification for Seamless Fittings and MEC/TS/05/21/026A 549-557

Flanges [SIZE DN 450 mm (18”) AND
ABOVE]
29. Technical Notes for Procurement of Items MEC/05/28/Q794/001/NOTES 558-564

for Slurry and Return Water Pipelines
30. Technical Specification of Assorted pipes MEC/TS/05/62/59A 565-569
31. Technical Specification of Long Radius MEC/TS/05/62/015 570-578

Bend
32. Technical Specification of Scrapper trap MEC/S/05/62/007 579-591

facilities
33. Technical Specification of Check valves MEC/TS/05/62/004 592-600
34. Technical Specification of Basket Filter & MEC/TS/05/62/017A 601-610

Accessories
35. Technical Notes for Gate & Globe 611-616

Valve
36. Technical specification for Horizontal 101176-S-M-009 617-633

Centrifugal Slurry Pump
37. Technical Specification for Slurry Valves & 101176-S-M-007 634-658

Actuator
38. Specification for Ball Valves MEC/TS/05/21/002 659-678
39. Specification for submerged arc MEC/TS/05/21/012B 679-720

longitudinal welded (SAWL) line pipe
40. Specification for submerged arc helical 721-764
MEC/TS/05/21/012C
welded
(SAWH) line pipe
41. Specification for 3-LPE Coating MEC/S/05/21/014 765-800
42. Amendments to line pipe and coating 801-803

technical specification
43. Techniical speciifiication for Fire 804-832

Fiighting
44. Technical Specification for fire detection 833-911

and alarm system & telecommunication
system

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facilities
CONTENTS
VOLUME-III OF IV
A. TECHNICAL SPECIFICATION FOR TELECOM WORKS

No
1. Technical specification for

MEC/05/E5/NMDC/TS-097 1-79
telecommunication systems
2. REMOTE TELEMETRY UNITS (RTU)
80-90
SPECIFICATIONS
3. SCADA SYSTEM SPECIFICATIONS
MEC /05/E5/T/ Q794&Q796 91-125
/SCADA
4. SYSTEM FUNCTIONAL REQUIREMENTS

126-150
of SCADA System
5. FEP Server System SPECIFICATION
MEC /05/E5/T/ 151-163
Q794&Q796/Sys-094
6. TECHNICAL SPECIFICATION
164-169
FOR
FEP Server PANEL
7. SPECIFICATION FOR LASERJET
170
PRINTER
8. SPECIFICATION FOR CHAIR
171
9. Technical Specification permanently 172-191

MEC/TS/05/E5/T/037 A
lubricated Telecom HDPE Duct and
Accessories for pipelines
10. Technical Specification for Optical Fibre 192-212
MEC/TS/05/E5/T/096 A
Cable & Associated Items for pipelines
11. Specification for Optical Fibre Cable & 213-239
MEC/S/05/E5/T/001 A
HDPE Duct Laying & Associated Works
12. Specification/ Procedure for Optical Fibre MEC/S/05/E5/T/002 A 240-247
Cable Testing
B. INSTRUMENTATION SPECIFICATION

No
1. Specification for Instrument Tubing MEC/S/05/E5/02 248-253
2. Specification for Instrument Tube Fittings MEC/S/05/E5/04 254-258
3. Specification for Instrument Valves and MEC/S/05/E5/05 259-264

Manifolds
facilities
4. Specification for Junction Box and Cable MEC/S/05/E5/06 265-271

Gland
5. Specification for Pressure Measurement MEC/S/05/E5/09 272-277
6. Specification for Instrument Cable MEC/S/05/E5/10 278-288
7. General Requirements For MEC/S/05/E5/12 289-307

Instrumentation
Specification for Flow Controllers and flow 308-311
8. MEC/S/05/E5/13
indicating switches
Specification for Field Instruments : 312-327
9. MEC/S/05/E5/14
Installation, Calibration and Pre-operational
Testing
Specification for Instruments Furnished 328-341
10. MEC/S/05/E5/15
with Engineered Equipment
11. Specification for Electromagnetic MEC/S/05/E5/16 342-349

Flowmeters
12. Specification for Nuclear density MEC/S/05/E5/17 350-356

measurement System
13. Specification for Temperature MEC/S/05/E5/18 357-361
measurement
14. Specification for Ultrasonic Level MEC/S/05/E5/19 362-368

Measurement
15. Specification for Level Point Switches MEC/S/05/E5/20 369-372
16. Specification for Cabling MEC/S/05/E5/21 373-387
17. Specification for Control Valves MEC/S/05/E5/22 388-392
18. Specification For Earthing and lightning MEC/S/05/26/23A 395-405

Protection
19. Specification for energy management system 406-419
20. Specification for PLC System 420-431
21. Specification for tank farm management 432-439

systems (TFMS)
22. Specification for master control station 440-443

(MCS)
23. Technical specification for Pipeline leak MEC/S/05/E5/T/Q794/099L 444-456

detection system (LDS)
facilities
C. ELECTRICAL WORKS
No
Technical Specification for Maintenance Free 457-462
1. MEC/S/05/E9/02A
Earthing System
Technical Specification for Electrical 463-478
2. MEC/S/05/E9/SPE
Equipment Furnished with Packaged
Mechanical Equipment
3. Technical Specification For Variable MEC/S/05/E9/033 479-496
Frequency Drives And Motors Design
Technical specification for Electrical motor 497-508
4. MEC/S/05/E9/010
operated valve actuators
5. Technical specification for Un-interrupted MEC/S/05/E9/071 509-519
power supply (ups) system
6. Specification for Ni-Cd Battery MEC/S/05/E9/071C 520-525
7. Specification for Solar Photovoltaic MEC/S/05/E9/078 526-546

(SPV) power supply System
8. Technical specification for Diesel MEC/S/05/E9/DG 547-600

Generator Set
D. CATHODIC WORKS
No
1. Specification for Corrosion Survey 601-607

MEC/S/05/21/16C
2. Specification for Temporary Cathodic 608-632

MEC/TS/05/E9/ 016A
Protection System
3. Specification for Permanent Cathodic 633-664
MEC/TS/05/E9/ 016B
Protection System
4. Specification for Cathodic Protection Power 665-675
MEC/TS/05/E9/ 082
Supply Module
5. Specification for Cathodic Protection 676-687
MEC/TS/05/E9/ 082A
Transformer Rectifier Unit
E. CIVIL & STRUCTURAL WORKS
No
Technical Specification for Civil Works 688-831
1.
2. Specification for Anti Buoyancy Measures 832-846

MEC/S/05/11/03
3. Specification for Dewatering 847-850

MEC/S/05/11/04
4. Specification for Shoring and Strutting 851-854

MEC/S/05/11/05
facilities
5. Specification for sheet Piling 855-860

MEC/S/05/11/06
6. Specification for Geo-Synthetics 861-870

MEC/S/05/11/07
7. Specification for Well Point System 871-874

MEC/S/05/11/08
8. Specification for Bored Cast in situ End 875-887

MEC/S/05/11/09
Bearing Piles
9. Specification for Under Ream Piles 888-900
MEC/S/05/11/10

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facilities
CONTENTS
VOLUME-IV OF IV PART-A
A. SURVEY DOCUMENTS AND DRAWINGS
Sl Description Document/Drawing No. Page No.

No
1. Survey report for kirandul to nagarnar 01-130

NMDC/A/OSR/R1
2. Hydrographic and Geotechnical XPL/1252/D & XPL/1252/F2 131-488

Investigation report
3. Topographical area survey report NMDC/A/ASR/2 & 489-554
NMDC/A/ASR/3
4. Corrosion Survey report 555-598
5. Soil investigation report 599-1003
6. PDI report NMDC/A/PDI/1 1004-1029
Note: Drawings and documents listed above and contained in Page no. 01-1029
are not uploaded due to large size and interested bidders have to collect the
CDs containing drawings and documents either from the office of MECON or
NMDC from the address mentioned in the NIT.

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facilities
CONTENTS
VOLUME-IV OF IV PART-B
A. SURVEY DOCUMENTS AND DRAWINGS
Sl Description Document/Drawing No. Page No.

No
1. Alignment Sheets 01-110
2. Crossing Sheets 111-140
3. Forest Compartment Map 141-146
4. Land Use Map 147-152
5. Route Map 153-155
6. Slope Map 156-160
7. Seismotectonic Map 161-162
Note: Drawings listed above and contained in Page no. 01-162 are not uploaded
due to large size and interested bidders have to collect the CDs containing
drawings either from the office of MECON or NMDC from the address
mentioned in the NIT.

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MECON LIMITED STANDARD TECHNICAL SPECIFICATION OF MAINLINE
DELHI CONSTRUCTION (ONSHORE)
SPECIFICATION NO : MEC/S/05/28/01
REV 0, EDITION - 1
OIL & GAS SECTION SERVICE – GAS/LIQUID/SLURRY
TECHNICAL SPECIFICATION
FOR
MAINLINE CONSTRUCTION (ONSHORE)
TECHNICAL SPECIFICATION NO.:

MEC/S/05/28/01
PREPARED AND ISSUED BY
MECON LIMITED
DELHI 110 092
KRISHNA PATEL SHALINI SINGH

0 15.10.2015 FIRST ISSUE SUNIL KUMAR
HARDEEP SINGH ABHISHEK AGGARWAL
REV DATE DESCRIPTION PREPARED BY CHECKED BY APPROVED BY
1 of 911
REV 0, EDITION - 1
CONTENTS
SL.NO. DESCRIPTION
1.0 SCOPE
2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS
3.0 REQUIREMENTS OF R.O.U. AND ACCESS THERETO
4.0 RIGHT-OF-WAY
5.0 HANDLING, HAULING, STRINGING AND STORING OF MATERIALS
6.0 TRENCHING
7.0 BENDING
8.0 LINING UP
9.0 LAYING OF PIPE
10.0 BACK-FILLING
11.0 TIEING-IN
12.0 SPECIAL INSTALLATIONS ON THE PIPELINE
13.0 WORKING SPREAD LIMITATIONS
14.0 CLEAN-UP AND RESTORATION OF RIGHT-OF-WAY
15.0 MAINTENANCE DURING DEFECTS LIABILITY PERIOD
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REV 0, EDITION - 1
AMENDMENT STATUS
Sl. Clause / Paragraph / Page Rev. Date By Verified

No. Annexure / Exhibit / No.
Drawing Amended Name Sig. Name Sig.
3 of 911
REV 0, EDITION - 1 Page 1 of 41
1.0 SCOPE
1.1 This specification covers the minimum requirements for the various activities to be
carried out by CONTRACTOR for or about the construction of cross-country pipelines.
1.2 The various activities covered in this specification include the following works of
pipeline construction:
 Clearing, grubbing and grading of Right-of-way
 Construction of all temporary facilities required in connection with the WORKS
 Staking of the pipeline route
 Handling, hauling, stringing and storing of all materials
 Trenching
 Field-bending of line pipe
 Lining-up
 Pipeline laying
 Backfilling
 Tieing-in
 Installation of auxiliary facilities and appurtenances forming a part of pipeline

installation
 Clean-up and restoration of Right-of-way;
 Maintenance during defects liability period.
1.3 This specification shall be read in conjunction with the conditions of all specifications
and documents included in the CONTRACT between COMPANY and CONTRACTOR.
1.4 CONTRACTOR shall, with due care and vigilance, execute the work in compliance with
all laws, by-laws, ordinances, regulations etc. and provide all services and labour,
inclusive of supervision thereof, all materials, excluding the materials indicated as
"COMPANY Supplied materials" in the CONTRACT, equipment, appliances or other
things of whatsoever nature required in or about the execution of the work, whether of
a temporary or permanent nature.
1.5 CONTRACTOR shall take full responsibility for the stability and safety of all operations
and methods involved in the WORK.
1.6 CONTRACTOR shall be deemed to have inspected and examined the work area(s) and
4 of 911
its surroundings and to have satisfied himself so far as practicable as to the form and
nature thereof, including sub-surface conditions, hydrological and climatic conditions,
the extent and nature of the WORK and materials necessary for the completion of the
WORK, and the means of access to the work area(s).
1.7 CONTRACTOR shall be deemed to have obtained all necessary information subject as
above mentioned as to risks, contingencies and all other circumstances, which may
influence the WORK.
1.8 CONTRACTOR shall, in connection with the WORK, provide and maintain at his own
costs, all lights, guards, fencing, watching etc., when and where necessary or required
by COMPANY 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.
2.1 Reference has been made in this specification to the latest edition of the following
codes, standards and specifications :
a) ANSI B 31.8 - Gas Transmission and Distribution Piping

Systems
b) ANSI B 31.4 - Pipeline Transportation System for Liquids and

Slurries (ANSI B31.4)
c) API 1104 - Standard for Welding Pipelines and Related

Facilities
d) API 1105 - Bulletin on Construction Practices for Oil and

Products Pipelines
e) Part 1992 - Transportation of Natural and Other Gas

Title 49 by Pipeline (US Department of Transportation -
Pipeline Safety Standards)
f) Part 195 - Transportation of Liquids by Pipeline (US

Department of Transportation - Pipeline Safety
Standards).
g) OISD 226 - Natural Gas Transmission Pipelines and City Gas

Distribution Networks
h) OISD 141 - Design, Construction And Inspection requirements

For Cross Country Liquid Hydrocarbon Pipelines
In case of differences between the requirements of this specification and that of the above referred
codes, standards and specifications, the requirements of this specification shall govern.
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2.2 For the purpose of this specification the following definitions shall hold:
 the words "Shall" and "Must" are mandatory.
 the works "Should, "May" and "Will" are non-mandatory, advisory or

recommended.
3.0 REQUIREMENTS OF R.O.U. AND ACCESS THERETO
CONTRACTOR shall, before starting any clearing operations, familiarise himself with all
the requirements of the Authorities having jurisdiction over the Right of Way for work
along the pipeline route or in connection with the use of other lands or roads for
construction purpose.
CONTRACTOR shall notify COMPANY well in advance during work progress, the
method of construction for crossing road, pipeline, cable, railway, river and other
existing obstacles.
CONTRACTOR shall not commence work on such crossings before having obtained
approval from the authorities and land owners concerned to the satisfaction of
COMPANY. The crossings shall be installed to meet at all times the requirements and
conditions of the permit issued by the authorities concerned. In the absence of any
specific requirements by authorities, CONTRACTOR shall comply with COMPANY'S
instructions.
The right of ingress and egress to the ROW shall be limited to points where such ROW
intersects public roads, Arrangements for other access required by the CONTRACTOR
shall be made by him at his own cost and responsibility, and for such access, the
conditions of this specifications shall also apply.
Where the ROW comes within 30 metres of an existing line or facility, CONTRACTOR
shall propose and provide methods to safe-guard the existing line or facility (e.g. a
demarcation fence). No work is allowed in such area without COMPANY's prior
approval.
3.1 Safety measures during construction of pipelines inside the area influenced
by high voltage lines
3.1.1 General
Pipelines which are constructed inside the area of high voltage lines may be electrically
influenced by the high voltage lines. The voltage caused by the influence may at times
be high enough to pose danger to personnel working on the pipeline. It is imperative
therefore, that the instructions given below should be strictly observed.
3.1.1.1 It is a necessity that all personnel working on the pipeline which is being laid in the
area influenced by the high voltage systems, be given clear instructions on measures
to be taken.
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3.1.1.2 Vehicles and equipment must be earth-connected. This may be effected by attaching
an uninsulated cable or chain (which touches the ground) of adequate length to the
underside of the vehicle.
3.1.1.3 If its not impossible for plant and/ or materials to come within 50m of the centre of the
high voltage systems, special measures must be taken to prevent any approach
beyond that distance, unless article 3.1.2 is complied with.
3.1.1.4 DURING THUNDERSTORMS OR WHEN DISCHARGES ARE OBSERVED ON INSULATORS

ALL PERSONNEL MUST LEAVE THE AREA OF THE HIGH VOLTAGE LINE AND
PIPELINE.
3.1.1.5 To prevent electrical voltage in a non-buried section of the pipeline from rising to
dangerous levels, the length of the pipeline section which has been welded together
before burial must not exceed the length at which the max. admissible voltage may be
induced. This length may be calculated using an approved calculation method.
3.1.1.6 Before a pipeline section is lowered into the trench the structure's earth electrodes
indicated in the drawings or determined with calculation method must have been
installed and connected both to the pipeline section already buried and to the section
which is about to be buried. The electrical connections which serve the purpose of
preventing dangerous voltages must have a min. area of 35mm2.
Said connections must not be interrupted until after the permanent safety earth
connections have been installed and connected to the entire uninterrupted pipeline.
3.1.1.7 The welded connection between the pipeline section and the section already buried
must be installed at a distance of at least 50m from the nearest point of a pylon base.
3.1.1.8 Personnel doing work inside the area of influence of the high voltage system must
wear electrically insulating foot-wear (e.g. rubber kneeboots) and wear insulating
rubber or plastic gloves.
3.1.2 Additional measures for work at less than 50m from the centre of the high
voltage system.
If work is done at less than 50m from the centre of the high voltage system, the
regulations below must be complied with in addition to the rules specified in clause
3.1.1.
3.1.2.1 The work must not be started until agreement has been reached with the authorities
which controls the high voltage system, about the implementation of the safety
measures specified in this section.
3.1.2.2 Measures must be taken to prevent excavating and hoisting equipments from
approaching high voltage lines to within any of the following distances.
This distance depends on the voltage carried. For individual connections the distance
7 of 911
must be :
0 - 50 KV 3m
40 - 200 KV 5m
200 - 380 KV 8m
The measures taken may be as follows :
1. Special selection of equipment, or limiting or blocking certain directions of

movement, or limiting the operational area, thereby making it impossible for
any work to be done at a distance from the high voltage line of less than the
accepted minimum.
2. In case the measures recommended in 1. above are not feasible, installation of

clearly visible markers of sufficient height or laying out a "no passage beyond
this point" line of drums painted bright red and white must prevent any work
being done inside the danger area. Further, an inspector must be present all
the time.
3.1.2.3 In the event that a vehicle, crane etc. should accidently come into contact with a live
cable of a high voltage system or flash-over of electrical charge occurs, the driver must
not leave his vehicle because this will pose a serious threat to his life.
The vehicle or crane must break the contact WITHOUT ANY HELP FROM OUTSIDE.
The driver must not leave his vehicle untill be has managed to leave "the dangerous
area, or alternatively, when the Electricity Authorities have given notice that the
cable(s) have been put out of circuit. In case a serious fire starts in the vehicle, he is
permitted to jump from the vehicle, clearing it as far as possible, while the jump
should possible be to a dry spot.
4.0 RIGHT-OF-WAY
The CONTRACTOR is required to perform his construction activities within the width of
Right-of-way set aside for construction of pipeline, unless he has made other
arrangements with the land owner and/ or tenant for using extra land. Variation in this
width caused by local conditions or installation of associated pipeline facilities or
existing pipelines will be identified in the field or instructed to the CONTRACTOR by
COMPANY.
The ROW boundary lines shall be staked by the CONTRACTOR, so as to prepare the
strip for laying the pipeline. CONTRACTOR shall also establish all required lines and
grades necessary to complete the work and shall be responsible for the accuracy of
such lines and grades.
4.1 Staking
Prior to cleaning operations CONTRACTOR shall :
8 of 911
1) Install Bench Marks, Intersection Points and other required survey movements.
2) Stake markers in the centreline of the pipeline at distance of maximum 100

metres for straight line sections and maximum 10 metres for horizontal bends.
Wherever ROW centreline has been staked on ground, CONTRACTOR shall
exercise care in accurately staking the pipeline centreline, in consultation with
COMPANY.
3) Stake two ROW markers at least at every 100 metres.
4) Set out a reference line with respect in pipeline centreline at a convenient

location. Markers on reference line shall be at a distance of maximum 100m for
straight line sections and maximum 10m for horizontal bends.
5) Install distance markers locating and indicating special points, such as but not
limited to :
 Contract limits, obstacle crossings, change of wall thickness, including

corresponding chainage, etc.
ROW markers shall be staked out at the boundary limits of Right-of-way wherever
possible. ROW markers shall be painted red with numbers painted in white. Number
shall be identical to centreline marker number with letters A (left side) and B (right
side) added, (looking, in flow direction). Reference markers shall also carry the same
information as its corresponding centreline markers.
Markers shall be of suitable material so as to serve their purpose and shall be coloured
distinctly for easy identification. CONTRACTOR shall be responsible for the
maintenance and replacement of the reference line markers until the permanent
pipeline markers are placed and the as-built drawings are submitted and approved.
Any deviation from the approved alignment shall be executed by CONTRACTOR after
seeking COMPANY approval in writing prior to clearing operations.
4.2 Monuments
All shrines, monument, border stones, stone walls and the like shall be protected and
shall be subjected to no harm during construction. Any violation of the above by the
CONTRACTOR shall be brought to the notice of the COMPANY and other concerned
authorities. Restoration of the above shall wholly be the responsibility of the
CONTRACTOR.
4.3 Fencing
Prior to clearing or grading of the Right-of-way or stringing of pipe, CONTRACTOR shall

open fences on or crossing the construction Right-of-way and install temporary gate of
sound construction made of similar materials and suitable quality to serve purpose of
original fence. Adjacent post shall be adequately braced to prevent slackening of the
remainder of the fence. Before such fences are cut and opened, CONTRACTOR shall
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notify the land owner or tenant, and where practicable, the opening of the fences shall
be in accordance with the wishes of said owner and tenant. In all cases where
CONTRACTOR removes fences to obtain work route, CONTRACTOR shall provide and
install temporary fencing, and on completion of construction shall restore such fencing
to its original condition.
CONTRACTOR shall install temporary fencing on either side of ROW where in

COMPANY's opinion, it is considered essential to ensure safety and non-interference,
especially in areas like grazing lands, villages etc.
Fencing shall be removable type wherever necessary, to permit crossing of traffic. The
type of fencing must be suitable for the situation in accordance with user. The pole
distance shall not be greater than 6m. The minimum height of the fencing shall be
1.2m above grade. Fencing can consist of one or more rows of smooth wire and/ or of
barbed wire.
Fencing shall be continuously maintained and the thorough-ways inspected to be shut

during the execution of the work.
4.4 Row Clearing and Grading
4.4.1 All stumps shall be grubbed for a continuous strip, with a width equal to trench top
width plus two metres on either side centred on the pipeline centreline. Further, all
stumps will be grubbed from areas of the construction Right-of-way, where Right-of-
way grading will be required. Outside of these areas to be graded and the mentioned
trench strip, at the option of CONTRACTOR, the stumps may either be grubbed or cut
off to ground level. Any stump cut off must be left in a condition suitable for rubber-
tyred pipeline equipment traffic.
4.4.2 All grubbed stumps, timber, bush undergrowth and root cut or removed from the
Right-of-way shall be disposed of in a manner and method satisfactory to COMPANY,
land-owner and/ or tenant, and Government Authorities having jurisdication and as
soon as practical after the initial removal. In no case, it shall be left to interfere with
the grading and laying operations. Whenever stumps are grubbed and a hole is left in
the ground, CONTRACTOR shall back-fill the hole and compact it to prevent water from
gathering in it and creating a big hole.
4.4.3 CONTRACTOR shall grade the pipeline Right-of-way as required for proper installation
of the pipeline, for providing access to the pipeline during construction, and for
ensuring that the pipeline is constructed in accordance with the good engineering and
construction practices.
4.4.4 CONTRACTOR shall grade sharp points or low points, without prejudice to section 6.0
of this specification, to allow the pipe to be bent and laid within the limits set forth in
these specifications and drawings as regards the minimum elastic curvature permitted,
and shall drill, blast or excavate any rock or other material which cannot be graded off
with ordinary grading equipment in order to make an adequate working space along
the pipeline.
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4.4.5 No temporary or permanent deposit of any kind of material resulting from clearing and
grading shall be permitted in the approach to roads, railways, streams, ditches,
drainage ditches and any other position which may hinder the passage and/or the
natural water drainage.
4.4.6 The Right-of-Way clearing and grading operations shall in no case involve embankment
structures of any type and class without prior approval of the authorities having
jurisdiction over the same.
4.4.7 In the case of natural or artificial deposits of loose soil, sand, heaps of earth, or other
fill materials, these shall be removed till stable natural ground level is reached so as to
ensure the construction of the pipeline ditch is in stable ground.
4.4.8 In the case of Right-of-Way clearing and grading on hillside or in steep slope areas,
proper barriers or other structures shall be provided to prevent the removed materials
from rolling downhill. The Right-of-Way cross fall shall not exceed 10%.
4.4.9 Wherever the pipeline Right-of-Way runs across plantations, alongside farmyards, built
up areas, groups of trees, horticultural spreads, gardens, grass-fields, ditches, roads,
paths, railways or any other area with restrictions of some kind, CONTRACTOR shall
grade only the minimum area required for digging and constructing the pipeline. In the
said places, CONTRACTOR shall carry out the works in such a way that damage done
from the pipeline construction is kept to a minimum.
4.5 Provision of Detours
CONTRACTOR shall do all necessary grading and bridging at road, water and other
crossings and at other locations where needed, to permit the passage of its men and
equipment. It is understood that the CONTRACTOR has recognised such restrictive
features of the Right-of-Way and shall provide the necessary detours and execute the
works without any extra cost to COMPANY. Public travel shall not be inconvenienced
nor shall be wholly obstructed at any point.
CONTRACTOR at his own cost shall furnish and maintain watchman detours, lanterns,
traffic lights, barricades, signs, wherever necessary to fully protect the public.
CONTRACTOR shall be responsible for moving its equipment and men across or around
watercourses. This may require the construction of temporary bridges or culverts.
Temporary bridging or access to fording required for Right-of-Way crossing water
courses shall be constructed. CONTRACTOR shall ensure that such temporary works
shall not interfere with normal water flow, avoid overflows, keep the existing
morphology unchanged and shall not unduly damage the banks or water courses. 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 COMPANY a copy of such approval.
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4.6 Steep and Rocky Terrain
Grading operations could normally be carried out along the Right-of-way with
mechanical excavators or manually. In certain areas, grading may have to be resorted
to exclusively by blasting.
In rough or steep terrain, CONTRACTOR may have to grade access roads and
temporary bypass roads for its own use. Where such access roads do not fall on the
Right-of-Way, CONTRACTOR shall obtain necessary written permission from land
owners and tenants and be responsible for all damages caused by the construction and
use of such roads, and at no extra cost to COMPANY, Wherever rocky terrain is
encountered, grading shall be carried out in all types of solid rocks which cannot be
removed until loosened by blasting, drilling, wedging or by other recognised means of
quarrying solid rocks.
Where use of explosives is required in connection with Right-of-Way grading and

trenching, CONTRACTOR shall comply fully with requirements of the use of explosives
as provided under clause 6.3 of this Specification.
4.7 Off Right-of-Way Damages
CONTRACTOR shall confine all its operations within limits of the Right-of-Way. Any
damage to property outside ROW shall be restored or settled to the CONTRACTOR's
account.
CONTRACTOR shall promptly settle all off Right-of-Way damage claims. Should
CONTRACTOR fail to do so, COMPANY shall give written notice to CONTRACTOR that if
CONTRACTOR does not settle such claims within seven days after such notice,
COMPANY shall have the authority to settle claims from the account of the
CONTRACTOR.
5.0 HANDLING, HAULING, STRINGING AND STORING OF MATERIALS.
5.1 General
The CONTRACTOR shall exercise utmost care in handling in pipe and other materials.
CONTRACTOR shall be fully responsible for all materials and their identification until
such time that the pipes and other materials are installed in permanent installation.
CONTRACTOR shall be fully responsible for materials, however, method of storage
shall be approved by COMPANY.
CONTRACTOR shall reimburse the COMPANY for the cost of replacement of all
COMPANY supplied materials damaged during the period in which such materials are in
the custody of the CONTRACTOR. It shall be CONTRACTOR's responsibility to unpack
any packing for the materials supplied by COMPANY.
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5.1.2 "Taking Over" of Line Pipe
The following stipulations shall apply in case CONTRACT provides for supply of line
pipe, bare and/or corrosion coated, by COMPANY.
CONTRACTOR shall receive and 'take over' against requisition, line pipe from the
COMPANY's designated place(s) of delivery as defined in the CONTRACT.
CONTRACTOR shall perform visual inspection of the bare pipes and coating of the
corrosion coated pipes, as the case may be, in the presence of COMPANY and all
damages shall be recorded. In the case of corrosion coated pipes CONTRACTOR at his
option may carry out holiday detection at a prescribed set voltage and record such
holidays, in the presence of COMPANY, at the time of 'taking over'. However, if
CONTRACTOR proposes to perform only visual inspection of coating, then repair of all
holidays found at the time of laying the pipeline shall be carried out by the
CONTRACTOR at no extra cost to COMPANY. The CONTRACTOR shall be entitled to
extra compensation for repair and rectification of defects recorded at the time of taking
over as per the rate set forth in the "CONTRACT". Repair of all damages after taking
over the delivery of the materials shall be to the CONTRACTOR'S cost. In case of delay
in handing over of COMPANY supplied material, CONTRACTOR shall be fully
responsible for stopping and rearranging means of transportation at no extra cost to
the COMPANY.
5.2 Handling and Hauling of Line Pipe
5.2.1 Bare Pipe
CONTRACTOR shall unload, load, stockpile and transport the bare pipes using suitable
means and in a manner to avoid denting, flattening, or other damage to pipes. Pipe
shall not be allowed to drop or strike objects which will damage the pipe but shall be
lifted or lowered from one level to another by suitable equipment. Lifting hooks when
used, shall be equipped with a plate curved to fit the curvature of the pipe. In loading
pipe on trucks each length shall be lowered to position without dropping and each
succeeding length shall rest on special supports on the truck and shall be separated
from the adjacent pipes. After loading, suitable chains and padding shall be used to tie
the load securely to each bolster. Pipes, when stock piled, shall be placed on suitable
skids to keep them clear of the ground and flood water. The CONTRACTOR shall
provide all necessary timber or other materials required for the stock-piling. While
stacking, the number of allowable layers of bare pipes shall be calculated as per API
RP5L1 and shall be agreed with COMPANY. The stacks must be properly secured
against sliding and shall consist of pipes of the same diameter and wall thickness.
Adjacent stacks of pipes having different dimensional characteristics shall be clearly
separated.
Pipes which are damaged at the time of delivery or "taking-over" (when line pipe is
supplied by COMPANY), particularly those which are dented, buckled, or otherwise
permanently deformed, must be stacked separately and may be transported to the
sites only when these defects have been repaired or eliminated.
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5.2.2 Corrosion Coated Pipes
The CONTRACTOR shall load, unload, transport and stockpile the coated pipes using
approved suitable means and in a manner to avoid damage to the pipe and coating.
CONTRACTOR shall submit to the COMPANY, a complete procedure indicating the
manner and arrangement used for handling and stacking of coated pipes for COMPANY
approval prior to commencement of handling operations.
Use of vaccum lifting equipments are preferred. Hooks may also be used for handling
the pipes provided they have sufficient width and depth to fit the inside of the pipe and
covered with soft material like rubber, teflon or equivalent, so as not to cause damages
to bevel or pipe ends. During hoisting, cables/wire ropes shall have sufficient
inclination compared to pipe axis so that they do not come into contact with external
coating.
Coated pipes may be handled by means of slings and belts of proper width (minimum
60mm) made of non-metallic/non - abrasive materials. In this case, pipes to be
stacked shall be separated row by row to avoid damage by rubbing the coated surface
in the process of taking off the slings. Use of round sectional slings are prohibited.
During handling, suitable handling equipment with proper length of booms shall be
used. Fork lifts may be used provided that the arms of the fork lift are covered by
suitable pads preferably rubber. Before lifting operations it is essential to ensure that
the pipe surface is free from foreign material with sharp edges. Belts/slings when used
shall be cleaned to remove hard materials such as stone, gravel etc. Coated pipes
shall not be bumped against any other pipe or any other objects. Rolling, skidding or
dragging shall be strictly forbidden.
Coated pipes at all times shall be stacked completely clear from the ground so that the
bottom row of pipes remain free from any surface water. The pipes shall be stacked at
a slope so that driving rain does not collect inside the pipe.
The coated pipes at all times shall be stacked by placing them on ridges of sand free
from stones and covered with a plastic film or on wooden supports provided with
suitable cover. This cover can, for example, consist of dry, germ free straw with a
plastic film, otherwise foam rubber may be used. The supports shall be spaced in such
a manner so as to avoid permanent bending of the pipes, particularly in case of small
diameter pipes with low wall thickness. The pipes shall be stacked so that the
uncoated bevelled ends are in line at one end thus making differences in length clearly
noticeable.
Stacks shall consist of limited number of layers so that the pressure exercised by the
pipe's own weight does not cause damages to the coating. Each pipe section shall be
separated by means of spacers suitably spaced for this purpose. Stacks shall be
suitably secured against falling down and shall consist of pipe sections having the same
diameter and wall thickness. The weld bead of pipes shall be positioned in such a
manner so as not to touch the adjacent pipes.
Coated Pipes stacked in open storage yards/dump yards shall be suitably covered on
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top to decrease direct exposure to sunlight.
The ends of the pipes during handling and stacking shall always be protected with
bevel protecters.
The lorries/rail wagons shall be equipped with adequate pipe supports having as many
round hollow beds as the number of pipes to be placed on the bottom of the lorry bed.
Supports shall be provided for at least 10% of the pipe length. These supports shall be
lined with a rubber protection and shall be spaced in a manner as to support equal
load from the pipes. The rubber protection shall be free from all nails and staples
where pipes are in contact. The second layer and all subsequent layers shall be
separated from other layers with adequate number of separating layers of protective
material such as straw in plastic covers or otherwise to avoid direct touch between the
coated pipes.
All stachions of lorries/rail wagons used for transportation shall be covered by non-
abrasive material like rubber belts or equivalent. Care shall be exercised to properly
cover the top of the stanchions and convex portions such as reinforcement of the
truck/rail wagon only, rivets etc. to prevent damage to the coated surface.
5.3 Stringing of Pipe
Pipes shall be unloaded from the stringing trucks and lowered to the ground by means
of boom tractor or swinging crane or other suitable equipment using lifting devices as
mentioned earlier. Dragging or sliding of pipe shall not be permitted. Special
precaution shall be taken during stringing of corrosion coated pipe as per the special
requirements of previous para. Stringing of pipe shall only be carried out in daylight
and after clearing and grading operations have been completed. Pipes shall not be
strung along the ROW in rocky areas where blasting may be required, until all blasting
is completed and the area cleared of all debris.
The stringing of the pipe on the ROW shall be done in such a manner so as to cause
the least interference with the normal use of the land crossed and to avoid damage to
and interference with the pipes. The sequence of pipes must be interrupted at suitable
intervals, spaced to coincide with passages, roads, railways, water crossings as well as
at other places if requested by landowner / tenants to permit use of land.
In case line pipe supply is by different manufacturers, CONTRACTOR shall string all line
pipes of one manufacturer before commencing the stringing of line pipes of another
manufacturer.
When parallel pipelines are being constructed, bumping against and contact with the
strung sections of pipe shall be avoided, whether the stringing of the pipes for the
individual lines is carried separately or simultaneously.
The pipe lengths shall be properly spaced in order to make easier the handling during
the welding phase.
It shall be the responsibility of the CONTRACTOR to see that pipe is strung as per the
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approved drawings for the proper placement of pipe by size, thickness, grade and
other specifications. Any additional handling of pipes due to failure to comply with the
requirements shall be at the CONTRACTOR's expense.
5.4 Repair of Damaged pipes
After the pipes have been strung along the ROW, they shall be inspected by the
CONTRACTOR and by the COMPANY. All defective pipe ends shall have to be repaired
as per the directions of the COMPANY or as per the requirements of this specification.
5.5 Materials other than linepipe
CONTRACTOR shall receive and take over against requisition all COMPANY supplied
materials from COMPANY's designated place(s) of delivery as defined in the
CONTRACT. CONTRACTOR shall perform visual inspection and defects, if any noted,
shall be recorded separately. The CONTRACTOR shall be entitled to extra
compensation for repair and rectification of such defects at the rates set forth in the
"CONTRACT".
The CONTRACTOR shall perform the necessary loading, unloading, hauling from points
designated by the COMPANY and storing, if necessary, of all materials. The
CONTRACTOR shall exercise care in handling, storing and distribution of materials in
order to avoid damage and deterioration of these materials and prevent their theft or
loss.
Materials excluding line pipe shall be stored in sheltered storages. Such materials shall
not be strung on the Right-of-Way but shall be transported in covered conveyances
for use only at the time of installation.
CONTRACTOR shall ensure that all valves and whenever applicable, other materials are
fitted with suitable end covers of the type approved by COMPANY. Materials with
worked surfaces such as flanges, pipe fittings, etc. must be stacked and handled so as
to avoid contact with the ground or with substances that could damage them.
The manufacturer's instructions regarding temperature and procedure for storing

materials which are subject to alteration of the original properties and characteristics
did to unsuitable storage must be strictly complied with and, if required, an adequate
heat conditioning shall be provided for these materials.
When supplied in containers and packages they must not be thrown or dropped, not
handled using hooks which could damage the container or the materials, either during
loading/unloading or during successive handling, until their final use.
Storage of coating materials which are susceptible to deterioration or damages

especially due to humidity, exposure to high thermal cconditions or other diverse
weather conditions, shall be suitably stored and protected. These materials shall be
kept permanently in store, supported above the ground in a dry place, protected
against the weather and transported for use only at the time and in quantities
necessary for immediate application. Deteriorated materials shall not be used and
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replaced with no extra cost to COMPANY.
5.6 Identification
CONTRACTOR shall provide all pipes, bends, etc. greater than 2" with serial numbers
as soon as possible and measure their length and state is on the pipes, etc. Pipes to be
bent shall be measured prior to bending. Identification (i.e. letter, number and length)
shall be indelible.
All serial numbers shall be recorded in a list, which shall also state appurtenant pipe
numbers.
Beside recording the stamped - in pipe numbers, length of pipe and painted-on serial
numbers, the stamped-in numbers of T-pieces, bends, valves, etc. and the batch
numbers of bends, T-pieces, valves, etc. and the make of valves, shall also be
recorded in said list.
Before a pipe length, pipe end, etc. is cut the painted serial number and stamped-in
pipe number shall be transferred by CONTRACTOR in the presence of COMPANY to
either side of the joint which is to be made by cutting, and the changes shall be
recorded in the above mentioned list stating the (new) length. The results shall be
such that all pipes, pups, etc. of diameter greater than 2" bear clear marks painted on.
CONTRACTOR shall explicitly instruct his staff that parts which cannot be identified
must not be removed, except after permission by COMPANY.
As a general rule parts must be marked as described above before being moved. In no
conditions may unmarked parts be incorporated into the WORK.
6.0 TRENCHING
6.1 Location
CONTRACTOR shall, excavate and maintain the pipeline trench on the staked center
line of the pipeline taking into account the curves of the pipeline.
6.2 Excavation
6.2.1 CONTRACTOR shall, by any method approved by COMPANY, dig the pipeline trench on
the cleared and graded Right-of-Way. In cultivable land and other areas specifically
designated by the COMPANY, top 60mm of the arable soil on the pipeline trench top
and 500mm on either side shall be excavated and stored separately to be replaced in
original position after backfilling and compacting rest of the trench.
Suitable crossing shall be provided and maintained over the open ROW where
necessary, to pemit general public, property owners or his tenants to cross or move
stock or equipment from one side of the trench to the other.
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Care shall be exercised to see that fresh soil recovered from trenching operation,
intended to be used for backfilling over the laid pipe in the trench, is not mixed with
loose debris or foreign material. The excavated material shall never be deposited over
or against the strung pipe.
6.2.2 In steep slope area or on the hillside, before commencing the works, proper barriers or
other protection shall be provided to prevent removed materials from rolling downhill.
6.2.3 On slopes where there is danger of landslide, the pipeline trench shall be maintained
open only for the time strictly necessary. Forever, the COMPANY may require
excavation of trench by hand, local route detours and limiting the period of execution
of the works.
6.2.4 In certain slope 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.
6.2.5 All sewers, drains ditches and other natural waterways involved in the execution of the
works shall be maintained open and functional. The same applies to canals, irrigation
canals, pipelines and buried facilities crossed by the ditch for which temporary pipeline
shall be laid, if required, and proper temporary installations provided.
6.3 Blasting
Blasting for trenching and the related removal of scattered rock and debris caused by
the blasting from the Right-of-Way and/or adjacent property, shall be performed by
CONTRACTOR as part of his work.
Every possible precaution shall be taken to prevent injuries and damages to persons
and properties during blasting operations, which shall be performed in accordance with
Standard Rules for Blasting.
CONTRACTOR shall obtain necessary permits for storage and use of explosives and
comply with the laws, rules and regulations of the respective Governmental agencies
having jurisdiction thereof. No blasting will be allowed without prior and due notice
given by CONTRACTOR to COMPANY, Government authorities, land-owners, property
occupants, adjacent work crew, and other concerned parties.
CONTRACTOR shall employ only such workmen who are experienced in the type of
work to be performed, to supervise, handle and use explosives.
6.3.1 Areas to be blasted are to be categorised as follows:
a) Where blasting is to be carried out beyond 50 meters away from any existing
pipeline or structures (either above or below ground) the CONTRACTOR shall
submit his proposed blasting procedure and perform a trial blast for
COMPANY's approval.
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b) Where blasting is to be carried out between 50 and 15 meters from any

existing pipeline or structure (either above or below ground) the CONTRACTOR
shall submit a procedure for controlled blasting e.g. break-holes, slit trench etc.
which will also detail out safety precautions to safeguard the existing pipelines.
This procedure will be approved by COMPANY prior to commencement and
performing of trial blasting.
c) No blasting is allowed within 15 metres of any existing pipeline or structure

(either above or below around).
6.3.2 All necessary precautions shall be taken to prevent stones from falling outside the
Right-of-way and in cultivated areas and to avoid any damage to the installation and
properties existing nearby.
6.3.3 Blasting and removal of debris shall be carried out prior to stringing the pipes.
6.3.4 Ground vibration due to blasting near the existing structures shall be continuously
monitored using certified instruments to be provided by CONTRACTOR and approved
by COMPANY and the peak particle velocities shall not exceed 50 mm/ sec.
COMPANY reserves the right to refuse blasting where possible danger exists to
property, existing utilities or other structures. In such locations other methods of
extracting rock shall be proposed by CONTRACTOR and shall be approved by
COMPANY.
6.4 Normal Cover and Trench Dimensions
The trench shall be excavated to a minimum so as to provide, on both sides of the

installed pipeline, a clearance as indicated in the job standard/ drawings and to a
depth sufficient to provide the minimum cover as indicated below. The dimensions in
the table below shall govern except as noted herein or as shown on the job standards
or detailed construction drawings or as required by authorities having jurisdiction,
whichever is greatest. Minimum depth of cover shall be measured from the top of pipe
corrosion/ concrete weight coating (as applicable) to the top of undisturbed surface of
the soil or top of graded working strip or top of road or top of rail whichever is lower.
Fill material in working strip shall not be considered to add to the depth of cover.
However, surface of fill material placed to fill hollows may be used to determine the
depth of cover subject to prior approval by COMPANY.
a) For Natural Gas pipelines-
Sl. No. Locations Minimum cover

in Meters
i Areas of agricultural, horticultural activity, limited or 1.0
no human activity, Industrial, commercial and
residential Area
ii Rocky Terrain 1.0
iii Drainage, Ditches at roads/ railway crossing 1.0
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Iv Minor river crossings/canal/drain/nala/ditches 1.5

v Major river crossings (below scour level) 2.5
vi River with rocky bed (below scour level) 1.5
vii Area under influence of tides 1.5
viii Cased/ Uncased road Crossing 1.2
viii Cased railway crossing 1.7
b) For Liquid/slurry pipelines-
Sl. No. Locations Minimum cover in

Meters
i Industrial, commercial, residential , cultivated, 1.2 (for Normal Soil)
agricultural and barren areas 1.5 (For rocky strata)
ii Minor water crossings/canal/drain/nala/ditches 1.5 (for Normal Soil)
1.0 (For rocky strata)
iii HDD Crossings rivers (below scour depth) 2.5
iv HDD Crossings at canals (below scour depth) 4.0
v River crossings (below scour)-open cut 2.5 (for Normal Soil)
1.0 (For rocky strata)
vi Cased/ Uncased road Crossing/station approach 1.2
vii Cased railway crossing 1.7
viii Marshy land/ Creek Area 1.5
Notes:
(i) The depth of cover shall be measured from the top of the pipe coating 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) The cover shall be measured from the top of road or top of rail, as the case may be;
(iii) For river/watercourses that are prone to scour and erosion, adequate safe cover
shall be provided below the predicted scour profile expected during the life time of
the pipeline;
(iv) When scour level is not known, an additional cover of at least 1 m shall be provided
from the existing bed of the river/water course except in case of Rocky River bed.
(v) The minimum cover requirements shall be applicable for all Location Classes;
(vi) Whenever the above provisions of cover cannot be provided due to site constraints,
additional protection in form of casings, bridging, etc. shall be provided.
(vii) Soft soil/sand padding of minimum 150 mm thickness to be provided around the pipe
where gravel or hard soil is encountered. In case of rocky areas rock-shield along
with 150 mm of soft soil / sand padding around the pipe should be provided.
(viii) 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.
(ix) In case the pipeline is to be laid through populated area (which otherwise could not
be avoided), additional protective measures to be provided be by way of providing
higher wall thickness pipe or laying at a greater depth or by providing casing pipe.
(x) In case pipeline is located within 1.5 m from any dwelling unit, the cover shall be
increased by 300 mm over and above that specified.
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6.5 Cutting and Removal of Paving
Whenever it is permitted by Authorities and / or COMPANY to open cut a paved road

crossing, or where the line is routed within the road pavement, CONTRACTOR shall
remove the paving in accordance with the restrictions and requirements of the
authorities having jurisdiction thereof or as directed by COMPANY. The open cut for
the road crossing shall be carried out only when the section of pipeline to be laid is
complete. After laying the pipeline, backfilling shall be immediately performed and all
the area connected with the works shall be temporarily restored.
Throughout the period of execution of such works, CONTRACTOR shall provide and
use warning signs, traffic lights or lanterns, barricades, fencing, watchman, etc. as
required by the local authorities having jurisdiction and/ or COMPANY.
For all roads, paths, walkway etc. which are open-cut, CONTRACTOR shall provide
temporary diversions properly constructed to allow the passage of normal traffic with
the minimum of inconvenience and interruptions.
The paving shall be restored to its original condition after the pipeline is installed.
6.6 Extra Depth and Clearance
At points where the contour of the earth way require extra depth to fit the minimum
radius of the bend as specified or to eliminate unnecessary bending of the pipe
according to customary good pipeline practice, or where a deep trench is required at
the approaches to crossings of roadways, railroads, rivers, streams, drainage ditches,
and the like, CONTRACTOR shall excavate such additional depth as may be necessary
at no extra cost to the COMPANY.
CONTRACTOR shall excavate to additional depth where the pipeline approaches and
crosses other pipelines, sewers, drain pipes, water mains, telephone, conduits, and
other underground structures, so that the pipeline may be laid with at least 50
centimeters free clearance from the obstacle or as specified in the drawings, or such
greater minimum distances as may be required by authorities having jurisdiction.
Where the pipeline crosses areas, whose easements specifically require greater than
normal depths of cover, the trench shall be excavated to extra depth in accordance
with the Right-of-way Agreements or as required.
CONTRACTOR shall excavate all such additional depths as may be necessary at no

extra cost to the COMPANY.
6.7 Grades, Bends and Finish of Trench
The trench is to be cut to a grade that will provide a firm, uniform and continuous
support for the pipe. Bends shall be made in the pipe at significant changes in grade of
the trench. COMPANY reserves the right to set the grade of the trench and locate the
bends if so desired, in which case CONTRACTOR shall excavate, at no extra cost, the
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trench and bend the pipe to such a grade. COMPANY 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 aproaches to crossings. Such trenching work shall be done by CONTRACTOR
at no extra cost to the COMPANY.
COMPANY intends that there will be a minimum of hand grading of the trench bottom.
However, to achieve this, CONTRACTOR will have to dig as square a bottom of the
trench as possible with his equipment. This in part can be obtained by adjusting and
adopting the crumbling shoe and digging teeth of the trenching machines and by use
of a drag behind the trenching machines or manually dressing-up the same.
CONTRACTOR shall do such hand work in the trench as is necessary to free the
bottom of the trench from loose rock and hard clods and to trim protruding roots from
the bottom and side walls of the trench.
6.8 Padding
In all cases where rock or gravel or hard soil is encountered in the bottom of the
trench, COMPANY will decide the exact extent of trench padding, that will be required.
The thickness of the compacted padding shall not be less than 150mm. In those areas
that are to be padded, the trench shall be at least 150mm deeper than otherwise
required, and evenly and sufficiently padded to keep the pipe, when in place, at least
150mm above bottom of excavated trench.
Acceptable padding shall be placed under the pipeline before its installation, and
around after installation to establish at both sides and on top of the pipe a permanent
layer of padding. The thickness of compacted padding on top of pipe corrosion coating
shall be at least 150mm. Padding materials that are approved by COMPANY shall be
graded soil/ sand and/ or other materials containing no gravel, rock, or lumps of hard
soil. Sand used for padding shall pass through sieve size ASTM-10 or ISO-2.00.
When specified in the CONTRACT, rock shield may be used in place of or in addition to
sand padding as indicated above. Such rock shield shall be in accordance with the
specification issued for the purpose and shall be subject to COMPANY approval.
6.9 Protection of Trench
CONTRACTOR shall keep the trench in good condition until the pipe is laid, and no
claim is to be made to the COMPANY by reason of its caving either before or after pipe
is laid.
All lumber, sheet-piling jacks or other 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 in accordance with these specifications at no extra cost
to COMPANY.
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6.10 Protection of Underground Utilities and Special Methods
Details of some underground utilities, as far as acquired by COMPANY, shall be

indicated in the Drawings. However, CONTRACTOR shall obtain plans and full details of
all existing and planned underground services from the relevant Local Authorities and
shall follow these plans closely at all times during the performance of work.
CONTRACTOR shall be responsible for location and protection of all underground lines
and structures. In special locations the use of trenching machine, backhoe may result
in damage to property and subsurface structures likely to be encountered during
excavation. At such places, CONTRACTOR shall excavate the trench manually to same
specification at no extra cost.
Where the pipeline crosses other underground utilities/ structures, the CONTRACTOR
shall first manually excavate to a depth and in such a manner that the utilities/
structures are located.
Temporary under pinning or any other type of supports and other protective devices
necessary to keep the interfering structure intact shall be provided by the
CONTRACTOR at his own cost and shall be of such design as to ensure against their
possible failure.
Despite all precautions, should any damage to any structure/ utility etc., occur, the
Owner/ Authority concerned shall be contacted by the CONTRACTOR and repair shall
forthwith be carried out by the CONTRACTOR at his expense under the direction and
to the satisfaction of COMPANY and the concerned Owner/ Authority. If CONTRACTOR
fails to repair in reasonable time, COMPANY reserves the right to have the repair
executed at the cost of the CONTRACTOR.
6.11 Encroachments and Working near other utilities
In locations, where pipeline has to be laid in the body of a road, canal, dyke or other
locations under jurisdiction of Government/ Public Bodies, the CONTRACTOR shall
perform such work without extra compensation, according to the requirement of
concerned Authorities. When it becomes necessary that CONTRACTOR has to resort to
hand digging, well point, erection of sheet piling or any other special construction
methods in these areas, no extra compensation shall be paid. CONTRACTOR shall
contact the Authorities concerned in order to become familiar with their requirements.
In locations, where the pipeline has to be laid more or less parallel to an existing
pipeline, cable and/ or other utilities in the Right-of-way, CONTRACTOR shall perform
the work to the satisfaction of the Owner/ Authority of the existing pipeline/ cable/
utility. In such locations CONTRACTOR shall perform work in such a way that even
under the worst weather and flooding conditions, the existing pipeline/ utilities remain
stable and shall neither become undermined nor have the tendency to slide towards
the trench.
CONTRACTOR shall be liable for any damage occuring to, or resulting from damage to
other pipelines, underground structure/ utilities, as laid down in clause 6.10 of this
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specification.
6.12 Provisions for negative buoyancy to the pipe
CONTRACTOR shall check if up-floating danger is present in open trench and then shall
take appropriate measures to prevent up-floating such as applying soil dams and
dewatering of trench or temporary filling of water into the line (in exceptional cases).
In the case of water on the ditch bottom when the pipeline is being laid, the ditch shall
be drained to the extent and for the time required to make a visual inspection of the
ditch bottom. After this inspection, the presence of water will be allowed provided its
level does not cause sliding of the ditch sides and pipe floating before backfilling when
no concrete weighting is provided.
The water pumped out of the ditch shall be discharged into a natural water course.
Wherever up-floating of the pipeline after backfilling is to be reckoned with, anti-

buoyancy measures shall be provided by CONTRACTOR for areas indicated in the
drawings or as may be encountered during construction, using one or a combination of
the following methods :
 weighting by applying a continuous concrete coating around the pipe;

 weighting by installing saddle weights;
 installing metal anchors screwed into the suboil in pairs;
 deeper burial of pipeline;
 provision of select backfill material.
The above provisions shall be in accordance with the relevant specifications and/ or job
standards/ drawings.
7.0 BENDING
CONTRACTOR shall preferably provide for changes of vertical and horizontal alignment
by making elastic bends. CONTRACTOR may provide cold field bends, at its option for
change of direction and change of slope. COMPANY at its option, may authorise
fabricated bends for installation at points where in COMPANY's judgement the use of
such bends is unavoidable.
Overbends shall be made in such a manner that the center of the bend clears the high
points of the trench bottom. Sag bends shall fit the bottom of the trench and side
bends shall conform and leave specified clearance to the outside wall of the trench.
7.1 Elastic Bends
The minimum allowable radius for elastic bends in the buried pipeline including that for
continuous concrete weight coated pipe shall be in accordance with relevant job
standards. The elastic bend shall be continuously supported over its full length. A
radius smaller than permitted in elastic bending shall require a cold bend.
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7.2 Cold Field Bends
7.2.1 The radius of cold field bends shall not be less than 40 times the pipe nominal
diameter for pipe diameter 18 inch and above and shall not be less than 30 times the
pipe nominal diameter for pipe diameter less than 18 inch.
7.2.2 CONTRACTOR shall use a bending machine and mandrel and employ recognized and
accepted methods of bending of coated pipe in accordance with good pipeline
construction practice. However, bending machines shall be capable of making bends
without wrinkles, buckles, stretching and with minimum damage to the coating.
7.2.3 CONTRACTOR shall, before the start of the work, submit and demonstrate to
COMPANY a bending procedure which shall conform with the recommendations of the
manufacturer of the bending machine. The procedure shall include amongst other
steps - lengths, maximum degree per pull and method and accuracy of measurement
during pulling of the bend. This procedure and the equipment used shall be subject to
COMPANY's approval.
7.2.4 Pipes with longitudinal welds shall be bent in such a way that the weld lies in the plane
passing through the neutral axis of the bend which shall be installed positioning the
longitudinal weld in the upper quadrants. If horizontal deviations are to be achieved by
joining more adjacent bends, the bending of the pipe lengths shall be made by
positioning the longitudinal welds alternatively 70mm above and below the plane
passing through the neutral axis in such a way that the bends are welded with the
longitudinal welds displaced by about 150mm and situated in the upper quadrants. In
case of vertical bends formed from a number of pipe lengths, the longitudinal welds
shall be positioned on the plane passing through the neutral axis of the bend to the
right and left alternatively.
7.2.5 The pads, dies and rolls of the bending equipment shall have relatively soft surfaces to
avoid damage to the pipe coating. Where applicable, fully retaining bending shoes shall
be used. Roller type bending machines are preferred.
7.2.6 The ends of each bent length shall be straight and not involved anyway in the bending.
The length of the straight section shall permit easy joining. In no event shall the end of
the bend be closer than 1.5m from the end of a pipe or within one meter of a girth
weld.
7.2.7 The ovalisation caused on each pipe by bending shall be less than 2.5% of the nominal
diameter at any point. Ovalisation is defined as the reduction or increase in the internal
diameter of the pipe compared with the nominal internal diameter. A check shall be
performed on all bends in the presence of COMPANY by passing a gauge consisting of
two discs with a diameter equal to 95% of the nominal internal diameter of the pipe
connected rigidly together at a distance equal to 300mm.
7.2.8 The wall thickness of 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 :
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50
Wall Thinning = ---------------
n+1
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.
7.2.9 Cold bent 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.
7.2.10 When pipelines are laid in parallel, the horizontal bends shall be concentric.
7.3 Mitre and Unsatisfactory Bends
All bends showing buckling, wrinkles, cracks or other visible defects or which are in any
way in disagreement, in whole or in part, with this specification shall be rejected.
No miter bends shall be permitted in the construction of the pipe line. CONTRACTOR
shall cut out and remove any bend or bends which do not meet the specifications and
shall replace the same with satisfactory bends at no additional cost to the COMPANY.
In the event the CONTRACT provides for supply of line pipe by COMPANY, the pipes
required for replacement will be furnished by COMPANY, but the cost of replacement of
such pipes shall be borne by CONTRACTOR.
Cutting of factory made bends and cold field bends for any purpose are not permitted.
8.0 LINING UP AND WELDING
Each length of pipe shall be thoroughly examined internally and externally to make
sure that it is free from visual defects, damage, severe corrosion (sea water pitting),
dirt, animals or any other foreign objects. Each length of the pipe shall be adequately
swabbed, either by use of canvas belt disc of proper diameter or by other methods
approved by the COMPANY. Damaged/corroded pipes shall be kept separate. Each
length of pipe shall be pulled through just before being welded.
All rust and foreign matters shall be removed from the beveled ends by power
operated brush. This shall be affected inside & out side and for a minimum distance of
25 mm from edge of bevel. The bevel shall be thoroughly inspected at this stage.
Should laminations, spilt ends or manufacturing defects in the pipe observed, the
length of the pipe containing such defects shall be removed from the line in
accordance with relevant specification.
Contractor shall align and weld together the Joints of pipe so as to construct a
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continuous pipeline. All welds in the pipeline made by Contractor shall be of strength
equal to that of pipe. All welding shall conform to Company’s welding specifications
enclosed with the Contract.
8.1 Pipe Defects and Repairs
It is CONTRACTOR's responsibility to repair all internal and/or external defects.
8.1.1 Acceptability of defects in the pipe detected during inspection at the work site shall be
determined in accordance with latest edition of COMPANY's own material specification
or CODE ANSI B31.8/B 31.4 whichever is more stringent.
8.1.2 The maximum permissible depth of dents in pipes upto and including 123/4" OD is 5mm
and for pipes over 12 3/4" OD is 2% of the nominal pipe diameter.
8.1.3 Dents which contain a stress concentrator such as scratch, gauge, arc burn or groove,
and dents located at the longitudinal, spiral or circumferential weld shall be removed
by cutting out the damaged portion of pipe as a cylinder.
8.1.4 Repair on line pipe shall be executed as specified in COMPANY's material specification
or Code ANSI B 31.8/B 31.4, whichever is more stringent. A record of all repairs is to
be maintained by CONTRACTOR. This record, provided with the pipe identification
number is to be submitted to the COMPANY.
8.1.5 If due to cutting or repairs, the pipe identification number is removed, it shall be
reprinted immediately by CONTRACTOR in the presence of COMPANY. In the event,
the CONTRACT provides for supply of line pipe by COMPANY, CONTRACTOR shall be
charged for any pipe length due to loss of identification number. No pipe without
identification number shall be transported and/or welded into the pipeline.
8.1.6 Repair of damaged pipe ends by hammering and/or heating is not allowed. If the
dented area is minor and at least 200mm away from the pipe end, and the steel is not
stretched, severed, or split in the COMPANY's opinion, the pipe may be straightened
with a proper jack.
8.2 Pipe Handling And Skid Spacing
8.2.1 When lifting pipe, care must be taken not to kink or overstress it. Proper pipe slings
approved by COMPANY shall be used. CONTRACTOR shall submit his method of
skidding and skid spacing for COMPANY's approval. A strip of soft material shall be
placed in between skid and pipe to protect the external coating of the pipe. The
material shall be approved by the COMPANY.
8.2.2 The maximum skid spacing is not allowed before the stringer bead and the top and
bottom reinforcements are completed, provided that the distance between the
incomplete weld and the skid shall not exceed 9 (nine) percent of the skid spacing.
8.2.3 Skids shall be atleast 1.20 meter long. For pipe with an O.D. of 12-3/4 inch and larger
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the skids in contact with the pipe shall have a width of at least 200mm. For pipe with
an O.D. of less than 12 inch the skids in contact with the pipe shall have a width of
atleast 150mm. Pipe supports shall be stable, so that pipe movement will not cause
the supports to move. Skids shall not be removed under a string before lowering in.
The welded pipe shall be maintained on skids at the minimum distance of 500mm
above ground. Crotches shall be installed at frequent intervals (atleast every 10th
support) with a greater number required at bends and undulation grounds.
8.3 Night Caps
At the end of each day's work or every time when joining and welding operations are
interrupted, the open ends on the welded strings of pipes shall be capped with a
securely closed metal cap or plug as approved by COMPANY so as to prevent the entry
of dirt, water, or any foreign matter into the pipeline. These covers shall not be
removed until the work is to be resumed. The caps/plugs used shall be mechanical
type and shall not be attached to pipe by welding or by any other means which may
dent, scratch or scar the pipe.
8.4 Temporary Caps
Whenever the welded strings of pipes are left open at intervals to be tied in later after
an appreciable time lag, under roads, railroads, rivers, marshy crossings, ets.,
temporary caps approved by COMPANY shall be welded to the ends of the pipe.
9.0 LAYING OF PIPE
9.1 Lowering In Trench
9.1.1 Lowering can start after removal from ditch bottom of all off cuts, pipe supports,
stones, roots, debris, stakes, rock projections below underside of pipe and any other
rigid materials which could lead to perforation or tearing of the coating. Sand padding
and / or rock shield shall be provided as required in accordance with clause 6.8 of this
specification.
9.1.2 Lowering shall follow as soon as possible, after the completion of the joint coating of
the pipeline. In the case of parallel pipelines, laying shall be carried out by means of
successive operations, if possible without interruption.
9.1.3 Before lowering in, a complete check by a full circle holiday detector for pipe coating
and for field joint coating shall be carried out and all damages repaired at
CONTRACTOR's cost. All points on the pipeline where the coating has been in contact
with either the skids or with the lifting equipment during laying, shall be carefully
repaired. If, after checking, it becomes necessary to place the pipeline again on
supports at the bottom of the trench, these must be padded in such a way as to
prevent damage to the coating, thus avoiding necessity for further repairs when the
pipe is finally raised and laid. Before the last operation, a check must be made of the
coating at points of contact with the supports.
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9.1.4 Before lowering in, short completed sections of the pipeline shall be cleaned with
compressed air in order to remove all dirt, etc. from the inside of pipe sections.
9.1.5 The pipeline shall be lifted and laid using, for all movements necessary, suitable
equipment of non-abrasive material having adequate width for the fragility of the
coating. Care shall be exercised while removing the slings from around the coated pipe
after it has been lowered into the trench. Any damage caused to the coating shall be
promptly repaired. Lowering in utilizing standard pipe cradles shall be permitted if
CONTRACTOR demonstrates that pipe coating is not damaged. No sling shall be put
around field joint coating.
9.1.6 Wherever the pipeline is laid under tension, as a result of an assembly error (for
example, incorrect positioning of bends, either horizontal or vertical), the trench shall
be rectified or in exceptional cases a new assembly shall be carried out, to be
approved by COMPANY, so that it fits the excavation and the laying bed.
9.1.7 Laying shall be carried out under safe conditions so as to avoid stresses and temporary
deformations of the equipments which may cause damage to the pipeline itself and to
the coating. In localised points where the right-of-way is restricted to the minimum
necessary for the transit of mechanical equipment, the laying shall be carried out using
other suitable means. The pipe shall be placed on the floor or the excavation, without
jerking, falling, impact or other similar stresses. In particular, care must be taken that
the deformation caused during the raising of the pipe work from the supports, does
not exceed the values for the minimum allowable radius of elastic curvature, so as to
keep the stresses on the steel and on the coating within safe limits. The portion of the
pipeline between trench and bank shall be supported by as many side-booms as
required and approved by COMPANY for holding the line in gentle S-curve maintaining
minimum elastic bend radius as specified in job standard. Lowering in and back-filling
shall preferably be carried out at the highest ambient temperature.
9.1.8 The pipeline must be laid without interruption for the whole or the length of section
available. Where water is present, no laying shall be permitted until the ditch has been
drained to the extent and for the time necessary to make visual inspection possible of
the bed on which the pipe is to be laid. Following such inspections, the presence of
water will be permitted, provided that it is not so high as to cause cave-in of the walls
of the trench or floating of the pipeline before backfilling, when weighting is not
provided for the pipe.
9.1.9 CONTRACTOR shall take precautions immediately after lowering in to prevent the
movement of the pipe in trench.
9.1.10 In laying parallel pipelines in the same trench, the minimum distances between the
pipeline indicated in the approved drawings shall be observed. Once the first pipeline
has been positioned, it shall in no way be disturbed by laying of the subsequent
pipeline.
At every seven meters along the trench sand/earth filled bags shall be placed between
the parallel pipelines so as to ensure maintenance of the minimum stipulated distance
between the parallel lines.
29 of 911
9.2 Overhead Sections and Sections in Tunnel
9.2.1 The following works shall be completed before proceeding with the assembly and
laying of overhead pipelines:
- Construction of the pipe support structures or of mounts on supports.

- Paints and/or coating of the pipework, as indicated in the engineering
specification.
9.2.2 The erection of the supports shall be carried out taking care that the elevation and
alignment is in accordance with the drawings.
In the case of metal work supports, prefabrication and/or assembly shall take into
account the maximum allowed free span and the supports shall not interfere with the
pipeline welds.
9.2.3 In case roller supports are used, the roller shall be lubricated, then checked for smooth
rotation and, in case of seizure, the defect shall be repaired or roller shall be replaced.
In the case of overhead section where the pipeline is slanting, the alignment of the end
supports shall be made after placing the pipeline in position. Before installation of the
pipe section, all the rollers shall be perfectly centered acting on the seat of the support
plates.
The above alignment operations shall be carried out before connecting the overhead
section with the ends of the buried section.
9.2.4 Lifting, moving and laying of the pipeline shall be carried out in accordance with the
provisions of clause 9.1.5.
An insulation sheet shall be installed to isolate the pipe from the support or support
from the earth.
The sheet shall be hard polyethylene at least 5mm thick.

It shall extend at least to 1cm outside the saddles or clamps.
9.2.5 Moving supports, if any, shall be centered on their support and allow for a movement
of at least 300mm in both directions.
9.2.6 A comprehensive report/method statement on the laying operation to be used shall be

submitted to the COMPANY well in advance for approval. The report as a minimum
shall include, but not limited to the following:
(a) Method of installation by lifting (as a preferred method).

(b) Pulling method and related calculations, whenever lifting method cannot be
used.
(c) Pulling device and its characteristics
(d) Method of anchoring the pulling device
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(e) Characteristics of the pulling rope

(f) Braking device, if any
(g) Pipeline assembly systems.
10.0 BACK-FILLING
10.1 Backfilling shall not be done until the pipe and appurtenances have the proper fit and
the pipe is following the ditch profile at the required depth that will provide the
required cover and has a bed which is free of extraneous material and which allows the
pipe to rest smoothly and evenly. Before any such work is done, it shall be the
CONTRACTOR's responsibility to first secure the approval of COMPANY. If any
backfilling is done without COMPANY's approval, COMPANY 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 issued for the purpose.
10.2 Backfilling shall be carried out immediately after the pipeline has been laid in the
trench, inspected and approved by the COMPANY, so as to provide a natural
anchorage for the pipeline, thus avoiding long exposure of coating to high
temperature, damaging actions of adverse weather conditions, sliding down of
trench sides and pipe movement in the trench. If immediate back filling is not
possible, a covering of atleast 200mm of earth, free of rock and hard lumps 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 backfilling. Deviations there of must have prior approval of
the COMPANY. The backfill material shall contain no extraneous material and/or hard
lumps of soil which could damage the pipe / coating or leave voids in the backfilled
trench. After the initial backfill has been placed into the trench to a level slightly above
the surrounding ground, CONTRACTOR shall compact the backfill material. The
surplus material shall be neatly crowned directly over the trench and the adjacent
excavated areas on both sides of the trench as per clause 6.2.1, to such a height which
will, in COMPANY's opinion, provide adequately for future settlement of the trench
backfill during the maintenance period and thereafter. The crown shall be high enough
to prevent the formation of a depression in the soil when backfill has settled into its
permanent position. Should depression occur after backfill, CONTRACTOR shall be
responsible for remedial work at no extra cost to COMPANY. Surplus material, including
rock, left from this operation shall be disposed of to the satisfaction of land owner or
authority having jurisdiction at no extra cost to the COMPANY.
For further requirements reference is made to Section of 14.0 "Clean-up and

Restoration of Right-of-Way" of this specification.
10.3 Rock, gravel, lumps of hard soil or like materials shall not be backfilled directly onto the
pipe unless 'padding' and/or rock shell has been provided as per Section 6.0 of this
specification. When "Padding" as described in Section 6.0 of this specification is to be
used, the following shall be applicable.
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Where rock, gravel, lumps of hard soil or like materials are encountered at the time of
trench excavation, sufficient earth, sand or select backfill materials shall be placed
around and over the pipe to form a protective cushion extending at least to a height of
150mm above the top of the pipe. Select backfill materials for padding that are
acceptable to COMPANY shall be soil, sand, clay or other material containing no gravel,
rock or lumps or hard soil. Whether such padding material would be taken from the
adjacent spoil bank or imported from elsewhere shall be directed by COMPANY. All
these works shall be carried out by CONTRACTOR at no extra cost to COMPANY. Loose
rock may be returned to the trench after the required selected backfill material has
been placed, provided the rock placed in the ditch will not interfere with the use of the
land by landowner, or tenant.
10.4 When the trench has been dug through drive ways or roads, all backfills shall be
executed with sand or a suitable material as approved by COMPANY and shall be
thoroughly compacted. In certain cases, special compaction methods, such as
moistening or ramming of the backfill in layers may be required by COMPANY.
COMPANY and any public or private authority having jurisdiction over a road, street or
drive way may require that the surface of the backfill be graveled with crushed rock or
some other purchased material and the road shall be repaved. In such instances,
CONTRACTOR shall comply with said requirements at no extra cost to COMPANY.
10.5 Trenches excavated in dykes which are the property of railways or which are part of
main roads shall be graded and backfilled in their original profile and condition. If
necessary, new and/or special backfill materials shall be supplied and worked-up. The
materials required may include gravel, special stabilization materials or stabilized
mixtures. However, special processing and/or compacting methods shall require the
approval of COMPANY and/or competent authorities.
10.6 The trench in irrigated and paddy fields shall be backfilled to within 300mm of the top,
then rammed and further backfilled until the trench is completely backfilled. Surplus
material remaining after the operation shall be spread over the ROW as specified in
Section 14.0 "Clean-up and Restoration of Right-of-Way", of this specification.
10.7 At the end of each day's work, backfilling shall not be more than 500 meters behind
the head end of lowered-in pipe, which has been padded and approved for backfill.
The backfill shall be maintained by CONTRACTOR against washouts etc., until the
completion and final acceptance of the work by COMPANY.
10.8 CONTRACTOR shall furnish materials and install breakers in the trench in steep areas
(slope generally 10% and more) for the purpose of preventing erosion of the backfill.
The type of breakers installed shall be as per the approved drawings. Breakers shall be
constructed of grout bags filled with a mixture of 4:1 Sand:Portland cement at
COMPANY's direction. CONTRACTOR may propose other methods such as foam dams
etc. which shall be subject to approval by COMPANY. Such works shall be at no extra
cost to COMPANY. CONTRACTOR shall pay attention to the direction of backfilling in
such steep areas.
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10.9 When backfilling the trenches in sloping terrains or steep areas, where in the opinion
of the COMPANY, the backfill may be washed out of the trench, sheet piling or other
effective water breakers across the trench shall be provided by CONTRACTOR. This is
to divert the flow of water away from the trench into normal drainage followed before
laying the line. In no case, the water is to be drained via the trench or via channels
other than those followed before the line was laid.
10.10 CONTRACTOR shall leave the pipe uncovered at certain locations to allow COMPANY to
survey the center line of the pipe and the level of the pipeline in the backfilled trench.
Within 48 hours after backfilling, COMPANY shall have carried out such survey and
informed CONTRACTOR of any realigning, if required. Thereafter CONTRACTOR shall
compact the backfill.
The maximum allowable deviation from the centerline for land sections as staked out
by COMPANY and as referenced by CONTRACTOR after backfilling is limited to:
Pipeline dia upto and including 24" : 200mm
Pipeline greater than 24" : 300mm
10.11 Before backfilling of the trench, CONTRACTOR shall comply with the requirements of
Clause 6.12 of this specification.
10.12 Stabilization of backfill shall be carried out by the CONTRACTOR in sandy areas and
other such places to obtain consolidated cover as directed by the COMPANY.
CONTRACTOR shall carry out the stabilization over the pipeline at no extra cost to
COMPANY.
The backfill shall be stabilized preferably with 150mm layer of marl, mattresses of
gatch other than straw or other stable materials. The width of stablisation shall be
atleast 5.0 meters on either side of the pipeline, plus one meter for every 10 meters
height of dune (where the line passes through the dune areas).
10.13 Temporary workers shall be installed during backfilling and the survey as per clauses
10.10 to locate the pipeline axis. These markers shall then be replaced with permanent
pipeline markers.
10.14 Backfilling shall be preferably carried out at the highest ambient temperature.
11.0 TIEING-IN
11.1 The unconnected sections of the pipe line at various locations have to be tied in after
the sections are coated, lowered and backfilled. The sections to be connected shall
have at the ends, sections of over lapping, uncovered pipe of sufficient length to
absorb, without inducing excessive stresses in the steel, small displacements necessary
for perfect alignment and connection of the ends.
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11.2 Tie-in shall preferably be carried out at ambient temperatures corresponding to the
average operating temperature in the case of a pipeline conveying fluids at normal
temperatures and at the maximum ambient temperature in the case where the pipeline
is carrying fluids at high temperature.
11.3 CONTRACTOR shall carry out tie-in-welding (including necessary cutting, bevelling,
grinding of pipe weld seams and line-up etc.) cleaning, priming, coating and backfilling
for the tie-in portion as per relevant specifications. CONTRACTOR shall also excavate
the required bell-holes for the connection. Bell-holes made to facilitate welding shall
provide adequate clearance to enable the welders to exercise normal welding ability
and skill. All tie-in welds shall be radiographically examined.
11.4 The tie-in should be done in such a way as to leave a minimum of strain in the pipe. If
necessary, with respect to the trench, realigning of the pipe shall be done to eliminate
force or strain in the pipe by the CONTRACTOR at no extra cost to COMPANY.
11.5 If a pup end cannot be avoided for tie-in, the minimum length that shall be added is
1.0 meters and two or more such pups shall not be welded together. All cut-off lengths
greater than 1.0 meters shall be moved ahead in order to be welded into the pipeline
at a suitable location. Tie-in with two or more pups may be used provided that they
each have minimum length of 1.0 meter and are separated by an entire length of pipe.
In no case more than three (3) welds shall be permitted on a 10 meter length of
pipeline.
11.6 In connecting pipes, special items, fittings and equipment where different wall
thickness are to be welded, CONTRACTOR shall follow the procedures indicated in
ANSI B31.8/ANSI B31.4, as applicable. The required tapering shall be done by
CONTRACTOR at no extra cost to COMPANY.
11.7 For tie-in of adjacent sections of pipeline already pressure tested, the pump used for
tie-in shall be of single length or off-cuts of pipe which have already been
hydrostatically tested. CONTRACTOR shall take care that sufficient number of
pretested pipes with different wall thicknesses are readily available.
12.0 SPECIAL INSTALLATIONS ON THE PIPELINE.
12.1 General
12.1.1 In addition to constructing the pipeline, CONTRACTOR shall also install certain other
auxiliary facilities and appurtenances.
CONTRACTOR shall do all work necessary at each of the installations to provide

facilities which are complete in all respects and ready for operation.
Without limiting the generality thereof, the work required to complete the installations
shall, where applicable, include all site surveys, site preparation, filling, grading,
fencing, foundations, installation of block valves, side valves, pipework, pipe supports,
pressure gauges, mechanical facilities, civil work, painting, installation of all electrical
equipments, motors, cables, conduit, wiring and fixtures and hooking up of same;
34 of 911
installation of all instruments, piping, valves and fittings; mount all instruments and
make all piping and electronic connections, etc.
On completion, all elements of each installation shall be checked out and tested for full
and correct operation in the presence of and to the satisfaction of COMPANY. All work
shall be carried our strictly in accordance with the appropriate codes, the approved
drawings, and this and other related specifications.
CONTRACTOR shall fabricate all piping and install valves and fittings as required by the
detailed engineering drawings prepared by him and approved by COMPANY.
Stainless steel lines will be "swaged" using permanent fittings installed with a hydraulic
device.
Cold bending for the fitting of 1/2" and 1/4" pipes is allowed when special bending
tools are used with guides to prevent flattening. The minimum radius allowed shall not
be less than R = 10 D where D is the outside diameter of pipe.
The bending tool shall be subject to COMPANY's approval.
CONTRACTOR shall ensure that the piping assemblies are not in a strain prior to the
final bolting or welding. CONTRACTOR shall also ensure that all equipment and piping
are thoroughly swabbed clean of all dust, refuse, welding-spatter, scale, or any
potentially detachable matter prior to the tie-in or final bolting.
12.1.2 Dimensional tolerances.
These tolerances apply to in line items and corrections for other lines. These tolerances
can be executed on items such as vents, drains, dummy supports, field supports,
temperature and pressure connections, where the deviation will not affect another
spool.
a) General dimension such as face to face, face or end to end, face or end to
center, and center to center : ± 3 mm.
b) Inclination of flange face from true in any direction: 4 mm per meter.
c) Displacement of branch connection from indicated location: ± 1.6mm. When
multiple branches are involved, the displacement of the branches shall not
exceed 3mm from a common point.
d) Rotation of flange bolt holes shall not exceed 1.6 mm.
12.1.3 Flanged connections.
CONTRACTOR shall ensure that all flange faces are parallel and centered, according to
standard practice, prior to final bolting. CONTRACTOR shall not use bolting forces as a
means for attaining alignment. A gasket of proper size and quality shall be installed
between the flanges at each joint.
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Bolts shall be tightened in diagonal sequence and shall be centered with equal
amounts of thread visible on both sides. Bolts shall be uniformly tightened to produce
a leak-proof joint. Bolts that yield during tightening shall be removed and discarded. It
is mandatory that a torque wrench is used for bolt tightening.
12.1.4 Threaded connections.
Damaged threads shall be cut from the end of a run and the pipe shall be rethreaded.
CONTRACTOR shall properly align all threaded joints. Pipe entering unions shall be true
to centreline so the union will not be forced during tightening. The threaded pipe shall
not project through fittings to cause interference with valves or other operating
mechanisms.
Except for the threaded connections of instruments, which will require periodic testing
and maintenance, all threaded connections shall be seal welded. The latter joints shall
be made up without pipe joint compound and with a minimum of oil from the threaded
cutter. Seal welds should taper into the pipe with as little discontinuity as possible and
should cover all threads.
12.1.5 Welded connections
Where the Ends of the piping components being welded have an internal surface
misalignment exceeding 1.6mm, the wall of the component extending internally shall
be trimmed by machining so that the adjoining internal surfaces will be approximately
flush. All welding shall be performed in accordance with the specification " Specification
for welding of pipelines and related facilities".
Tie - ins between fixed points shall be made at maximum ambient temperature.
.
12.1.6 Civil Work
Civil work shall be provided in accordance with Specifications issued for the purpose.
12.1.7 Painting
All exposed surfaces like piping, valves, structures, and miscellaneous appurtenances
shall be painted in accordance with the specifications issued for this purpose. The
corrosion coating on pipe surface will end approximately 0.3 meter above the finish
grade and it will be necessary for CONTRACTOR to provide a clean interface at the
junction of the protective coating and the paint.
12.1.8 Coating of buried-Installations, etc.
All buried valves, insulating joints, flowtees, bends, other in-line fittings and
appurtenances shall be coated with minimum three coats of approved quality of coal-
tar epoxy or any other equivalent suitable COMPANY approved coating at no extra cost
to the COMPANY. For buried pipes either heat shrink tapes conforming to COMPANY's
specification or coal tar epoxy shall be used. CONTRACTOR shall submit to COMPANY
a report used alongwith all the test certificates. Only after obtaining written approval
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from the COMPANY, CONTRACTOR shall commence the work of coating.
12.1.9 Clean-up
After all required tests have been concluded satisfactorily CONTRACTOR shall clean up
the site as laid down in the specifications issued for the purpose. The Site finish shall
be graded in accordance with the approved drawings.
12.2 Installation of Valves and Valve Stations
12.2.1 Block and sectionalising valve stations shall be installed as shown on the approved
drawings. It is CONTRACTOR's responsibility to have the units completely assembled,
tested and made fully functional including all related instruments etc.
12.2.2 The civil and structural work shall be carried our in accordance with the relevant
specifications issued for the purpose and in accordance with the approved drawings as
directed by COMPANY. This work as a minimum shall include clearing, grading,
fencing, foundations, etc, as required. All above ground structures shall be painted as
per the specification and color code given by the COMPANY.
12.2.3 A suitable concrete foundation as directed by COMPANY shall be constructed on which

the valve shall be firmly installed, after embedding an insulating sheet of hard
polyethylene with a thickness of atleast 5mm or equivalent. Such insulating sheet is
also to be installed under pipe clamps, etc.
12.2.4 Valves with flow arrows shall be installed according to the normal flow in the pipeline.
During, welding, the valves shall be in fully open position. In addition all
manufacturer's instructions shall be followed.
Care shall be taken to avoid entry of sand particles etc. to valve body, seals etc. during
transportation, storage, assembly and installation.
12.2.5 For valves and piping installed below ground and/or above ground, the anti-corrosion
coating/painting shall be as per the requirements of the relevant specifications issued
for the purpose. The anti-corrosion coating below ground shall extend upto 300mm
above grade at the lowest point.
12.2.6 Sectionalizing valves shall be installed on sections of the pipeline in the horizontal
position only or with an inclination not greater than that allowed by the valve
manufacturer. Installation shall be done in such a way that there is no strain in the
welded joint while the pipeline at upstream and downstream sides are straight.
12.2.7 All valves shall always be handled using equipment and methods to avoid impact,
shaking and other stresses. In particular, the equipment and tools for lifting and
handling shall never be done through handwheel, valve stem, joints and other parts
which may suffer damage.
12.2.8 All sectionalizing valve and any other inline assemblies shall be prefabricated and
tested hydrostatically ex-situ as per applicable specification. All such assemblies shall
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be installed at the locations shown in the drawings only after successful completion of
the hydrostatic test and dewatering. Thereafter the ends of the assembly shall be
closed off. CONTRACTOR shall carry out necessary excavation, cutting, bevelling and
welding of the tie-ins required for the installation of such assembly. The tie-in joints
shall be radiographically examined over 100% length and also 100% ultrasonically
examined prior to backfilling. All works shall be executed in accordance with the
relevant specifications issued for the purpose.
12.3 Installation of Scraper Launchers and Receivers
12.3.1 Scraper stations shall be fabricated and installed as per the approved drawings and
whenever applicable as per the requirements of clause 12.2 of this specification. It is
CONTRACTOR's responsibility to have the units completely assembled, tested and
made fully functional including all instruments & related piping.
12.3.2 The civil and structural works for the scraper stations shall be carried out as per the
relevant specifications, in accordance with the drawings and as directed by the
COMPANY. The work as a minimum shall include site survey, site preparation, clearing,
grading, fencing, foundations, etc. as required.
12.3.3 It shall be CONTRACTOR's responsibility to maintain elevations shown on the approved

drawings and to carry out any pipework adjustments, necessary for this purpose. Field
cuts shall be square and accurate and field welds shall not be performed under stress
of pipe ends.
12.3.4 The painting for the scraper stations shall be carried out as per "Specifications for
Painting". The underground sections shall be coated as specified for the pipeline upto
atleast 300mm above grade.
12.3.5 The hydrostatic testing of the scraper stations shall be executed after installation in
accordance with the relevant specification issued for the purpose.
12.4 Installation of Insulation Joints
12.4.1.1 Insulation joints shall be installed at the locations shown in the drawings.
CONTRACTOR shall obtain approval from the COMPANY before installation of the
insulation joints.
12.4.2 Handing and installation of the insulating joints shall be carried out with all precautions
required to avoid damage and excessive stresses and that the original pup length is
not reduced.
12.4.2 The insulating joints and the welded joints shall be protected by external coating as
per relevant specifications issued for the purpose.
12.4.4 The in-line inserting shall be made on the buried pipeline; care shall be taken to
operate at an external temperature as close as possible to the pipeline operating
temperature.
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The joints shall be inserted on straight sections and laid on a fine sand bed.
12.4.5 During the execution of the in-line connection welding, the propagation of heat shall be
avoided. To achieve this, the joint shall be kept cold by means of nags continuously
wetted.
12.4.6 Insulating joints shall be electrically tested before welding into the pipeline. The
electrical conductance test shall be carried out using a Megger. Measurement of the
insulation resistance across the joints shall be approx. one (1) Mega Ohm. The tests
shall be repeated after installation and welding of the joint into the pipeline to verify
that the assembly is undamaged.
13.0 WORKING SPREAD LIMITATIONS
CONTRACTOR shall, in general, observe the following maximum distances between the
working mainline spread:
Between ROW grading, clearing and backfilling : 30 Kms
Between backfilling and final clean-up : 05 Kms
The above limitations do not apply to point spreads such as continuous rock blasting,
river crossing, etc.
Any deviations from the above shall require prior approval of COMPANY. COMPANY
reserves the right to stop the work, in case the approved spread limitations are
exceeded and CONTRACTOR shall not be paid any compensation for stoppage of work.
14.0 CLEAN-UP AND RESTORATION OF RIGHT OF WAY
14.1 CONTRACTOR shall restore the ROW and all sites used for the construction of
pipelines, water crossing and other structures in accordance with COMPANY's
instructions, and deliver them to the satisfaction of COMPANY.
14.2 Surplus Materials
The following stipulations shall apply in case CONTRACT provides for supply of line
pipe, bare and/or corrosion coated, by COMPANY.
All surplus and defective materials supplied by COMPANY shall be collected by

CONTRACTOR and delivered to designated stockpile areas.
All Pipe-ends shorter than 1.0m shall be returned to COMPANY being scrap, all pipes
longer than 8.0m shall be reconditioned (bevels, coating, provided with pipe letter,
number and length) and be returned to COMPANY's designated stockpile areas
together with all undamaged, unused COMPANY supplied materials. All pieces between
1.0 and 8.0m shall be charged to the CONTRACTOR by COMPANY. CONTRACTOR
shall record these returned materials in the Material account, to be prepared by him.
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14.3 Disposal
14.3.1 All surplus and defective materials supplied by CONTRACTOR and all trash, refuse and
spoiled materials shall be collected and disposed of by CONTRACTOR.
14.3.2 The ROW shall be cleared of all rubbish, broken skids, empty cans, card board, sacks,
stamps, trash, and leftover construction material. All burnable matter shall be burned,
but only after obtaining appropriate permits for such burning. If burning is not allowed,
CONTRACTOR shall haul the clean-up material to approved dumping area. All scrap
metal and unburnable material shall be disposed of, in an appropriate manner, but
never be buried in the ROW.
14.3.3 Surplus soil can only be removed from the Owner's plot after authorisation by
COMPANY.
14.3.4 All dumping fees connected with the disposal of materials shall be to the account of
CONTRACTOR.
14.3.5 All loose stones and rock exposed by the construction operations and scattered over
the ROW or adjacent grounds shall be removed by CONTRACTOR and be transported
to a location considered suitable by the authorities having jurisdiction, for satisfactory
disposal. For stones, gravel or other hard material which may be buried in the trench
the provisions of the specifications shall apply with the understanding that the use of
the land by the land-owner and/or tenant will not be interfered with.
14.4 Temporary Structures
All auxiliary structures such as bridges, culverts, sheet piling, posts, signs, etc., which
were erected or installed by CONTRACTOR as temporary measure, shall be removed.
However, it may be necessary to remove the fence of ROW during the maintenance
period.
14.5 Repair of Damage
Damages to roads, bridges, private property shall be repaired by CONTRACTOR. All

fences and other structures which are damaged during construction shall be restored
to original condition.
Slopes, water course sides or banks which have been partially or totally demolished
during the execution of the works shall be properly consolidated and restored without
waiting for their natural consolidation and settling.
All boundary stones which have been moved or removed during the work must be
reset in their original location to the satisfaction of the landowner concerned.
14.6 On completion of clean-up, the ROW shall be restored to such stable and usable
condition as may be reasonably consistent with the condition of the ROW prior to
40 of 911
laying the pipeline. The COMPANY shall be completely indemnified and held harmless
by CONTRACTOR from any and against all claims, demands, losses, expenses etc. that
may arise in this behalf or the COMPANY may anyway suffer or sustain, relative to,
arising out of, or in connection with same. The COMPANY may require from the
CONTRACTOR signed Releases from land owners regarding satisfactory
indemnification and restoration of their lands.
14.7 Special precautions shall be taken near slopes prone to erosions and land slides. All
necessary steps shall be taken to ensure the rapid growth of grass by providing wicker
barriers and by regulating the drainage of surface waters.
14.8 All cadastral or geodetric markers which may have been removed during the execution
of the works shall be restored in their exact position.
14.9 Ditches for which no instructions for restoration have been issued, or restoration
cannot be done according to existing banks because of the absence of it, shall be
restored as instructed by COMPANY. The bed of ditches crossed by the pipeline, shall
be cleaned over the full width or the ROW, also outside the ROW if necessary. This
restoration might involve the supply and installation proper materials for backfill and
protection, sodding or other precautions to prevent erosion or guarantee the stability.
Work has to be done after deliberation and acceptance of the authorities and
COMPANY. Other field drains have to be restored by hand and/or special equipment to
be used for that purpose as soon as possible and if necessary, also outside the ROW.
14.10 Any subsidence, cave-ins, wash-outs, which have been caused during the pipeline
construction and maintenance, caused by whatever reason within the edge of ditches
and open drains, shall be repaired by CONTRACTOR immediately or at first notice
given by COMPANY.
14.11 After the clean-up, the ROW of pastures has to remain fenced and to be removed
during the maintenance period. When agricultural and other traffic (requested by
tenant) have to cross the ROW the cross-overs have to be fenced with the same
material as the ROW. If necessary, special materials have to be used to allow traffic on
the cross-over. Fencing of the right-of-way as specified shall not be removed until
CONTRACTOR has obtained written permission by COMPANY. In general this has to be
done during the maintenance period.
14.12 All openings in or damage to the fence or enclosures shall be repaired by installing new
fencing of quality which shall be at least equal to the parts damaged or removed.
Provisional gates shall be removed and replaced with new fencing. All repairs to fences
and enclosures shall be carried out to the complete satisfaction of COMPANY, land
owner and/or tenant.
14.13 If, in the opinion of COMPANY, the sod in pasture land has been damaged by vehicles
and wheel tracks are visible, the ROW shall be tilled with a disc-harrow or rotary
cultivator several times. The damaged sod shall be firmly cut up and thoroughly mixed
through the top-soil. In general the ROW has also to be ripped. After this procedure
no closed-in layers must be found and sufficiently loose top-soil 25 to 30cm thick must
be present. The whole procedure has to be approved by COMPANY. Subsequently, the
41 of 911
entire ROW which is part of pasture land, shall be prepared for seeding and fertilized
according to the instructions of COMPANY.
14.14 In crop fields the tillage shall consist of passing over the land several times with a disc
harrow, cultivating with a spading machine, or plow, to a depth of approx. 20 cm. In
general the ROW has also to be ripped. After this cultivation process no closed-in
layers must be found in the ROW. The equipment used and methods adopted shall
require the approval of COMPANY. Ripping, has to be done with rippers with a distance
of 50 cm between the ripper blades. The type to be used shall be approved by
COMPANY.
14.15 A sapling of any plant/tree uprooted or cut during construction shall be planted along
the route as per the direction of the COMPANY and in accordance with the Forest
Preservation Act, 1981. The cost of sapling and its plantation shall be to
CONTRACTOR's account.
14.16 The ROW and the backfilled trench in particular has to be finished in such a way that
after settlement of the soil the fields are at their original level.
If during the maintenance period certain parts of the ROW are lower than the original
level, COMPANY can order CONTRACTOR to bring these parts to the original level. If
the level of the ROW for clean-up is ordered by COMPANY, risk of above mentioned
additional restoration shall not be to CONTRACTOR's account.
In cases where heavy damage has occurred to the structure of the subsoil as a result
of special circumstances, COMPANY reserves the right to order CONTRACTOR to carry
out special work. Said special work can include:
- spading with dragline (depth 30 - 80 cm);

- spading with dragline (depth 80 - 100 cm);
- fertilizing;
- cover with sand.
If during clean-up operations, soil shortages become apparent outside the trench,
CONTRACTOR shall supplement said soil shortage using suitable materials, approved
by COMPANY.
If site and/or climatic conditions should render this necessary, COMPANY shall have the
right to order CONTRACTOR to suspend certain parts of the WORK related to the
clean-up and postpone it to a later date.
14.17 Soil Surplus
If on site, as a result of the work and after careful 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 plot of land. It shall not be
permitted to remove the surplus from the plot concerned, unless it concerns rejected
soil which has to be removed. Working up surplus soil or removal of rejected soil shall
42 of 911
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 COMPANY has given prior permission for mixed excavation of the sub-soil as
well as in cases where COMPANY deems mixed excavation permissible, the above
provision of separate storage of the upper layer of sub-soil shall not apply to the
working up of the soil surplus.
In cases where the soil surplus can be worked up in other plots where soil shortages
have arisen due to the WORK, this shall only be done after prior permission by land-
owner, land-user and COMPANY.
14.18 Soil Shortages
If due to unforeseen circumstances during backfilling and compacting there isn't

enough soil to fill the trench properly, or to install the crown height as stipulated,
CONTRACTOR shall supply the necessary backfill material.
Soil shortages shall be supplemented and applied before the 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.
15.0 MAINTENANCE DURING DEFECTS LIABILITY PERIOD
Defects liability Period (defined as period of liability in the CONTRACT) means the
period of 12 months calculated from the date certified in the Completion Certificate.
COMPANY reserves the right to carry out instrumented pigging survey of the
completed pipeline.
CONTRACTOR shall be responsible for making good with all possible speed at his
expense any defect in or damage to any portion of the Work which may appear or
occur during the Defects liability Period and which arise either:
a) from any defective material (other than supplied by COMPANY), workmanship

or design (other than a design made, furnished or specified by COMPANY and
for which CONTRACTOR has disclaimed responsibility in writing), or
b) from any act or omission of CONTRACTOR done or omitted during the said
period.
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If such defect shall appear or damage occur, COMPANY shall forthwith inform
CONTRACTOR thereof stating in writing the nature of the defect or damage.
If any such defect or damage be not remedied within a reasonable time, COMPANY
may proceed to execute the work at CONTRACTOR's risk and expense, provided that
he does so in a reasonable manner. Such defect or damage can be, but is not limited
to:
- Clean up of ROW, including water courses

- Sagging or sinking of site level or pipe supports
- Sliding of ditch banks
- Repair of fencing or removal of construction fencing
- Repaving of pavements, repair of pavements, repair of coating, painting
- Realigning markers, signs
- Leak/burst of pipe, leaking flanges, washouts
- Short-circuit in casings
- Construction defects such as dents, ovality, welding offsets/defects, etc.
detected during intelligent pigging survey.
- etc.
Company reserves the right to have the required Computerised Potential Logging Test
executed during the DEFECTS LIABILITY PERIOD and whenever conditions are more
favorable for this job. The work shall at or as soon as practicable after the expiration of
the Defects Liability Period be delivered to COMPANY in the conditions required by the
CONTRACT, fair wear and tear excepted, to the satisfaction of COMPANY.
CONTRACTOR shall finish the work, if any outstanding, at the date of completion as
soon as possible after such date and shall execute all such work.
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MECON LIMITED STANDARD TECHNICAL SPECIFICATION OF WELDING OF
DELHI ONSHORE PIPELINES
REV 0, EDITION - 1
FOR
WELDING OF ONSHORE PIPELINES
SPECIFICATION NO.: MEC/S/05/28/02

MECON LIMITED
DELHI 110 092
0 15.10.2015 FIRST ISSUE KRISHNA PATEL SHALINI SINGH

HARDEEP SINGH ABHISHEK AGGARWAL SUNIL KUMAR
45 of 911
REV 0, EDITION - 1
CONTENTS
SL.NO. DESCRIPTION
01.0 SCOPE
02.0 APPLICABLE CODES, STANDARDS & SPECIFICATIONS
03.0 MATERIAL SPECIFICATIONS
04.0 WELDING CONSUMABLES
05.0 EQUIPMENT & ACCESSORIES
06.0 WELDING PROCESSES
07.0 BEVEL CLEANING AND BEVEL INSPECTION
08.0 ALIGNMENT AND SPACING
09.0 WEATHER CONDITIONS
10.0 WELDING
11.0 HEAT TREATMENT
12.0 INSPECTION AND TESTING
13.0 REPAIR OF WELDS
14.0 DESTRUCTIVE TESTING OF WELDED JOINT - BUTT WELDS
15.0 ULTRASONIC INSPECTION
16.0 AUTOMATED ULTRASONIC TESTING (AUT)
17.0 RADIOGRAPHY
ANNEXURE-I - ELECTRODE QUALIFICATION TEST RECORD

ANNEXURE-II - STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION
ANNEXURE-III - FORMAT FOR WELDING PROCEDURE SPECIFICATION (WPS)
ANNEXURE-IV - FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR)
ANNEXURE-V - FORMAT FOR MANUFACTURER'S RECORD FOR WELDER OR WELDING
OPERATOR QUALIFICATION TESTS
ANNEXURE-VI - RADIOGRAPHIC PROCEDURE QUALIFICATION RECORD FOR PIPE WELDING
ANNEXURE-VII - WELDERS IDENTIFICATION CARD
ANNEXURE-VIII - TYPE OF SOURCE AND FILMS TO BE USED FOR RADIOGRAPHY
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REV 0, EDITION - 1
AMENDMENT STATUS

47 of 911
01. SCOPE
This specification stipulates requirements for fabrication of all types of welded joints of
carbon steel main pipeline systems covering the pipeline and its facilities, which will
include the following:
• All line pipe joints of the longitudinal and circumferential butt welded and socket
welded types.
• Branch connections
• Joints in welded/ fabricated piping components.
• Attachments of castings, forgings, flanges and supports to pipes.
• Attachments of smaller connections for vents/ drain pipes and tappings for
instrumentation.
• Welded manifold headers and other sub-assemblies.
Note: Any approval accorded to the Contractor shall not absolve him of his
responsibilities and guarantees.
02. APPLICABLE CODES, STANDARDS & SPECIFICATIONS
All welding works, equipment for welding, heat treatment, other auxiliary functions and
the welding personnel shall meet the requirements of the latest editions of the
following codes, standards and specifications as listed below :-
• Code for Gas Transmission and Distribution Piping System (ANSI B31.8)
• Pipeline Transportation System for Liquids and Slurries (ANSI B31.4)
• Standard for welding of Pipelines and Related Facilities (API 1104).
• Specification for welding Electrodes and Filler Materials (ASME Sec. II C).
• Non Destructive examination (ASME Sec. V).
• Welding and Brazing Qualification, ASME Sec. IX.
03. MATERIAL SPECIFICATIONS
• In general carbon steel is used in this specification. The details of material

specifications will be given in a welding Specification Chart attached along with
other project data sheets.
48 of 911
• The CONTRACTOR will keep a record of test certificates of all the materials for the
reference of the welding engineer.
04. WELDING CONSUMABLES
The CONTRACTOR shall provide at his own expenses all the welding consumables
necessary for the execution of the job such as electrodes, oxygen, acetylene etc. and
the same shall be approved in advance by the Purchaser/ Consultant.
The welding electrodes/ filler wires supplied by the CONTRACTOR shall conform to the
class specified in the welding specification chart. The materials shall be of the make
approved by the COMPANY.
The electrode shall be suitable for the welding process recommended and base metal
used. Physical properties of the welds produced by an electrode recommended for the
welding of a particular base metal shall not be lower than the minimum values
specified for the base metal unless otherwise specified in Welding Specification Chart
and shall correspond to the physical properties of the class of electrode adopted. The
choice of electrode shall be made after conducting the required tests on the electrodes
as per relevant standards, and shall be the sole prerogative of the COMPANY.
The CONTRACTOR shall submit batch test certificates from the electrode
manufacturers giving details of physical and chemical tests carried out by them for
each batch of electrode to be used.
Electrode Qualification test records shall be submitted as per Annexure-I with respect
to the electrodes tested by the CONTRACTOR and submitted for approval of the
COMPANY.
All electrodes shall be purchased in sealed containers and stored properly to prevent
deterioration. The electrodes removed from the containers (except cellulosic coated
electrodes) shall be kept in holding ovens at the temperature recommended by the
electrode manufacturer. Ovens shall be used for low hydrogen electrodes only. Out-of-
the oven time of electrodes, before they are consumed, shall not exceed the limits
recommended by the electrode manufacturer. The electrodes shall be handled with
care to avoid any damage to the flux covering.
The electrodes used shall be free from rust, oil grease, earth and other foreign matter
which affect the quality of welding.
Different grades of electrodes shall be stored separately. Cellulosic electrodes used

shall however be used as per specific recommendations of manufacturer.
04.01 Shielding Gas
The composition and purity of shielding gas when required by the welding processes
other than shielded metal arc welding, when permitted by the COMPANY, shall have
prior approval of the COMPANY. Where appropriate, gases or gas mixture of the
following quality shall be used.
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a) argon complying with BS 4365
b) carbon dioxide complying with type 1 specified in BS 4105
c) gas mixture that have been proved to be satisfactory as a result of procedure

approval tests.
When a gas mixture is used which has specified additions, e.g. 2% O2, 5% CO2 the
variation of such addition shall not exceed ± 10% of that stated. Moisture content shall
correspond to a dew point of - 30°C or lower.
05. EQUIPMENT & ACCESSORIES
5.1 The CONTRACTOR shall have sufficient number of welding and cutting equipment,
auxiliaries and accessories of sufficient capacities to meet the target schedule.
5.2 All the equipment for performing the heat treatment including transformers,
thermocouples, pyro-meters, automatic temperature recorders with suitable calibration
arrangements, etc. shall be provided by the CONTRACTOR, at his own expenses and
these shall bear the approval of the COMPANY. Adequate means of measuring current
and voltage shall be available.
5.3 Redoing of any work necessitated by faulty equipment or operation used by the
CONTRACTOR, will be done at his own expense.
06. WELDING PROCESSES
6.1 Welding of various materials under this specification shall be carried out using Shielded
Metal Arc Welding process (SMAW) / FCAW with the approval of the COMPANY.
6.2 The welding procedure adopted and the consumables used shall be specifically.
6.3 A combination of different welding processes or a combination of welding consumables

of different classes / makes could be employed for a particular joint, only after duly
qualifying the welding procedures to be adopted and obtaining the approval of the
Company.
6.4 The welding processes to be employed are given in the welding specification chart. Any
deviation desired by the CONTRACTOR shall be obtained through the express consent
of the COMPANY.
6.5 Automatic process shall be employed only with the express approval of the COMPANY.
The welding procedure adopted and consumables used shall be specifically approved.
6.6 A combination of different welding processes or a combination of electrodes of

different classes/ makes could be employed for a particular joint only after qualifying
the welding procedures to be adopted and obtaining the approval of the COMPANY.
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07. BEVEL CLEANING AND BEVEL INSPECTION
Line pipe supplied by COMPANY shall have bevel ends as specified in the applicable
specification for Line Pipe attached with the Bid Package. Any modification thereto, if
required by CONTRACTOR due to his special welding technique shall be carried out by
the CONTRACTOR at his own cost.
Before welding, all rust and foreign matter shall be removed from the bevelled ends by
power operated tools. This shall be effected inside and outside and for a minimum
distance of 25mm from the edge of the weld bevel. The bevels shall be thoroughly
inspected at this stage. If any of the ends of the pipe joints are damaged to the extent
that, in the opinion of COMPANY, satisfactory weld spacing cannot be obtained and
local repair by grinding cannot be successfully done, the damaged ends shall be cut
and re-bevelled to the satisfaction of the COMPANY, with an approved bevelling
machine. Manual cutting and weld repairs of bevels is not allowed. Should laminations,
split ends or inherent manufacturing defects in the pipe be discovered, the lengths of
pipe containing such defects shall be removed from the line to the satisfaction of
COMPANY. On pipes which have been cut back, a zone extending 25mm back from the
new field bevel, shall be ultrasonically tested to the requirement of the line pipe
specification to ensure freedom from laminations. The new bevel shall be subjected to
100% visual and 100% dye penetrant/ MPI tests. A report shall be written for all
testing and records kept.
08. ALIGNMENT AND SPACING
Immediately prior to line-up CONTRACTOR shall inspect the pipe ends inside and
outside for damage, dents, laminations etc. Pipe for welding shall be set up, correctly
spaced, allowing for temperature changes during welding, in correct alignment and
shall in no circumstances be sprung into position. Temporary attachments of any kind
shall not be welded to the pipe. Welds joining the sections of the pipelines, valve
installation or similar welds classified as tie-in welds shall be made in the trench.
Otherwise the alignment and welding shall be made alongside the ditch with the pipe
supported on skids and back pad or other suitable means approved by COMPANY, at
least 500mm above the ground, unless approved by the COMPANY in specific cases.
Seam orientation of welded pipe shall be selected to ensure that at the circumferential
welds, the longitudinal welds shall be staggered in the top 90° of the pipeline, or
250mm whichever is the lesser. A longitudinal joint shall pass an appurtenance of a
structural element at a minimum distance of 50mm. Should a section of the line
containing uncompleted welds fall from the skids, the CONTRACTOR shall immediately
inform COMPANY.
Every effort shall be made to reduce misalignment by the use of the clamp and
rotation of the pipes to obtain the best fit. For pipe of same nominal wall thickness off-
set shall not exceed 1.6mm. The off set may be checked from outside using dial
gauges. Any branch connection, sleeve, etc. shall be atleast 150mm from any other
weld. The welds for fittings shall be so located that the toe of the cold dressing is
permissible only in cases of slight misalignment and may only be carried out with a
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bronze headed hammer. Hot dressing shall not be permitted. When welding pipes of
different wall thickness (as directed by COMPANY) a special transition piece shall be
used. This shall have a minimum of 1:4 taper. The welds shall be subject to both
ultrasonic and radiographic inspection.
The root gap shall be accurately checked and shall conform to the qualified welding
procedure. The use of internal line-up clamps is mandatory for pipe diameters 10" and
above. However, in some cases (tie-in welds, flanges, fittings, diameter of pipe 10"
etc.) where it is impossible to use internal clamps, an external line-up clamp may be
used.
The internal line-up clamp shall not be released before the entire root pass has been
completed.
When as external line-up clamp is used, all spaces between bars or at least 60% of the
first pass shall be welded before the clamp is released and the pipe remaining
adequately supported on each side of the joint.
Segments thus welded shall be equally spaced around the circumference of the pipe.
Slag, etc. shall be cleaned off and the ends of the segments shall be prepared by
grinding, so as to ensure continuity of the weld bead.
09. WEATHER CONDITIONS
The parts being welded and the welding personnel shall be adequately protected from
rain and strong winds. In the absence of such a protection no welding shall be carried
out. The completed welds shall be suitably protected in case of bad weather
conditions.
10.0 WELDING
10.1 Root Pass
a) Root pass shall be made with electrodes/ filler wires recommended in the
welding specification chart attached along with other project data sheets. The
size of the electrodes used shall be as per the approved welding procedure.
b) Position or roll welding (for yard double jointing) may be permitted. Separate
procedures shall be submitted and qualified for up hill, down hill, vertical down
and roll welding. The vertical up method of welding shall be used for the root
pass of the tie-ins, special crossings, fittings and special parts, filled welds,
repairs and when an external line up clamp is used. The down hill welding may
be used for root run welding of tie-ins and special crossings when (a) the edges
are machined or have equivalent preparation (b) line up clamps are used and
the fit up is geometrically and mechanically similar to one of the oridinary line
welding without misalignment or uneveness.
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c) The root pass of butt joints shall be executed properly so as to achieve full
penetration with complete fusion of the root edges. Weld projection inside the
pipe shall not exceed 1.6 mm wherever not specified by the applicable code.
d) Any deviation desired from the recommended welding technique and electrodes
indicated in the welding specification chart shall be adopted only after obtaining
express approval of the COMPANY.
e) Welding shall be continuous and uninterrupted during a pass.
f) On completion of each run, craters, welding irreigularities, slag, etc., shall be

removed by grinding and chiselling.
g) While the welding is in progress care shall be taken to avoid any kindof
movement of the components, shocks, vibration and stresses to prevent
occurance of weld cracks.
h) Fillet welds shall be made by shielded metal arc welding process irrespective of
the thickness and class of piping. Electrode size shall not exceed 3.25mm
diameter for socket joints. Atleast two passes shall be made on socket weld
joints
i) Peening shall not be used.
10.2 Joint Completion
In case of manual welding, the first pass shall be carried out by a minimum of two
welders, working simultaneously and so placed as to cause minimum distortion of the
pipe.
The number of welders and the allowable welding sequences shall be as those laid
down in the qualified welding procedure specification. Once the deposit of the first
pass has been started, it must be completed as rapidly as possible, reducing
interruptions to the minimum. The welding and wire speed shall be approximately
same as that established in the Qualified Welding Procedure Specification (QWPS).
The pipe shall always be adequately supported and must not be pumped or shaken
during welding. The clamp shall be removed, as indicated in clause 8.0 above. Before
starting the second pass, the first pass shall be cleaned and flattened with rotating
grinders.
The interruption between completion of the first pass and starting the second pass
shall be as stated in the procedure specification.
For crack prevention a top and bottom reinforcement of at least one electrode shall be
applied before lowering the pipe on the skid.
The welding speed selected shall enable production of a bead which is sufficiently thick
53 of 911
and which shows no undercutting.
The time lapse between second and third pass shall be as stated in the procedure
specification, normally not exceeding five minutes. After completion of the third or
following passes, welding operations may be suspended, so allowing the joint to cool
down, provided that the thickness of the weld metal deposited is equal to at least 50%
of the pipe thickness. Upon restarting, depending on the materials, wall thickness and
welding process, a preheating to atleast 100°C shall be carried out. Subsequent passes
up to weld completion shall be protected to avoid rapid cooling, if meteorological
conditions so dictate. Cleaning between passes shall be done carefully so as to reduce
the possibility of inclusions.
Electrodes starting and finishing points shall be staggered from pass to pass. Arc-
strikes outside the bevel on the pipe surface are not permitted. Arc - strike or arc-burn
on the pipe surface outside the weld, which are caused accidentally by electrical arcs
between the electrodes, electrode holder, welding cable shall be removed by grinding
in accordance with a procedure approved by COMPANY and the repair checked by
ultrasonic, radiographic, magnetic particle or dye penetrant tests which the COMPANY
feels necessary. The pipe wall thickness after grinding shall not be less that the
minimum thickness limit permitted for the pipe. Repair of arc-strikes by welding is
prohibited.
The completed weld shall be carefully brushed and cleaned and shall appear free from
spatters, scales, etc.
These requirements apply not only to completed welds but also to the bare strip at
least so wide so as to allow full skid examination at both ends of the pipe to allow a
good ultrasonic inspection when it is required.
11.0 HEAT TREATMENT
11.1 Preheating
Preheating, if required, shall be carried out as per the following :
a) Preheating requirements for the various materials shall be as per the welding
specification chart.
b) Preheating shall be performed using resistance or induction/ heating methods.

Preheating by gas burners, utilizing acetylene or propane gas may also be
carried out. Oxypropane gas may be used with the permission of the COMPANY
under careful supervision.
c) Preheating shall extend uniformly to at least three times the thickness of the
joint, but not less than 50mm, on both sides of the weld.
d) Preheating temperature shall be maintained over the whole length of the joint
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during welding. Temperature indicating crayons or other temperature indicating

devices shall be provided by the CONTRACTOR to check the temperature.
11.2 Postweld Heat Treatment
a) Post weld heat treatment, wherever required for joints between pipes and
fittings, pipe body and supports shall be carried out by the CONTRACTOR at his
expense as per the relevant specifications, applicable standards and the
instructions of the COMPANY.
b) The heat treatment of welded joints shall be carried out as per the
requirements laid down in ANSI B31.8 / ANSI B31.4 and other special
requirements mentioned in welding specification chart.
c) The CONTRACTOR shall submit for the approval of the COMPANY, well before
carrying out actual heat treatments the details of the post weld heat treatment
procedure, as per Annexure-II attached, that he proposes to adopt for each
of the materials/ assembly/ part involved.
d) Post weld heat treatment shall be done in a furnace or by using an electric

resistance or induction heating equipment, as decided by the COMPANY.
e) While carrying out local post weld heat treatment, technique of application of
heat must ensure uniform temperature attainment at all points of the portion
being heat treated. Care shall be taken to ensure that width of heated band
over which specified post weld heat treatment temperature is attained is atleat
as that specified in the relevant applicable standards/ codes.
The width of the heated band centered on the weld shall at least be equal to
the width of weld plus 2" (50mm). The temperature gradient shall be such that
the length of the material on each side of the weld, at a temperature exceeding
half the heat treatment temperature, is atleast 2.5 r*t where is the bore radius
and t is the pipe thickness at the weld.
f) Throughout the cycle of heat treatment, the portion outside the heat band shall
be suitably wrapped with insulation so as to avoid any harmful temperature
gradient on the exposed surface of pipe. For this purpose temperature at the
exposed surface of the pipe shall not be allowed to exceed 400°C.
g) The temperature attained by the portion under heat treatment shall be

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

employed. The calibration chart of each recorder shall be submitted to the
COMPANY prior to starting the heat treatment operation and its approval shall
be obtained.
i) Immediately on completion of the heat treatment, the post weld heat

treatment charts/ records alongwith the hardness test results on the weld joints
(whenever required as per the welding specification chart) shall be submitted
to COMPANY for its approval.
j) Each joint shall bear an identification number which shall be maintained in the
piping sketch to be prepared by the CONTRACTOR. The joint identification
number shall appear on the corresponding post weld heat treatment treatment
charts. The same identification numbers shall also be followed for identification
on corresponding radiographic films. The chart containing the identification
number and piping sketch shall be submitted to the COMPANY in suitable
folders.
k) Vickers hardness/ Brinnel hardness of the heat affected zone as well as of the
weld metal, after heat treatment shall be measured using a suitable hardness
tester and shall not exceed the maximum hardness specified in the welding
specification chart. The weld joint shall be subjected to reheat treatment, when
hardness measured exceeds the specified limit, at the CONTRACTOR's own
expense.
l) The CONTRACTOR shall arrange for the hardness testing and shall maintain the
records of all the joints tested. These records shall be checked by the
COMPANY.
12.1 General
a) The COMPANY's Inspector shall have free access to all concerned areas, where
the actual work is being performed. The CONTRACTOR shall be also provide
the COMPANY's inspector all means and facilities necessary to carry out
inspection.
b) The COMPANY is entitled to depute its own inspector to the shop or field where
pre-fabrication and erection of pipelines are being done, with (but not limited
to) the following objectives :-
i. To check the conformance to relevant standards/ specifications and

suitability of various welding equipment and the welding performance.
ii. To supervise the welding procedures qualification.
iii. To supervise the welder's performance qualification.
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iv. To carry out visual/NDT examination of the weldings.
v. To check whether shop/ field welding is being executed is in

conformity with the relevant specification and codes of practice
followed in pipe construction.
c) CONTRACTOR shall intimate sufficiently in advance the commencement of

qualification tests, welding works and acceptance tests, to enable the
Company’s inspector to be present to supervise the same.
12.2 Welding Procedure Qualification
a) Welding procedure qualification shall be carried out in accordance with the

relevant requirements of API 1104 latest edition or other applicable codes and
other job requirements by the CONTRACTOR at his expense. The
CONTRACTOR shall submit the welding procedure specification chart format as
per Annexure-III (attached) immediately after the receipt of the order.
b) COMPANY's inspector will review, check and approve the welding procedure
submitted and shall release the procedure for procedure qualification tests. The
procedure qualification test shall be carried out by the CONTRACTOR under
field conditions at his own expense. A complete set of test results in format as
per Annexure-III & Annexure-IV (attached) shall be submitted to the
COMPANY's Inspector for approval immediately after completing the procedure
qualification test and atleast 2 weeks before the commencement of actual
work. Standard tests as specified in the code shall be carried out in all cases. In
addition to these, tests, other tests like radiography, macro/ micro examination,
hardness tests, dye penetrant examination, charphy V-notch etc. shall be
carried out on specimens. It shall be the responsibility of the CONTRACTOR to
carry out all the tests required to the satisfaction of the COMPANY's Inspector.
The destructive testing of welded joints shall be as per Clause 14.0.
12.3 Welder's Qualification
a) Welders shall be qualifed in accordance with the API 1104 and other applicable
specifications by the CONTRACTOR at his expense. The butt weld test pieces of
the qualification test shall meet the radiographic test requirements specified in
Clause 12.5 and 16.0 of this specification. The COMPANY's Inspector shall
witness the test and certify the qualification of each welder separately. Only
those welders who have been approved by the COMPANY's Inspector shall be
employed for welding. CONTRACTOR shall submit the welder qualification test
reports in the standard format as shown in Annexure-V and obtain express
approval, before commencement of the work. It shall be the responsibility of
57 of 911
CONTRACTOR to carry out qualification tests of welders and obtain written

approval, before commencement of works.
b) The welders shall always have in their possession the identification card as
shown in Annexure-VII and shall produce it on demand by the COMPANY's
Inspector. It shall be the responsibility of the CONTRACTOR to issue the
identity cards after it has been duly certified by the COMPANY.
c) No welder shall be permitted to work without the possession of identity cards.
d) If a welder is found to perform a type of welding or in a position for which he is

not qualified, he shall be debarred from doing any further work. All welds
performed by an unqualified welder shall be cut and redone by a qualified
welder at the expense of the CONTRACTOR.
12.4 Visual Inspection
Inspection of all welds shall be carried out by COMPANY as per the latest editions of
the applicable codes and specifications. All finished welds shall be visually inspected for
parallel and axial alignment of the work, excessive reinforcement, concavity of welds,
shrinkage, cracks, under-cuts, dimensions of the weld, surface porosity and other
surface defects. Undercutting adjacent to the completed weld shall not exceed the
limits specified in the applicable standard/ code.
12.5 Non Destructive Examination
The non destructive examination shall mainly consist of examination using x-ray
radiography as detailed in Clause 16.0.
12.5.1 Radiographic examination of one hundred percent (100%) girth welds will be required
by the COMPANY.
The non-destructive examination shall mainly consist of examination using Automated

Ultrasonic Testing (AUT) as detailed in clause no. 16.0. This shall be applicable for all
welds made by automatic GMAW process with narrow gap edge preparation and welds
made by semi-automatic FCAW process.
The CONTRACTOR shall make all the arrangements for the AUT of work covered by
the specification at his expense. The CONTRACTOR shall furnish all the reports to the
COMPANY, immediately after examination together with the corresponding
interpretation reports on the approved format. The details of the AUT reports along
with the joint identification number shall be duly entered in a register and signed by
the CONTRACTOR and submitted to the COMPANY for approval. The COMPANY will
review all the AUT records of welds and inform the CONTRACTOR to those welds,
which are unacceptable. The decision of the COMPANY shall be final and binding in this
regard.
For 150# Rating Pipeline, welds shall meet the standards of acceptability as set forth in
58 of 911
API 1104. However for higher class rating pipeline welds shall meet the standards of
acceptability as set forth in API 1104 and as well as the requirements laid in
subsequent paragraphs.
The CONTRACTOR shall make all the arrangements for the radiographic examination of
work covered by the specification at his expense.
All requirements mentioned in the specification shall be arranged and executed by the
CONTRACTOR through his own resources. In addition, Radiography examination shall
be required in the following cases as per clause no. 17.0 of this Specification for pipes
with wall thickness 9.5mm and above, ultrasonic inspection is required in the following
cases as per clause 15.0 of this specification.
a) On the first 100 welded joints corresponding to each automatic GTAW / GMAW
and Semi-automatic FCAW welding procedure used.
b) When 20mm or more are cut from the pipe end as supplied, the ends shall be
ultrasonically inspected for an additional length of 20mm to assure no
lamination exist.
c) When welds are repaired.
d) When in the opinion of COMPANY, ultrasonic inspection is required to confirm

or clarify defects indicated by radiography.
e) When automatic procedure is used at least 10 cm on each weld shall be

ultrasonically inspected at COMPANY's discretion.
f) Welding of Transition piece of pipe.
In addition, Radiography inspection may be required for certain critical welds of the
pipeline, i.e. tie-ins, welding of valves, flanges, randomly selected at COMPANY
discretion. All fillet and groove welds, other than those AUT examined, shall be
subjected to Dye-Penetrant /MP testing followed by manual Ultrasonic testing.
The non-destructive testing system used for inspecting welds must by approved by the
COMPANY.
All other welds made of FCAW and SMAW processes and the Tie-in joints having API
bevel shall be examined by Radiography. When Radiography is used, the provisions
stated in this para shall be applicable.
- For all production welds, X-ray Radiography by internal crawlers be used.
Welds shall meet the standards of acceptability as set forth in API 1104 and as well as
the requirements laid in subsequent paragraphs.
The CONTRACTOR shall make all the arrangements for the Radiography examination
of work covered by the specification at his expense.
59 of 911
The COMPANY will review all the radiographs of welds and inform the CONTRACTOR
regarding unacceptable welds. The decision of the COMPANY shall be final and binding
in this regard.
All the requirements mentioned in the specification shall be arranged and executed by
the CONTRACTOR through his own resources. In addition, Ultrasonic inspection is
required in the following cases as per clause no. 15.0 of this specification:
a) On the first 10 welded joints corresponding to each automatic GMAW and semi-
automatic FCAW welding procedures used.
b) When welds are repaired.
c) When in the opinion of COMPANY, Ultrasonic inspection is required to confirm
or clarify defects indicated by Radiography.
In addition, Ultrasonic inspection may be required for certain critical welds of the
pipeline, i.e. tie-ins, welding of valves, flanges, randomly selected at COMPANY
discretion. All fillet and groove welds, other than those are subjected to Radiography,
shall be subjected to Dye-Penetrant/MP inspection. The non-destructive testing system
used for inspecting welds must by approved by the COMPANY.
Acceptance Criteria
Weld quality is judged on the basis of the acceptability criteria mentioned below:
Any weld which as a result of radiographic and/ or ultrasonic examination in the

opinion of COMPANY exhibits imperfections greater than the limits stated in API-1104
latest edition or as superseded in this specification shall be considered defective and
shall so be marked with an identification point marker.
In addition to the API-1104 requirements, the welds containing cracks including crater
cracks regardless of size of location are unacceptable.
1. Any length of inadequate penetration of the root bead as defined by API-

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

on the day to day work done on welding, radiography, ultrasonic testing. The
CONTRACTOR shall present the records to the COMPANY on day to day basis and
whenever demanded, for approval.
12.6 Destructive Testing
The COMPANY has the authority to order the cutting of upto 0.1% of the total number
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of welds completed for destructive testing at no extra cost of COMPANY. The

destructive testing of weld joints shall be made as per Clause 14.0.
In addition, welds already cut out for defects for any reason may also be subjected to
destructive testing. The sampling and the re-execution of welds shall be carried out by
the CONTRACTOR at his own expense. If the results are unsatisfactory, welding
operations shall be suspended and may not be restarted until the causes have been
identified and the CONTRACTOR has adopted measures which guarantee acceptable
results. If it is necessary in the COMPANY's opinion the procedure shall be re-qualified.
The weld joint represented by unsatisfactory welds shall stand rejected unless
investigation prove otherwise.
13.0 REPAIR OF WELDS
13.1 With the prior permission of COMPANY, welds which do not comply with the standards
of acceptability shall be repaired or the joint cut out and re-welded.
A separate welding procedure specification sheet shall be formulated and qualified by

CONTRACTOR for repair welds simulating the proposed repair to be carried out.
Separate procedures are required to be qualified for (a) thorough thickness repair (b)
external repair and (c) internal repair. Welders shall be qualified in advance for repairs.
The root pass, for repairs opening the root, shall be done by the vertical uphill
technique. The procedure shall be proven by satisfactory procedure tests to API 1104
including the special requirement of the specification, and shall also be subject to
metalographic examination, hardness surveys and Charpy tests to determine the
effects of repair welding on the associated structure.
Root sealing or single pass repair deposit shall not be allowed. Internal root defects
shall be ground thoroughly and welded with a minimum of two passes. However, while
grinding for repairs, care shall be taken to ensure that no grinding marks are made on
the pipe surface anywhere.
The repair shall be subjected, as a minimum requirement to the same testing and
inspection requirements as the original weld. The re-radiography of repaired weld shall
be limited to 6” weld length on either edge of the repaired area. A 100% ultrasonic
test shall be done at the repaired area externally. Any repaired area that is wide,
irregular or rough shall be rejected and a full cut out shall be done. Single pass repairs
shall be subjected to 100%, Dye-Penetrant / MP testing.
Repairs are limited to a maximum of 30% of the weld length. Not more than two
repairs are permitted on the same location. A report of all repairs shall be maintained
by CONTRACTOR and submitted every day to the Company / Consultant.
13.2 Weld Rejected by Accumulation of Defects
Where a weld is rejected by the accumulation of defect clause, as defined by API 1104
and this specification, repairs within these limitations are permitted. Defects in the
filling and capping passes shall be repaired preferentially.
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14. DESTRUCTIVE TESTING OF WELDED JOINT - BUTT WELDS
14.1 Preparation
Having passed the visual and the non-destructive-inspection the test weld shall be
subject to mechanical test.
After satisfactory completion of all visual and non-destructive testing the test weld shall
be set aside for a period not less than 24hours. No further work on the test weld and
no cutting of test specimens from the weld shall be performed until a period of at least
24 hours has expired. Having passed the visual and the nondestructive inspection, the
test weld shall be subjected to mechanical test.
Weld specimens shall be taken from the positions indicated in Fig. 1 of this
specification from areas as free from defects as possible; for this reason it is necessary
to take the previous non-destructive tests into account. The minimum number of tests
to be carried out is given in Table-1 of this specification.
The tests shall be carried out in laboratories approved by the COMPANY. The
specimens shall be prepared in accordance with the figures given in the paragraphs
which refer to the individual tests.
14.2 Tensile Strength
Specimens shall be taken from the position indicated in Fig. 1 & 1A of this
specification. Two ISO type specimens and two API - type specimens shall be taken.
The ISO test specimen are shown in Fig. 2 of this specification.
14.2.1 Method
The test shall be carried out in accordance with ISO:375.
Table-1
Type and Number of Test Specimens for
Procedure Qualification Test & Production Welds
Pipe Size, Number of Specimens

Out Side
Diamter- Tensile Tensile Nick Root Face Side Macro Hard- Impact Total
Inches API ISO Break Bend Bend Bend Bend ness
Wall Thickness - ½ inch (12.7mm) and Under
Under 2-3/8 0 0 2 2 0 0 0 0 0 4
2-3/8 to 4- 0 0 2 2 0 0 0 0 0 4
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½ incl.
Over 4-½ 2 0 2 2 2 0 2 2 12 24
less than
12.75
12- 3/4 and 2 2 4 4 4 0 2 2 24 44

over
Wall Thickness - Over ½ inch (12.7mm)
4-½ and 0 2 0 0 0 2 0 0 0 4
smaller
Over 4-½ 2 0 2 2 2 0 2 2 12 24
less than
12-3/4
12-3/4 and 2 2 4 0 0 8 2 2 24 44
over
14.3 Nick-Break Test
14.3.1 Preparation
Specimens for Nick-break test with notches thus worked can break in the base metal,
instead of in the fusion zone; therefore an alternative test piece may be used after
authorisation by the COMPANY with a notch cut in the reinforcement of outside weld
bead to a maximum depth of 1.5mm measured from the surface of the weld bead.
14.4 Macroscopic Inspection
14.4.1 Preparation
Specimens shall be taken from the positions indicated in Fig. 1 of this specification and
shall be prepared in accordance with ASTM E2 and E3.
The width of the macrosection has to be at least three times the width of the weld.
The section is to be prepared by grinding and polishing and etched to clearly reveal the
weld metal and heat affected zone.
14.4.2 Method
Specimens shall be carefully examined under the microscope, with a magnification of

atleast 25 times (25:1). The COMPANY may ask for a macrograph with 5 times (5:1)
magnification for DOCUMENTATION purposes.
14.4.3 Requirements
Under macroscopic examination, the welded joints shall show good penetration and
fusion, without any defect exceeding the limits stated in the evaluation criteria of the
nick break test.
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14.5 Hardness Test
14.5.1 Preparation
The prepared macrosection is to be used for hardness testing using the Vickers
method with 10 kg load Indentations are to be made along traverses each
approximately 1mm below the surface on both sides of the weld.
In the weld metal a minimum of 6 indentations equally spaced along the traverses are
to be made. The HAZ indentations are to be made along the traverses for
approximately 0.5mm each into unaffected materials, and starting as close to the
fusion line as possible.
One indentation on each side of the weld along each traverse is to be made on parent
metal. Refer Fig.3. The indentations are to be made in the adjacent regions as well on
the opposite sides of the macrosection along the specified traverses.
14.5.2 Method
The test shall be carried out in accordance with Recommendation ISO R81, Vickers
hardness, using a laboratory type machine controlled as pre-recommendation ISO R146
and using a diamond pyramid penetrator set at 2.37 rad (136°) with a load of 10 kg.
14.5.3 Requirements
Hardness value shall not exceed the limit specified in welding Specification chart. In
case of a single reading having a slightly (+10 HV) higher value than the specified
limit, further indentations shall be made to check if the high value was an isolated
case.
All the hardness values contained from the heat affected zone shall not exceed 100 HV
with respect to the average hardness of the values obtained for the base metal. If
these additional tests give a hardness within the specification limit the slightly higher
value may be accepted.
14.6 Charpy - V - Notch Impact Test
14.6.1 Specimens shall be taken from the position indicated in Fig. 1 of this specification. The
test specimens will be prepared in accordance with ISO R148. Charpy V-notch
specimens shall have dimensions as given in Fig. 3 of this specification.
Three test specimens shall be taken from each sample and they shall be cut and
worked so that their length is transverse and perpendicular to the weld bead with the
notch position as shown in Fig. 4 of this specification. The notch shall be perpendicular
to the roller surface. The test specimen width shall depend upon the pipe wall nominal
thickness as following :
Sl. Nominal Wall Thickness in mm Test Specimen width mm
No.
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1. Over 12 10
2. Over 9.5 and upto 12 7.5
3. From 7 upto 9.5 5
4. Less than 7 2.5
14.6.2 Test Method
The test shall be carried out as indicated in ISO R148 "Beam impact test V-notch".
Test pieces shall be immersed in a thermostatic bath and maintained at the test
temperature for at least 15 minutes. They shall then be placed in the testing machine
and broken within 5 seconds of their removal from the bath. The test temperature
shall be as mentioned in Special conditions of the Contract.
14.6.3 Requirements (Note-1)
The impact energy shall be as follows :
Sl. Test Specimen in "Average of three Minimum Single

No. mm Specimens (Note-2) Value (Note-1)
Joules (Min.) Joules
1. 10.0 27.0 22.0

2. 7.5 21.5 17.0
3. 5.0 18.5 15.0
4. 2.5 10.0 8.0
Note :
1) Only one value is permitted to be lower than average value upto the value
specified.
2) These values are specified for resistance to brittle fracture only, where
additional requirements are specified in project data sheet. (Ex. pipeline
materials with arrest properties i.e. a higher upper shelf charpy V-energy for
resistance against propagating ductile fractures) the same shall be followed.
14.7 Bend Test Requirements
The Bend test Specimens shall be made and tested as per the requirements of API
1104 Sixteenth Edition May 1983 except that the dimensions of the Jig for guided bend
test Fig. 5 para 2.6 API 1104 shall be modified as follows:
Radius of the Plunger `A' : 2t

Radius of the die `B' : 3 t + 1.6mm
Radius of the die `C' : 50.8mm
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The acceptance criterion on shall however be as per para 2.643 and 2.653 of API 1104
nineteenth edition Sept. 1999.
Note : t = thickness of specimen
15. ULTRASONIC INSPECTION
In addition to the radiographic inspection, ultrasonic inspection is required as per

conditions listed in paragraph 12.5 of this specification. This section concerns manual
ultrasonic inspection. However ultrasonic by automatic equipment may be used if
15.1 Equipment and Operators
The CONTRACTOR who carries out the ultrasonic inspection shall have sufficient
qualified personnel equipment and instruments at his disposal to be able to effect the
tests without hindering or delaying the pipeline assembly operations.
The operators shall be fully qualified as per a recognised standard (ASME Sec. V or
equivalent) and they shall have as minimum level II as described in para 11.4.3, API
1104; nineteenth edition. The operators shall be able to :
 calibrate the equipment ;

 perform an operational test under production conditions;
 interpret the screen picture ;
 evaluate the size and location of reflectors
 interpret the type of defects detected
The COMPANY has the option of checking the ability of personnel employed for
ultrasonic testing by means of qualification tests.
The CONTRACTOR appointed to carry out ultrasonic inspection shall supply all the
instruments necessary for their execution on site.
15.2 Specification for Ultrasonic Inspection Procedure Qualification
Before work begins, the CONTRACTOR shall present a specification describing the
proposed U.T. procedure qualification.
This specification shall state, as an indication only but not limited to the following
information :
 type of U.T. equipment used

 type and dimensions of transducers
 frequency range
 details for calibration
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 coupling medium
 inspection technique
 record details
 reference to the welding procedure where it is intended to adopt the
specification.
 temperature range of the joints to be inspected.
15.3 Qualification of Ultrasonic Inspection Procedure
The ultrasonic inspection procedure shall be approved by the COMPANY. Before

inspection begins, the COMPANY may require the qualification test of the ultrasonic
inspection procedure. This specification test consists in testing (under normal operating
conditions) some CONTRACTOR welds made according to the same production
procedure, where there are typical defects the test intends to detect.
This test shall be conducted in the presence of the COMPANY. The Ultrasonic
inspection procedure shall be approved by the Company.
15.4 Test Procedure
Circumferential welds shall be inspected from both sides using angled probes.
The surface with which the probes comes into contact shall be free of metal spatter,
dirt, iron oxide, and scales of any type; therefore it shall be necessary to clean a strip
at least 50mmwide on both sides of the weld with steel wire brushes and anyhow the
cleaned strip must be atleast wide enough to allow full skip examination.
If, during the test, echoes of doubtful origin appear, it shall be necessary to inspect a
convenient area on the pipe surface, close to the weld, with a straight beam transducer
in order to check whether any manufacturing defects are present which could have
interfered with the ultrasonic beam.
By way of an example, the equipment shall include but not be limited to the following:-
 ultrasonic equipment and coupling medium

 sample sections for calibration of instruments
 equipment for cleaning of surface to be examined
 rules calibrated in centimeters for exact location of the position of defects.
The characteristics of the above - listed instruments and equipment shall guarantee:
a) that the required standards of the inspection procedure, as previously

established and approved by the COMPANY, are satisfied.
b) continuous operation
All the instruments and equipment shall be approved by the COMPANY before
being used. The COMPANY has the authority to reject any item which is
considered unsuitable. The decision of the COMPANY is final. The
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CONTRACTOR appointed to carry out ultrasonic inspections shall also ensure

the operational efficiency and maintenance of the instruments and equipment,
and shall immediately substitute any item rejected by the COMPANY.
All the instruments and equipment necessary for carrying out ultrasonic
inspection on site shall satisfy the requirements laid down by the public boards
of institutions which regulate `safety at work'.
15.5 Ultrasonic Instruments
The Ultrasonic Instruments shall satisfy the following:
 be pulse-echo type, able to generate, receive and display, on the screen a

cathode ray tube (CRT) pulse at frequencies between 1 and 6 MHz. The useful
part of the CRT screen shall be at least 70mm wide and at least 50mm high.
 shall have variable amplification, with steps of 1 or 2 dB over a range of a least
60 dB.
 the regulation control shall be accurate to within ±1 db and this accuracy shall
be certified by the instrument manufacturer.
 may be powered by a battery or an electric generator. In the first case, the
autonomy of operation (endurance) of the instrument shall be sufficient to
carry on working without frequent interruptions, and the instruments shall be
equipped with an automatic switch which switches it off when the battery runs
down; in the second case, there must be a voltage stabilizing device with a
tolerance of ±2 Volts.
15.6 Probes
The probes used shall have dimensions, frequencies, and a refraction angle suited to
the type of steel, the diameter, the thickness of the pipe and to the joint design.
15.7 Reference Sample Pieces
The efficiency of the equipment used, the effective refraction angle of the probe, and
the beam output point, shall be checked using a V1 and V2 sample block, IIW type or
calibration block ASTM E-428.
For manual Ultrasonic testing and automated Ultrasonic testing, the reference sample
pieces shall be as described in API 1104, Nineteenth Edition, para 11.4.5.
For the calibration of runs and the regulation of detection sensitivity during the test, a
calibration piece shall be used. This piece shall be taken from the production material,
and will be at least 150mm long (measured in the direction of the axis), and at least
50mm wide (measured in the direction of the circumference) (see Fig. 5 of this
specification).
In the middle of the inside and the outside surface of the calibration piece a groove
shall be made. The groove will have a rectangular cross-section, a flat bottom and the
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following dimensions.
 depth : 1 ± 0.1mm
 breadth (measured parallel to the 150mm side) : 1 ± 01mm
 Length (measured parallel to the 50mm side) not less than 30mm
In addition, the calibration piece shall have a hole, 2mm in diameter, passing through
its thickness and positioned so that during calibration the echoes returning from the
two grooves do not interfere with those returning from the hole.
15.8 Calibration
For a precise check of the sound paths necessary for a full inspection of the weld joint,
the probe shall be moved (half skip and full skip distance) until internal and external
notches on the test piece are detected (See Fig. 5 of this specification).
The relevant defect limits the path lengths on the time base. The calibration of
reference sensitivity is obtained by utilising the through - drilled test hole in the
thickness of the reference block to draw the distance - amplitude correction curve
relevant to the test probe.
Calibration shall be carried out according to the following procedure ; place its internal
vertex until the maximum height of echo is displayed on the screen ; this echo is
adjusted to 80% of full screen height by means of the sensitivity adjuster set in dB.
Without varying the amplification, the probe placed at full skip distance from the hole
is moved to detect the external vertex of the hole until the maximum height of echo is
obtained. The straight line connecting the peaks of the two echoes obtained by the
above procedure, represents 100% reference level, while the one connecting the two
points at half height of the same echoes represents "50% reference level".
The two straight lines shall be marked on the screen with a pen. Calibration shall be
repeated each time tests are re-started ; at intervals not longer than 30 minutes during
normal operations; each time the conditions fixed in advance are altered. This
calibration is applicable provided that the crystal of the probe is 8 x 9mm size. Should
this size of the crystal be different, the value of the sensitivity obtained from the
calibration by a crystal of a different size shall be brought to the value of sensitivity
obtained from the calibration by a 8 x 9mm crystal. The sensitivities of the two
different size probes shall be compared through the echoes obtained on the notch of
the test piece with the probe position at half skip of the distance.
15.9 Regulation of Amplification During Production Testing
Scanning sensitivity shall be as provided in API 1104 para 11.4.7.2 &11.4.7.3.
15.10 Qualification of Ultrasonic Testing Operators
Before the inspection begins or during the same inspection, the COMPANY may require
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a qualification test for the ultrasonic equipment operators.
15.11 Evaluation of Indications Given by Ultrasonic Tests
Each time that echoes from the weld bead appear during production testing, the
instrument amplification shall be altered to coincide with the reference amplification
and the probe shall be oved until maximum response is obtained, paying attention all
the time of the probe-tube coupling.
If, under these conditions, the heights of the defect echo are equal to or greater than
that of the reference echo, the defect shall be evaluated according to other clauses of
this Specification. If the defect has also been detected by the radiographic and or
visual examination, the dimensions shall be judged according to the type of
examination which detects the greater defect. Returns which are less that 50% of the
reference echo, will not be considered. If returns are above 50% but lower than 100%
of the reference echo, and if the operator has good reasons to suspect that the returns
are caused by unfavourably oriented cracks, the same shall be informed to the
COMPANY. Moreover, when there is a defect to be repaired, such defect shall be
removed for a length corresponding to the one where no more return echo is given.
15.12 Other Equipment
The use of rules calibrated in centimeters, attached if possible to the probe, for the
precise location of the position of welding defects, is recommended. Defect location is
effected by measuring the projection distance between the probe output and the
reflecting surface.
The operators carrying out the tests shall have besides the probing instrument, tools
for cleaning the pipe surface (files, brushes, etc.), as well as, the coupling liquid or
paste appropriate for the temperature of the section to be examined.
16.0 AUTOMATED ULTRASONIC TESTING (AUT)
 INTRODUCTION
The specification shall be applicable for Automated Ultrasonic Testing (AUT) system
suitable for pipeline girth welds. The system shall be based on focused pulse-echo,
tandem or through transmission methods enhanced with mapping image and
augmented by Time Of Flight Diffraction (TOFD) technique.
 REFERENCE DOCUMENTS
ASTM E 1961-98 “Standard Practice for Mechanized Ultrasonic examination of Girth

Welds using Zonal Discrimination with Focused Search Units”. The inspection system
shall meet and exceed the requirements of ASTM E 1961-98.
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Appendix-E, “Automated Ultrasonic Girth Weld Testing”, OS-F101, Submarine Pipeline

Systems, January 2000.
API Std. 1104 – “Welding of Pipeline and Related Facilities”.
 APPROVED AGENCIES
Automated Ultrasonic Testing (AUT) systems and agencies who have proven track
record and have done a single project of diameter 20” or above and minimum length
of 50 km and also have inspected a cumulative length of 500 km or above on large
diameter Pipe lines in the last ten years shall be accepted. The agency should have
been approved by the reputed inspection agencies. The track record shall be submitted
to the COMPANY for approval prior to engagement.
 AUT SYSTEM
The system shall meet and exceed the requirements of ASTM E1961-98.
The system shall provide an adequate number of examination channels to ensure the
complete volumetric examination of the weld through the thickness in one
circumferential scan. The evaluation zones should be of maximum 2.0mm height. The
instrument linearity should be such that the accuracy is within 5%.
Each examination channel should be selective for pulse-echo or through transmission

mode gate position and length for a minimum of two gates and gain.
TOFD techniques & B-scan mapping should be available to improve characterization.

Recording thresholds should be selectable to display signals between 0 and 100% of
full screen height for simple amplitude and transit time recording and it should be from
0 to 100% for B-scan or mapping type recording of data. Two recordable signals
output per gate should be available being either analog or digital and representative
of signal height and time of flight. Measuring distance accuracy of circumferential weld
shall be within 1.0 cm from zero (0) position.
Electronic noise shall be lower than acoustical noise in all channels for the probes and
sensitivities to be used during inspection. The signal to noise ratio for each channel
during examination shall be at least ≥ 20 dB for shear waved probes.
 COUPLING
The coupling shall be obtained by using a medium suitable for the purpose. It shall be
suitable for the temperature used. No residue shall remain on the pipe surface. A
method should be employed to determine that constant coupling is achieved during
examination. An examination of the test piece with its surface wiped dry should
produce a record showing an absence of the couplant recording signal.
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 SEARCH UNITS
The search unit shall meet all the requirements specified in Para 6.4 of ASTM E1961¬-
98.
 CALIBRATIONS
Reference standards shall be manufactured from a section of unflawed project specific
line pipe supplied by pipeline CONTRACTOR. The agency shall then submit the
reference standard design to the COMPANY before manufacturing. No design changes
in the reference standard shall be made without the prior approval. Annexure A3 of the
standard ASTM E1961-98 provides an example for minimum requirements for
reference standards.
The system shall be optimized and calibrated as stated in Para 7.0 and 8.0 of ASTM E
1961-98. Static and Dynamic calibration shall be done and the approved procedure
shall clearly state the gain setting fixed for each channel.
The reference standard should be used to verify the scanning sensitivity at the start of
each shift and thereafter at intervals not exceeding two (2) hours or ten (10) welds.
A re-calibration shall be carried out if :
a) The calibration of an inspection function differs more than +/- 3dB from the
previous calibration
b) The gate settings need to be adjusted with more than +/- 1.5 mm with the
previous calibration – i) after a weld repair, ii) after equipment breakdown.
In case the calibration differs from the initial setting, outside the given tolerances, the
applicable probe(s) and coupling shall be checked. If the calibration has to be changed,
the welds before this calibration upto the previous calibration will be re-examined.
The reference standard design for calibration shall be approved separately. The
procedure for calibration and verification shall be same as given above.
 PROCEDURE
A detailed AUT procedure shall be prepared and qualified for each wall thickness and
joint geometry to be examined prior to the start of any NDT work. Repair procedure
shall be separately qualified for each joint geometry. All the requirements of ASTM
E1961-98 should be met. The procedure as a minimum shall include the following:
- Functional description of equipment

- Reference standards and guidelines controlling equipment maintenance
- Instructions for scanning device, Ultrasonic instrument, Ultrasonic electronics,
Hard & Software for recording processing, Display presentation and storage of
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inspection data
- Transducer configuration(s), characteristics types coverage.
- Number of examination zones for each wall thickness to be examined.
- Gate settings
- Equipment settings -Description of calibration blocks including type, size and
location of calibration reflectors, a) calibration intervals, b) calibration records -
Static and dynamic calibration procedure
- Identification of inspection starting point scanning direction and indication of
length inspected
- Method for scanner alignment and maintenance of alignment
- Allowed temperature range
- Couplant coupling and coupling control and channels provided to indicate lack
of coupling and method to ensure constant coupling
- Transducer and over all functional checks
- Height and length sizing methodology
- Surface condition and preparation
- Description of inspection work
- Acceptance criteria and instructions for reporting including example of recorder
chart and form to be used.
- A table indicating corresponding channel no., probe, type, location of reflector,
probe coupling etc.
 Setting of Inspection Gates
Pulse-echo and Tandem Channels

With each transducer positioned for the peak signal response from the calibration
reflector the detection gates are to be set. The gate shall start 2-6mm (allowance for
width of heat affected zone) before the theoretical weld bevel preparation. The gate
ends shall be after the theoretical weld centerline. All gates will be programmed to
record amplitude and/or transit distance information. The length of the transit distance
in the root channel will be extended to enable root penetration registration.
Mapping Channels
The mapping gates in the body of the weld shall start 2-6mm (allowance for width of
heat affected zone) before the theoretical weld bevel preparation. The gate length will
be extended to enable cap reinforcement registration. The mapping gates in the root
will be set identical to the pulse-echo transit distance channels to enable the
registration of the root penetration.
TOFD Channel
The TOFD gate start will be set 1 µSec before the arrival of the lateral wave and
should extend up to the first back wall echo to achieve full cover of wall thickness.
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Note: The gate settings may be altered if geometry indications dictate.
Sensitivity Settings
With each transducer positioned for the peak signal response from the calibration
reflector (flat bottom holes), the detection gates are to be set. In this position, the
probe holder is fixed to the probe frame. The equipment sensitivity (echo amplitude)
for all inspection channels shall be set at 80% Full Screen Height (FSH).
Mapping channels in the body of the weld will be used to detect the presence of
porosity and in addition to identify the position of the weld cap reinforcement for
pattern recognition purpose. The sensitivity as a minimum is equal to the related
pulse- echo channels, increased with additional gain to ensure proper detection.
Mapping channels in the root will be used to identify the position of the root
penetration for pattern recognition purpose. The sensitivity as a minimum shall be
equal to the related pulse-echo channels, increased with additional gain to ensure
proper detection.
The lateral wave of the TOFD channel sensitivity is set at 80% FSH.
 TRAINING AND QUALIFICATION
1. All Inspectors’ of the COMPANY (Owner) shall be imparted training at the

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

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

All the requirements stated in Para 9 and 10 of ASTM E1961-98 shall be followed a
minimum.
 INTERPRETATION OF RESULTS
General
With the transit distance measurements and with the information from the mapping
and TOFD channels visible on the result presentation, indications shall be judged
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whether they are from the weld geometry or from the defects. The coupling channels
will check for coupling loss; in case of coupling loss, a re-scan shall be carried out.
Inspection Result
The inspection result should be evaluated and/or reported as follows:
Welds shall be evaluated using both the pulse-echo and TOFD criteria shown below.
This shall be performed in parallel and rejection against either of these criteria shall be
cause for rejection of the weld. The exceptions to this are described in the following
notes:
1. All indications in the pulse echo channels should be evaluated which exceed the
threshold level of 20% FSH.
2. Defect length shall be measured for the pulse-echo channels from the point
where the signal exceeds 20% FSH to the point the signal falls below. The
largest height assessed with TOFD or the greatest measured amplitude with
pulse-echo shall be assumed to apply over the whole defect length.
3. If the indication cannot be resolved by TOFD i.e. the upper and lower flaw
diffraction tips cannot be separately distinguished, no measurement can be
made to determine the defect height. In this case, the signal from the pulse-
echo channels will be solely used to determine that particular area of the scan.
4. Defects shall be assessed for interaction as follows:
a) Horizontal interaction
If the distance between two adjacent defects is less than the length of
the smaller of the two defects, then the defect shall be treated as a
single defect.
b) Vertical interaction
Vertical interaction of defects shall be assessed using TOFD. If the

distance between the two adjacent defects is less then the height of the
shorter of the two defects, than the defect shall be treated as a single
defect. Where the individual defects cannot be resolved by TOFD for
the vertical interaction, then the defects are assumed to interact and
shall be treated as a single defect.
5. The maximum allowable accumulated defect length shall be as per the criteria
given in welding specification.
 ACCEPTANCE CRITERIA
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Weld quality shall be judged on the basis of the acceptability criteria mentioned in
welding specification.
17.0 RADIOGRAPHY
17.1 Scope
This covers the radiographic inspection of all types of welded joints of the main
pipeline.
The welded joints shall include the following :-
i. Full girth welds on the mainline construction including double jointing of pipe, if
adopted.
ii. Welds for installation of block valves, insulating joints and other appurtenances
and tie-ins.
iii. Welds at scraper launching and receiving barrels.
iv. Terminal Piping
17.2 Applicable Standards
This specification shall apply in conjunction with the following (all latest edition):
i. API 1104, Standard for welding Piplines and Related Facilities.
ii. ANSI B31.8, Code for Gas Transmission and Distribution Piping Systems.
iii ANSI B31.4- Pipeline Transportation System for Liquids and Slurries
iv. ASTM E94, Recommended practice for Radiographic Testing.
v. ASTM E142, Standard Method for Controlling Quality of Radiographic Testing.
vi. The American Society for Non-destructive Testing. Recommended Practice No.
SNT - TC-1A Supplement A.
17.3 Procedure
17.3.1 The radiographic examination procedure to be adopted shall be submitted by the

CONTRACTOR as per Annexure VI.
17.3.2 The procedure of radiographic examination shall be qualified to the entire satisfaction
of COMPANY prior to use. It shall include but not be limited to the following
requirements :
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i. Lead foil intensifying screens, at the rear of the film shall be used for all
exposures.
ii. Type 2 and 3 films as per ASTM E-94 shall be used.
iii. A densitometer shall be used to determine film density. The transmitted film
density shall be 2.0 and 3.5 throughout the weld. The unexposed base density
of the film shall not exceed 0.30.
iv. Radiographic identification system and documentation for radiographic

interpretation reports and their recording system.
17.3.3 The CONTRACTOR shall qualify each procedure in the presence of the COMPANY prior
to use.
17.3.4 The procedure of radiographic examination shall produce radiographs of sufficient

density, clarity and contrast so that defects in the weld or in the pile adjacent to the
weld, and the outline and holes of the penetrameter are clearly discernible.
17.3.5 All the girth welds of mainline shall be subjected to 100% radiographic examination.
The CONTRACTOR shall furnish all the radiographs to the COMPANY, immediately after
processing them, together with the corresponding interpretation reports on approved
format. The details of the radiographs all alongwith the joint identification number shall
be duly entered in a register and signed by the CONTRACTOR and submitted to the
COMPANY for approval.
17.3.6 When the radiation source and the film are both on the outside of the weld and located
diametrically opposite each other, the maximum acceptable length of film for each
exposure shall not exceed the values given in Table-4 of API 1104. The minimum film
overlap, in such cases, shall be 40mm. The ellipse exposure technique may be used on
nominal pipe sizes of 2 inch and smaller provided that the source of film distance used
is a minimum of 12 inch.
17.3.7 Three copies of each acceptable radiographic procedure (as per Annexure-VI) and
three copies of radiographic qualification records, shall be supplied to COMPANY. One
set of the qualifying radiographs on the job shall be kept by the CONTRACTOR's
authorised representative to be used as a standard for the quality of production
radiographs during the job. The other two sets shall be retained by COMPANY for its
permanent record.
17.3.8 Three copies of the exposure charts relating to material thickness, kilo voltage, source
of film distance and exposure time shall also be made available to COMPANY by the
CONTRACTOR.
17.3.9 The CONTRACTOR shall, on a daily basis, record for each radiograph (1) radiograph's
number, (2) welder's number (3) approximate chainage of weld location, (4) whether
or not the welds meet the specified acceptance standards and (5) the nature and
approximate location of unacceptable defects observed. It must be possible to relate
back to a particular butt weld and welder on piping drawing and pipe line alignment
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drawing.
17.3.10 Each day's production of processed radiographs shall be properly packaged separately,
identified by at least the (1) date, (2) radiographic unit, (3) job locations, (4) starting
and ending progress survey stations and (5) shall include original and three copies of
the daily radiographic record. The package shall be submitted to the COMPANY daily
when possible, but in no event later than noon of the following day.
17.3.11 The CONTRACTOR shall provide all the necessary facilities at site, such as a dark room
with controlled temperature, film viewer etc. to enable the COMPANY to examine the
radiographs.
17.3.12 The CONTRACTOR, if found necessary, may modify the procedure of radiographic
examination suiting to the local conditions prevailing. This shall, however, be subject to
the approval of the COMPANY.
17.3.13 COMPANY shall have free access to all the CONTRACTOR's work facilities in the field.
17.3.14 Any approval granted by the COMPANY shall not relieve the CONTRACTOR of his
17.4 Radiation Source
17.4.1 Radiographic examination shall be carried out using x-radiations, Radiographic

examination by Gamma rays may be allowed, at the discretion of the COMPANY, in
case of inaccessible joints. Radiography by Gamma-Ray for tie-in joints shall be
acceptable provided Du AGFA film or equivalent is used and the reqd. sensitivity
obtained. Radiography by Gamma-Ray for tie-in-joints shall be acceptable provided D4
AGFA film or equivalent is used and the required sensitivity obtained.
17.4.2 Whenever possible, pipeline welds will be inspected by placing the radiation source
inside the pipe, on the pipeline axis, with a radiation of 6.28 rad. (360°C).
If it is impossible to place the radiation source inside the pipe, the weld will be
inspected with the source on the outside. An overlap of at least 40mm at the ends of
each film shall be required to ensure that the first and last location increment numbers
are common to successive films and to establish that no part of a weld has been
omitted.
17.5 Level of Quality
The quality level of Radiographic sensitivity required for radiographic inspection shall
be at least equivalent to the values in Fig. 6
17.6 Penetrameters
The image quality indicator (abbreviation : IQI) shall be used for the qualification of
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the welding procedure and during normal line production. Radiographic sensitivity shall
be measured with the wire image quality indicator (Penetrameter). The penetrameter
shall be selected according to DIN54109 or ISO1027. For radiographs made with the
source on the outside, a penetrameter shall be placed on each side of the film with the
smaller wiere of the penetrameter turned towards the end of the film itself. When a
complete weld is radiographed in a single exposure using a source inside the piping,
four penetrameter approximately equally spaced around the circumference shall be
used. During the procedure qualification, IQI shall be placed both on the source side
and on the film side. The sensitivity obtained with IQI on the source side shall not be
less than the values shown in Fig. 6 of this specification.
The sensitivity limit may be considered to have been reached when the outline of the
IQI, its identification number and the wire of the required diameter show up clearly on
the radiograph.
The COMPANY may authorise use of types of IQI other than those planned, provided
that they conform with recognised standards and only if the CONTRACTOR is able to
demostrate that the minimum sensitivity level required is obtained. For this
demostration, a test shall be carried out comparing the IQI specified and the
CONTRACTOR's, to show up the identification number and other details of the
proposed IQI, which must be visible in the test radiograph.
17.7 Film Identification Markers
All films shall be clearly identified by lead numbers, letters, and/or markers. The image
of the markers shall appear on the films, without interfering with the interpretation.
These markers positions shall also be marked on the part to be radiographed and shall
be maintained during radiography.
17.8 Protection and care of film
17.8.1 All unexposed films shall be protected and stored properly as per the requirements of
API 1104 standard and ASTM E.94.
17.8.2 The exposed and unexposed film shall be protected from heat, light, dust and
moisture. Sufficient shielding shall be supplied to prevent exposure of film to damaging
radiation prior to and following the use of the film for radiographic exposure.
17.9 Re-radiography
17.9.1 The weld joints shall be re-radiographed in case of unsatisfactory quality of the
radiographs, at the expense of the CONTRACTOR.
17.9.2 All the repaired weld joints shall be re-radiographed at no extra cost to the COMPANY
in the same manner as that followed for the original welds. In addition, the repaired
weld areas shall be identified with the original identification number plus the letter R to
indicate the repair.
79 of 911
17.9.3 When evaluating repair film, radiographers shall compare each section (exposure) of
the weld with the original film to assure repair was correctly marked and original defect
removed.
17.9.4 The COMPANY will review prior to any repair of welds, all the radiographs of welds
which contain, according to the CONTRACTOR's interpretation, unacceptable defects.
The final disposition of all unacceptable welds shall be decided by the COMPANY.
17.10 Qualification of Radiographers
17.10.1 Pipeline radiographers shall be qualified in accordance with the requirement of API
1104 and to the full satisfaction of COMPANY.
17.10.2 Certification of all the radiographers, qualified as per 16.10.1 above, shall be furnished
by the CONTRACTOR to the COMPANY before a radiographer will be permitted to
perform production radiography. The certificate record shall include :
i. Background and Experience Record

ii. Training Course Record
iii. Technical Examination Record
iv. Doctor's report on radiographer's Oaecuer 0-1 acquity eye test.
v. Date of qualification
17.10.3 The radiographers shall be required to qualify with each radiographic procedure they
use, prior to performing the work assigned to him in accordance with the specification.
17.11 Preservation of Radiographs
17.11.1 The radiographs shall be processed to allow storage of films without any discoloration
for at least three years. All the radiographs shall be presented in suitable folders for
preservation alongwith necessary documentation.
17.11.2 All radiographs shall become property of the COMPANY.
17.12 Equipment and Accessories
17.12.1 CONTRACTOR shall make necessary arrangement at his own expense, for providing
the radiographic equipment, radiographic film and all the accessories for carrying out
the radiographic examination for satisfactory and timely completion of the job.
17.12.2 For carrying out the mainline radiographic examination the CONTRACTOR shall be
equipped with suitable mobile/ stationary type dark rooms.
These shall have all the required facilities for film processing. Film viewer used shall be
equipped with the film illuminator that has a light source of sufficient intensity and
suitably controlled to allow viewing film densities upto 4.0 without damaging the film.
80 of 911
17.13 Radiation Protection
17.13.1 CONTRACTOR shall be responsible for the protection and personnel monitoring of
personnel with or near radiation sources.
17.13.2 The protection and monitoring shall comply with local regulations.
17.13.3 In view of visual hazards in the handling of Radioactive source of material,

CONTRACTOR shall be solely responsible for complying with all rules and regulations
set forth by Atomic Energy Commission or any other Government agency of India in
this regard and COMPANY shall not be responsible and shall be kept indemnified by the
CONTRACTOR for default (s) of whatever nature by the CONTRACTOR. Safety
equipment as considered adequate by the COMPANY for all necessary personnel shall
be made available for use and maintained for immediate and proper use by the
CONTRACTOR.
17.14 Display of Safety Instructions
17.14.1 The safety provisions shall be brought to the notice of all concerned by display on a
notice board at a prominent place at the work spot. The person responsible for the
"safety" shall be named by the CONTRACTOR.
17.15 Enforcement of Safety Regulations
17.15.1 To ensure effective enforcement of the rules and regulations relating to safety
precautions, the arrangement made by CONTRACTOR shall be open to inspection by
COMPANY or its representatives.
17.16 First Aid and Industrial Injuries
17.16.1 CONTRACTOR shall maintain first aid facilities for its employees and sub-contractors.
17.16.2 CONTRACTOR shall make outside arrangements for ambulance service and for
treatment of industrial injuries. Names of those providing these services shall be
furnished to COMPANY prior to start of work and their telephone no. shall be posted
prominently in CONTRACTOR's field office.
17.16.3 All critical industrial injuries shall be reported promptly to the COMPANY and a copy of
CONTRACTOR's report covering each personal injury requiring the attention of
physician shall be furnished to the COMPANY.
17.17 No Exemption
17.17.1 Notwithstanding the above there is nothing in these to exempt the CONTRACTOR from
the operation of any other act or rules in force.
81 of 911
ANNEXURE-I
Sheet 1 of 3
ELECTRODE QUALIFICATION TEST RECORD
A. Tested at (Site name) Date :
Manufacturer's Name :
Brand Name :
Batch Number & Size Tested :
Classification & Code :
Intended for Welding in Position :
In combination with (if any) :
Code of Reference :
(used for testing)
Special requirements (if any) :
B. All Weld Tensile Test
Base Material used :
Pre-heat temp. :
Postweld Heat Treatment Details :
Visual Examination :
Radiographic Examination Results :
Tensile Test Results :
Sl.No. Identification No. U.T.S. Yield Point Elongation
1.
2.
82 of 911
ANNEXURE-I
Sheet 2 of 3
C. Impact Test Results
Test Temperature : Notch in :
Type of Specimens : Size of Specimens :

(Charpy)
Sl.No. Specimen No. Impact Valve Average

1.
2.
3.
4.
5.
6.
D. Chemical Analysis Result
Electrode Size used :
Batch No. :
%C %S %P %SI %Mn %Cr %Ni %Mo Other
E. Fillet Weld Test Results
Welding Positions :
Base Materials :
Size of Electrode used :
Visual Inspection Results : 1)

2)
3)
Macro Test results :
83 of 911
ANNEXURE-I
Sheet 3 of 3
Fracture Test Results :
Remarks :
F. Other Test Results
1. Transverse Tensile Test :
In combination with :
Position of Welding :
Preheat Temperature :
Post Weld Heat Treatment :
Radiography :
Identification No. U.T.S. Fracture in Remarks
2. Guided Bend Test
Position ID No. Root, Face or Side Bend Remarks

1.
2.
3.
4.
5.
Any other Tests :
Conclusion :
84 of 911
ANNEXURE-II
Sheet 1 of 2
STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION
Name of the Heat-Treater :
Name of the Project : Specification Reference No.:
1. General Details
Name of the Equipment :
Name of the Assembly/ Part :
Assembly/ Part Drawing No. :
Material :
2. Furnace Details
Type of Heating : Gas/ Oil/ Elec. Res./ Induction Type of Heating

(Tick mark)
Capacity (Size) :
Maximum Temp.(°C) :
Method of Temp. :
Measurement
Atmosphere Control :
3. Heat Treatment Cycle Details
Changing Temp. °C :
Rate of Heating, °C/ Hr. :
85 of 911
ANNEXURE-II
Sheet 2 of 2
Soaking Temp. °C :
Soaking Time, Hrs. :
Rate of Cooling, °C/ Hr. :
Mode of Cooling :
4. Other Details, if any.
Notes :
The following documents shall be furnished alongwith the specifications :
i. Material Test Certificates
ii. Assembly/ Part Drawing.
86 of 911
ANNEXURE-III
Sheet 1 of 3
FORMAT FOR WELDING PROCEDURE SPECIFICATION (WPS)
________________________________________________________________________________
Company Name ________________________ By __________________________________
Welding Procedure Specification No. _____________ Date __________ Supporting PQR No. (S)
_________ Revision No. ________________ Date ________________
Welding Process (es) _________________________ Type (s) _____________________________
(Automatic, Manual, Machines or Semi Auto)
________________________________________________________________________________
JOINTS
Joint Design ____________________________________________________________

Backing (Yes) _________________________________________(No) ___________________
Backing Material (Type) _________________________________________
Sketches Production Drawings. Weld Symbols Written
Description should show the general arrangement of the parts to be welded. Where applicable, the
root specing and the details of weld groove may be specified.
(At the option of the Manufacturer sketches may be attached to illustrate joint design weld layers
and bead sequence e.g. for notch toughness procedures, for multiple process procedures, etc.)
________________________________________________________________________________
BASE METALS
P.No. ____________ Group No. ____________ to P. No. ____________ Group No. ___________
OR
Specification type and grade _______________________________________________________
to Specification type and grade ________________________________________________
OR
Chern. Analysis and Mech. Prop. ____________________________________________________
to Chern. Analysis and Mech. Prop. ___________________________________________
Thickness Range :
Base Metal: Groove ____________________________________ Fillet ________________
Deposited Weld Metal: Groove ___________________________ Fillet ________________
Pipe Dia Range : Groove : _____________________________________ Fillet ________________
Other ______________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
87 of 911
ANNEXURE-III
Sheet 2 of 3
FILLER METALS
F.No. ___________________________________________ Other _____________________________

A.No. ___________________________________________ Other _____________________________
Spec. No. (SFA) _____________________________________________________________________
A WS No. (Class) ____________________________________________________________________
Size of filler metals __________________________________________________________________
____________________________________________________________________
(Electrodes, Cold Wire, Hot Wire etc.)
Electrode-Flux (Class) ________________________________________________________________

Flux Trade Name ________________________________________________________________
Consumable Inset ________________________________________________________________
Each base metal/filler metal combination should be recorded individually.
WPS NO. _____________________ Rev. _______________
POSITIONS : POSTWELD ED HEAT TREATMENT
Position (s) of Groove ______________________ Temperature Range ___________________
Welding Progression: UP _____ Down ____ Time Range _________________________
Position (s) of Fillet _______________________
PREHEAT GAS
Shielding Gas (es) ___________________
Preheat Temp. Min. ___________________ Percent Composition (mixtures) _________
___________________________________
Interpass Temp. Max. ___________________ Flow Rate __________________________
Gas Backing ________________________
Preheat Maintenance ___________________
Trailing Shielding Gas Composition _______
ELECTRICAL CHARACTERISTICS
Current AC or DC__________________________ Polarity _______________________

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

(Spray arc, short circuiting arc, etc.)
Electrode Wire feed speed range _________________________________________________________

_______________________________________________________________________________________
88 of 911
ANNEXURE-III
Sheet 3 of 3
TECHNIQUE
String or Weave Bead ___________________________________________________________

Orifice or Gas Cup Size___________________________________________________________
Initial and Interpass Cleaning (Brushing, Grinding, etc.) _________________________________
________________________________________________________________________________
Method of Back Gouging ___________________________________________________________

Oscillation _______________________________________________________________________
Contact Tube to Work Distance ___________________________________________________________

Multiple or Single Pass (per side) ___________________________________________________________
Multiple or Single Electrodes ___________________________________________________________
Travel Speed (Range) ___________________________________________________________
Peening _____________________________________________________________________________
Other _______________________________________________________________________________
_____________________________________________________________________________________
Weld Process Filler Metal Current Volt Travel Others

Layer(s) Class Dia Type Amp. Range Speed
Polarity Range Range
e.g.
Remarks,
comments,
Hot wire
Addition,
Technique
Torch Angle,
etc.
89 of 911
ANNEXURE-IV
Sheet 1 of 3
FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR)
RECORD ACTUAL CONDITIONS USED TO WELD TEST COUPON
________________________________________________________________________________________
Company Name __________________________________________________________________________
Procedure Qualification Record No. _____________________________________ Date _________________
WPS No. _____________________________
Welding Process (es) _____________________________________________________________________

Types (Manual, Automatic, Semi-Auto) _______________________________________________________
JOINTS
Groove Design of Test Coupon
(For combination qualification the deposited weld metal thickness shall be recorded for each Filler metal or process weld)
________________________________________________________________________________________
BASE METALS POSTWELD HEAT TREATMENT

Material Sepc. ____________________________ Temperature _____________________________
Type of Grade ____________________________ Time ___________________________________
P.No. __________ to P.No. _____________________ Other ___________________________________
Thickness of Test Coupon _____________________ ________________________________________
Diameter of Test Coupon _____________________ ________________________________________
Other __________ ___________________________ ________________________________________
FILLER METALS GAS

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

Position of Groove ___________________________ Current _________________________________
Weld Progression (Uphill, Downhill) ______________ Polarity _________________________________
Other __________ ___________________________ Amps. _________________________________
Tungsten Electrode Size ___________________
Other __________________________________
90 of 911
ANNEXURE-IV
Sheet 2 of 3
PREHEAT TECHNIQUE
Phreheat Temp. ___________________________ Travel Speed ___________________________
Interpass Temp. ___________________________ String or Weave Bead ______________________
Oscillation _______________________________
Multipass or Single Pass (per side) ___________
Single or Multiple Electrodes ________________
Other __________________________________
GUIDED BEND TESTS
Type of Figure No. Result
TOUGHNESS TESTS
Specimen Notch Notch Test Impact Lateral Exp. Drop Weight

No. Location Type Temp. Value % Shear Mils Break No Break
FILLET WELD TEST
Result - Satisfactory: Yes _______ No _______ Penetration into Parent Metal: Yes ______ No. ______
Marco – Results _______________________________________________________________________
OTHER TESTS
Type of Test _______________________________________________________________________________

Deposit Analysis ____________________________________________________________________________
Other _____________________________________________________________________________________
__________________________________________________________________________________________
Welder's Name ___________________ Clock No. __________________ Stamp No. _____________________
91 of 911
ANNEXURE-IV
Sheet 3 of 3
Test Conducted by _______________________ Laboratory Test No. _______________________
We certified that the statements in this record are correct and test welds were prepared, welded and tested in
accordance with the requirements of Section IX of the ASME Code.
Date : ___________ Manufacturer : ____________________
By : _____________________________
(Detail of record of tests are illustrative only and may be moulded to conform to the type and number of tests
required by codes and specifications).
92 of 911
ANNEXURE-V
Sheet 1 of 2
FORMAT FOR MANUFACTURER'S RECORD FOR WELDER OR WELDING OPERATOR

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

_____________________________________________________________________________________
Using WPS No. ________________ Rev. ________________
The above welder is qualified for the following ranges
Variable Record Actual Values Qualification Range

Used in Qualification
Process __________________ __________________
Process Type __________________ __________________
Backing (metal,
Weld metal, flux, etc) __________________ __________________
Material Spec. _________ to _________ _________ to _________
Thickness
Groove __________________ __________________
Filler __________________ __________________
Diameter
Groove __________________ __________________
Filler __________________ __________________
Filler Metal
Spec. No. __________________ __________________
Class __________________ __________________
F. No. __________________ __________________
Position __________________ __________________
Weld Progression __________________ __________________
Gas Type __________________ __________________
Electrical Characteristics
Current ________________ __________________
Polarity __________________ __________________
ANNEXURE-V
93 of 911
Sheet 2 of 2
Guided Bend Test Results
Type and Fig. No. Result
Radiographic Test Results

For alternative qualification of groove welds by radiography
Radiographic Results _______________________________________________________________
Fillet Weld Test Results
Fracture Test (Describe the location, nature and size of any crack of tearing of the specimen _____
Length and Per Cent of Defects _________________________ inches _____________%
Macro Test – Fusion _______________________________________________________________
Appearance - Fillet Size (ing) ______________x___________ Convexity or Concavity ___________
Test Conducted by _____________________________ Laboratory - Test No. _________________
We certify that the statements in this record are correct and that the test welds were prepared.
Welded and tested in accordance with the requirements of Section IX of the ASME Code.
Date ___________________ Organization __________________

By ___________________________
(Details of record tests are illustrative only and may be modified to conformation to the type &
number of tests required by the Code).
Note: Any essential variables in addition to those above shall be recorded.
94 of 911
ANNEXURE-VI
Sheet 1 of 1
RADIOGRAPHIC PROCEDURE QUALIFICATION RECORD
FOR PIPE WELDING
1. Location
2. Date of Testing
3. Name of the Contractor / Agency
4. Material : Carbon steel / Alloy Steel / Stainless Steel
4.A Technique: DWSI / SWSI / DWDI
5. Diameter & Thickness:
6. Type of Weld Joint:
7. Radiation Source:
8. Intensifying Screens/Lead Screens:
9. Geometric Relationship:
10. Limit of Film Coverage:
11. Film Type and Make:
12. Exposure Time:
13. Processing:
14. Density:
15. Sensitivity:
16.* Type of penetrameter:

(Source side)
17.* Type of penetrameter:

(Film side)
Signature of Contractor / Agency with Seal

Approval of MECON’s Inspector
* Ref. Para regarding recommended practice on placement of penetrameters Article 22, SE 142, ASME
Sec. V.
* For "Random Radiography" lines placement of penetrameters as per Article 2, ASME, Sec. V is
permitted.
95 of 911
ANNEXURE-VII
Sheet 1 of 1
WELDERS IDENTIFICATION CARD
Name :
Photograph
Identification :
Date of Testing :
Process :
Thickness Range :
Diameter Range :
F. No. :
Date of Approval of Welding :
Position(s) :
Approved by : Employer's Signature with seal
96 of 911
ANNEXURE-VIII
Sheet 1 of 1
Type of Source and Films to be used for RADIOGRAPHY
NOMINAL WALL SHOP WELDED JOINTS IN-SITU WELDS

THICKNESS (T) IN mm SOURCE FILM : CEN Class SOURCE FILM : CEN Class
T> 19 All Materials Gamma Ray C5 Gamma Ray C5
8T< 19 Carbon Steel Gamma Ray C4 Gamma Ray C4
All other Gamma Ray C3 Gamma Ray C3
materials
<8 Carbon Steel Gamma Ray C3 Gamma Ray C3/C1
Other than
Inspection
Class IV *
All other X-Ray C4 X-ray with C4 or Equivalent to be
materials and used. Gamma Ray (Se 75 Source
Carbon Steel only) with C3/C2 Equivalent may
of Inspection be allowed only if in the
Class IV * assessment of the owner's
inspector, Joints are inaccessible
for X-ray equipment and
radiographic sensitivity is achieved.
Note: Integral to above table
1) Films slower than the above may have to be used, if required radiographic sensitivity is not achieved
consistently.
* Piping classes where 100% RT is specified. Refer Std. Spec. No. ____________.
COMPARISON OF FILMS FROM DIFFERENT MANUFACTURERS
CEN Classification KODAK AGFA FUJI

--- CX D8 ---
C5 AA400 D7 IX 100
C4 T200 D5 IX80
C3 MX125 D4 IX50
C2 M100 D3 ---
CI DR50 D2 IX25
--- SR** --- ---
* * Special films, extremely fine grain & very high resolution
97 of 911
ANNEXURE-VIII
Sheet 1 of 1
Type of Source and Films to be used for RADIOGRAPHY
NOMINAL WALL SHOP WELDED JOINTS IN-SITU WELDS

THICKNESS (T) IN mm SOURCE FILM : CEN Class SOURCE FILM : CEN Class
T> 19 All Materials Gamma Ray C5 Gamma Ray C5
8T< 19 Carbon Steel Gamma Ray C4 Gamma Ray C4
All other Gamma Ray C3 Gamma Ray C3
materials
<8 Carbon Steel Gamma Ray C3 Gamma Ray C3/C1
Other than
Inspection
Class IV *
All other X-Ray C4 X-ray with C4 or Equivalent to be
materials and used. Gamma Ray (Se 75 Source
Carbon Steel only) with C3/C2 Equivalent may
of Inspection be allowed only if in the
Class IV * assessment of the owner's
inspector, Joints are inaccessible
for X-ray equipment and
radiographic sensitivity is achieved.
Note: Integral to above table
1) Films slower than the above may have to be used, if required radiographic sensitivity is not achieved
consistently.
* Piping classes where 100% RT is specified. Refer Std. Spec. No. ____________.
COMPARISON OF FILMS FROM DIFFERENT MANUFACTURERS
CEN Classification KODAK AGFA FUJI

--- CX D8 ---
C5 AA400 D7 IX 100
C4 T200 D5 IX80
C3 MX125 D4 IX50
C2 M100 D3 ---
CI DR50 D2 IX25
--- SR** --- ---
* * Special films, extremely fine grain & very high resolution
98 of 911
WELDING SPECIFICATION CHARTS FOR
SUPPLY, LAYING & CONSTRUCTION OF SLURRY
AND WATER PIPELINE ALONG WITH ASSOCIATED
FACILITIES
99 of 911
WELDING SPECIFICATION CHARTS TO SPECIFICATION FOR WELDING OF
ONSHORE PIPELINES NO. : MEC/S/05/28/02
24” LINE PIPE THK RANGE 8.7 to 11.1 mm

PIPES API 5L Gr X-60
MATERIAL FITTINGS -
SPECIFICATIONS FLANGES -
OTHERS -
BASE METAL ‘P’ NO 1

GROOVE JOINTS SINGLE SIDE BEVEL
BUTT OTHER THAN BUTT
WELDING PROCESS
FILLER PASS :
ROOT PASS : SMAW SMAW/FCAW ROOT PASS : N.A. FILLER PASS : N.A.
FILLET JOINTS / SOCKET JOINTS : N.A.
GROOVE JOINTS
FILLER & FILLER PASS :
WELDING MATERIAL ROOT PASS : E6010 CAP PASS N.A.
HOT PASS: E7010 E7010/E71T8G ROOT PASS : N.A.
BACKING RING : N.A. CONSUMABLE INSERT : N.A.
JOINT PREPARATION API 1104 / ASME SEC. –IX, latest edition
GASES PURGING : SHIELDING :

GAS COMPOSITION PURGING : SHIELDING :
0
PREHEATING PREHEAT TEMP: 100 C MIN POST HEATING :
CONTINUITY OF WELDING AND PREHEAT : REFER TO SPECIFICATION
HOLDING TEMP : N.A. HOLDING TIME :
POST WELD HEAT
RATE OF HEATING: N.A. MIN. HOLDING TIME :
TREATMENT
METHOD OF COOLING : N.A. RATE OF COOLING :
WIRE SPEED
MECHANICAL CHARPY ‘V’ NOTCH VALUE : MIN: 22 J AVERAGE : 27 J
PROPERTY AT TEMPERATURE : 0°C
REQUIREMENTS HARDNESS :
CODE OF FABRICATION : API 1104 / ASME SEC. –IX
TECHNICAL NOTES :
1. Root pass Welding shall be carried out by SMAW and Hot & other passes may be carried out by SMAW/ FCAW.
2. The Non-Destructive Testing (NDT) shall be examined by X-ray using internal crawlers.
The batch of the welding consumables shall be selected to match the minimum feed strength and UTS values of
3. the line pipe, API5L Gr. X60.
WELDING SPECIFICATION CHART Specification No. : Rev.

LAYING & CONSTRUCTION OF SLURRY
AND WATER PIPELINE ALONG WITH
ASSOCIATED FACILITIES MEC/WSC/01 0
M/S NMDC
MECON Limited
100 of 911
22” LINE PIPE THK. RANGE : 8.7 - 17.5 mm

PIPES API 5L Gr X-70
MATERIAL FITTINGS -
SPECIFICATIONS FLANGES -
OTHERS -

GROOVE JOINTS
WELDING PROCESS FILLER PASS :
ROOT PASS : SMAW ROOT PASS : N.A. FILLER PASS : N.A.
SMAW/FCAW
GROOVE JOINTS
ROOT PASS : FILLER & CAP PASS
ROOT PASS : N.A.
E6010
HOT PASS: E8010-G/P1
WELDING MATERIAL E8010-G/P1 /E81T8G FILLER PASS : N.A.

GASES PURGING : SHIELDING :

GAS COMPOSITION PURGING : SHIELDING :
range may vary.
PREHEATING PREHEAT TEMP: 80°C – 100°C min. POST HEATING :
HOLDING TEMP : HOLDING TIME :
POST WELD HEAT
RATE OF HEATING: MIN. HOLDING TIME :
TREATMENT
METHOD OF COOLING : RATE OF COOLING :

CODE OF FABRICATION : API 1104 / ASME SEC. –IX / B 31.8, latest edition
Technical Notes :
Root pass Welding shall be carried out by SMAW process and Hot & other passes may be
1. carried out by SMAW/ FCAW.
2. The Non-Destructive Testing (NDT) shall be examined by Auto UT / X-Ray using internal crawlers.
3. The batch of the welding consumable shall be selected to match the minimum feed strength and UTs values of the line
pipe, API 5L Gr. X-70.

LAYING & CONSTRUCTION OF SLUURY
MECON LIMITED AND WATER PIPELINE ALONG WITH MEC/WSC/02 0
ASSOCIATED FACILITIES
OF M/S NMDC
101 of 911
Terminal Piping : PIPING CLASS: A1A, B1A, D1A

ASTM A106 GR.B, API 5L GR B PSL2, API 5L GR X-60 PSL2,
PIPES
API 5L GR X-70 PSL2, IS-1239 (BLACK) ASSORTED PIPES
MATERIAL ASTM A105, ASTM A234 GR.WPB, ASTM A234 RG.WPB-W, MSS SP-75
FITTINGS
SPECIFICATIONS GR.WPHY-52, MSS SP-75 GR.WPHY-65
ASTM A105, ASTM A694 GR.F-52, ASTM A694 GR.F-65, ASTM A694 GR.F-70,
FLANGES
ASTM A516 GR.70
OTHERS -

GROOVE JOINTS SINGLE SIDE BEVEL
WELDING PROCESS ROOT PASS : GTAW FILLER PASS : ROOT PASS : GTAW FILLER PASS : SMAW /
/ SMAW GTAW/SMAW / SMAW GTAW
FILLET JOINTS / SOCKET JOINTS : SMAW
GROOVE JOINTS
ROOT PASS : ROOT PASS :
FILLER & CAP PASS FILLER PASS :
ER70S-2 / E6010 ER70S-2
WELDING MATERIAL ER70S-2/ ER80S-2/ ER70S-2/ ER80S-2/
HOT PASS: ER70S-2 HOT PASS: ER70S-2
E7018-1/ E8018-1 E7018-1/ E8018-1
/E7018-1/E8018-1 /E7018-1/E8018-1
FILLET JOINTS / SOCKET JOINTS : E7018-1
GASES PURGING : SHIELDING : Argon

GAS COMPOSITION PURGING : SHIELDING : 99.995%
PREHEATING / INTER PREHEAT TEMP 10 -100 Deg POST HEATING : NA
PASS INTERPASS : Max 200 Deg
HOLDING TEMP : HOLDING TIME :
POST WELD HEAT
RATE OF HEATING: MIN. HOLDING TIME :
TREATMENT
METHOD OF COOLING : RATE OF COOLING :

CODE OF FABRICATION : API 1104 / ASME SEC. –IX, latest edition
TECHNICAL NOTES :

LAYING & CONSTRUCTION OF SLURRY
AND WATER PIPELINE ALONG WITH
ASSOCIATED FACILITIES MEC/WSC/03 0
MECON Limited
102 of 911
MECON LIMITED STANDARD TECHNICAL SPECIFICATION OF
DELHI HYDROSTATIC TESTING OF ONSHORE PIPELINE
REV 0, EDITION - 1
FOR
HYDROSTATIC TESTING OF ONSHORE
PIPELINE

MEC/S/05/28/03
MECON LIMITED
DELHI 110 092

103 of 911
REV 0, EDITION - 1
CONTENTS
SL.NO. DESCRIPTION
1.0 SCOPE
3.0 GENERAL
4.0 HYDROSTATIC TEST PROCEDURE MANUAL
5.0 TEST PRESSURE
6.0 EQUIPMENT AND INSTRUMENTATION
7.0 PROCEDURES
8.0 ACCEPTANCE
9.0 TERMINATION
10.0 TEST REPORT
11.0 MEASUREMENTS
12.0 CALCULATION
13.0 PRECAUTIONS DURING THE TEST
14.0 PRESERVATION OF PIPELINE
TABLES
TABLE A DIFFERENCE BETWEEN WATER THERMAL EXPANSION FACTOR AND STEEL THERMAL
EXPANSION FACTOR.
FIGURES
FIG.1 WATER COMPRESSIBILITY FACTOR VS PRESSURE AND TEMPERATURE.
104 of 911
REV 0, EDITION - 1
AMENDMENT STATUS

105 of 911
1.0 SCOPE
1.1 This specification covers the minimum requirements of supply, works and operations to be
performed by CONTRACTOR for hydrostatic testing of cross-country steel pipelines
transporting hydrocarbons in liquid or gaseous phase and slurry under high pressure. This
specification does not cover the requirements of drying / pre-commissioning of the tested
pipelines. This specification shall be read in conjunction with the conditions of all specifications
2.1 Reference has been made in this specification to the latest edition/ revision of the following
codes, standards and specifications.
a) ANSI B 31.8 Gas Transmission and Distribution Piping Systems.

b) ANSI B 31.4 Pipeline Transportation System for Liquids and Slurries (ANSI
B31.4)
c) API RP 1110 Pressure Testing of Liquid Petroleum Pipelines.
d) ASME Sec. VIII Div-1 Boiler & Pressure Vessel Code.
e) OISD 226 Natural Gas Transmission Pipelines and City Gas Distribution
Networks
2.2 In case of conflict between the requirements of this specification and that of the above
referred coded, standards, and specifications, the requirements of this specifications shall
govern.
2.3 For the purpose of this specification the following definitions shall hold:
- the words 'shall' and 'Must' are mandatory;
- the words 'Should', 'May', and 'Will' are non-mandatory, advisory or recommended.
3.0 GENERAL
3.1 Hydrostatic test shall be performed on the entire length of the pipeline. Hydrostatic test shall
be performed in accordance with approved Hydrostatic Test Diagrams for each test section.
The maximum length of each test section shall not exceed 50 kms.
3.2 For pipeline sections which in COMPANY's opinion, once installed would require an inordinate
amount of effort for repair in case of a leak, a provisional pre-test shall be conducted.
However, after installation, such pretested sections shall be tested again alongwith the entire
pipeline.
3.3 Hydrostatic test shall commence only after mechanical and civil works completion, i.e., all
welds have been accepted and the pipeline has been laid and backfilled according to the
specifications. Hydrostatic test shall include those sections which have been previously tested,
viz. Rail/ road crossing, major water crossings including test on banks and in place after
106 of 911
installation, and scraper traps at the terminals. CONTRACTOR shall perform all works required
for hydrostatic testing after obtaining prior written approval from the COMPANY.
3.4 The pipeline shall be tested in accordance with the requirements of the latest edition of ANSI
B 31.8 or ANSI B 31.4, OISD 226 as applicable, and requirements laid down in this
specification.
4.0 HYDROSTATIC TEST PROCEDURE MANUAL
CONTRACTOR shall prepare for COMPANY's approval a hydrostatic test procedure manual. The
procedure shall strictly comply with the requirements of this specification and shall be
submitted to COMPANY for approval well in advance. The procedure manual shall include all
temporary materials & equipment, but not be limited to the following items:
a) For the systems to be tested, a diagram indicating all fittings, vents, valves, temporary
connections, relevant elevations and ratings. The diagram shall also indicate injection
locations and intake and discharge lines.
b) Estimated amount of test water, water sources, including required concentration of

corrosion inhibitors and additives, procedure for inhibitor injection and control of
concentration.
c) Filling and flushing procedures, including a complete description of all proposed

equipment and instruments (including spares), their location and set-up.
d) The type and sequence of pigs and the pig tracking systems for cleaning and removal
of air pockets. Pig inspection procedures, including procedure to be followed in case
the calliper pig indicates damage.
e) Procedures for levelling and stabilization after filling and for pressurization and to allow
for temperature stabilization.
f) Pressure testing procedure including a complete description of all proposed equipment

and instruments (including spares), their location and set-up, and proposed system for
observation and recording of data during the pressure test.
g) Procedure for detection and location of leaks.
h) Procedure for dewatering the pipeline section(s) after testing, including a complete
description of all proposed equipment and instruments, (including spares), their
location and set-up, the type and sequence of pigs and the pig tracking system along
with the pig specifications.
i) Forms for recording the test data.
5.0 TEST DURATION AND PRESSURE
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5.1 The duration of hydrostatic test shall be a minimum of 24 hours after stabilization and the test
pressure shall be as indicated in the approved hydrostatic test diagram.
5.2 Unless specified otherwise in the CONTRACT, the hydrostatic test pressure shall be as follows :
For pipeline handling hydrocarbon in gaseous phase :
a) 1.25 times the design pressure for pipeline located in Class-1 and Class-2 locations as
per ASME B 31.8.
b) 1.4 times the design pressure for pipeline located in Class-3 and Class-4 locations as
per ASME B 31.8.
For pipeline handling Liquid / Slurry
a) 1.1 times the design pressure as per ASME B 31.4.
6.0 EQUIPMENT AND INSTRUMENTATION
The CONTRACTOR shall furnish all necessary equipment for performing the work as stated
in cleaning, flushing, filling, levelling, stabilizing, testing and dewatering procedures. This
shall include the following :
a) Pigs for filling , cleaning and gauging including
- Cleaning pigs with spring loaded steel wire brushes except for internal coated pipes. In
this case pigs to be provided with nylon / polyurethane brushes.
- Four cup batching pigs
- Calliper pigs with gauge plate diameter equal to 95% of the heavy wall pipe in the pipe
sections. Gauging pig fitted with gauge plate.
The CONTRACTOR shall provide sufficient number of pigs including spares.
b) Fill pumps : The CONTRACTOR shall determine the type and number of fill pumps
in order to guarantee the following :
Differential head 20% greater than the maximum required.

Flow rate : 400m3 / hr. min. ; 1000m3 / hr. max.
If a single pump is used, a standby unit must be available.
c) Variable speed positive displacement pumps equipped with a stroke counter to

pressurise the line with a known stroke and capable of exceeding the maximum test
pressure by at least 20 bar.
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d) Two positive displacement meters to measure the volume of water used for filling
the line. These meters shall be provided with a callibration certificate not older than
one month.
e) Portable tanks of sufficient size to provide a continuous supply of water to the pump
during pressurizing.
f) Bourdon pressure gauges of suitable pressure range and accuracy.
g) Dead weight testers with an accuracy of 0.01 bar measuring in increments of 0.05 bar
provided with a calibration certificate not older than one month.
h) Two 48 hours recording pressure gauges tested with charts and ink gauges tested with
dead weight tester prior to use. These shall be installed atp the test heads.
i) Pressure recording charts.
j) Two temperature recorders for fill water.
k) Thermocouples for measuring the pipe wall temperature.
l) Two laboratory thermometers 0°C to 60°C range, accuracy ± 0.1 degree to be used in
thermowells.
m) Means to measure the volume of water necessary to drop the line pressure by 0.5 bar
(container on scales or graduated cylinder).
n) Injection facilities to inject additives into the test medium in the required proportions.
o) Communication equipment suitable for a continuous connection between the beginning

and the end of the test section and with the inspection team along the line, in
accordance with the requirements of local Authorities.
p) The temporary scraper traps shall be installed according to the testing sections fixed in
the test procedure manual. Proper piping and valuing arrangements shall be available
to allow launching and receiving of each pig independently.
The test heads shall be sized in conformity with ASME specification Section VIII,
Division 2 with particular reference to Appendices 4 and 5.
q) Thermocouples for assuring the temperature of the pipe wall shall be installed on the
pipeline to be tested:
- 1 thermocouple at about 500m distance from the pumping head.

- 1 thermocouple every 2500m of the pipe the spacing may be increased to maximum
5000m depending on the terrain and nature of sub-soil along the alignment of section.
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- 1 thermocouple at about 500m distance from the terminal head.
The spacing may be increased to maximum 5000 metre depending on the terrain and nature
of sub soil along the alignment of test section.
Thermocouples shall be attached on the external surface of the pipe after removal of external
coating and shall be adequately protected and COMPANY's coating instructions shall be
followed.
7.0 PROCEDURES
7.1 Equipment and/or parts which need not or must not be subjected to the test pressures, must
be disconnected or separated from the pipeline to be tested.
7.2 If the difference of minimum and maximum atmosphere temperature should cause thermal
instability on the pipe section directly exposed to atmospheric condition, the scraper traps and
above ground pipeline shall be properly protected.
The pipeline test shall exclude long segments of line exposed to atmospheric conditions, viz.
Aerial lengths on piers, suspension bridges, etc., which shall be tested separately.
7.3 The test medium shall be soft non-aggressive water furnished by the CONTRACTOR. The
water to be used shall be filtered, shall not be contaminated, and free from sand or silt.
CONTRACTOR shall submit laboratory test reports of water used for testing. The possible use
of sea water shall be subject to its degree of cleanliness, the possibility of obtaining a pre
determined salinity neutralization and the use of corrosion inhibitors, this at the sole discretion
of COMPANY. CONTRACTOR shall provide COMPANY approved corrosion inhibitors, oxygen
scavengers and bactericides to be added to the test water. The CONTRACTOR shall furnish
and install all temporary piping which may be necessary to connect from source of water to its
pumps and manifolds/ tankage.
7.4 Before filling operation the CONTRACTOR shall clean the pipeline by air driven pigs provided
with spring loaded bushes and chisels to remove all mill scale rust/ sand from the inside of
pipe section. For this purpose temporary headers for air cleaning shall be attached to the
pipeline. The number of pig runs is depending upon the cleaning results and shall be
determined by the COMPANY at site.
7.5 “After cleaning the pipeline by using air and acceptance by Company, gauging shall be carried
out by using gauging pig. The gauge plate diameter shall be equal to 95% of inside diameter
of the heaviest wall pipe in the test section. While computing the ID of heaviest wall pipe,
pipe manufacturing tolerance shall not be considered. A 10mm thick aluminium plate shall be
used for making gauge plate.
After receipt of gauging pig at the other end, the gauge plate shall be inspected in the
presence of Company representative. A deformed, bent or severally nicked plate or damaged
pig shall be evidence of gauging pig run failure and the same is not acceptable to company.
110 of 911
In such cases the Contractor shall repair and rectify the line and repeat the gauging pig run to
the satisfaction and approval of the Company Representative. Any obstruction and/ or faults
such as dents, buckles, flat spots, etc. analysed and noted during gauging pig run shall be
located and any necessary repair work shall be performed to rectify the same to the
satisfaction of the Company. A written approval shall be obtained from Company regarding
successful completion of gauging pig run.
After acceptance of gauging operation, air header shall be cut and removed. Pre-tested test
headers loaded with three numbers of four cup batching pig shall be welded to test Section.
Un-inhibited water equal to 10% of the volume of test section shall be introduced in front of
the first pig. The first pig shall be launched by introducing about 1.5 km un-inhibited water.
Then the second pig shall be launched by pumping the inhibited water till the second pig is
received at the other end. The thermal stablisation and pressurisation can now the started”.
7.6 Thermal Stabilization
After a check has been made to confirm if the pressure has attained at least 1 bar (g) on the
highest section, thermal stabilization can be started.
Thermal equilibrium between the pipeline and environment shall be checked through the
thermocouples installed on the pipeline.
Temperature readings shall be made at 2 hours-intervals. Thermal stabilization shall be

considered to have been achieved when a difference not higher than 1°C is attained between
the average values of the last two readings. Thermal stabilization completion shall be
approved by COMPANY.
7.7 Pressurisation
Pressurisation shall be performed in the presence of COMPANY at moderate and constant rate
not exceeding 2 bars/min. One pressure recording gauge shall be installed in parallel with the
dead weight tester. Volume required to reach the test pressure shall be recorded periodically
throughout the pressurization as follows:
- each 5 bar increments up to 80% of test pressure as recorded by the dead weight
tester;
- each 2 bar increment between 80% to 90% of test pressure as recorded by the dead
weight tester;
- each 0.5 bar increment between 90% of test pressure to full test pressure as recorded
by the dead weight tester.
The pressurizing shall be cycled according to the following sequence:
a) Pressurize to 50% of test pressure, hold pressure for 1 hour.

b) Drop pressure to static head of test section at test head.
c) Pressurize to 75% of test pressure, hold pressure for 1 hour.
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d) Drop pressure to static head of test section at the test head.

e) Pressurize to test pressure.
During the pressurization to each test pressure, two tests shall be carried out for the
calculation of air volume in the pipeline under test.
In case, during the hold pressure periods indicated above, a decrease in pressure is observed,
the operations shall not be repeated more than twice, after which the line shall not be
considered capable of test, until the CONTRACTOR has isolated and eliminated the cause for
the lack of water tightness.
7.8 Air Volume Calculation
In order to check the presence of air in the pipeline, two separate consecutive pressure
lowering of 0.5 bar shall be carried out.
For calculation of air in the pipeline the second pressure lowering shall be used, and the
relevant drained water shall be accurately measured (V1). This amount measured shall be
compared to the theoretical amount (Vp) corresponding to the pressure lowering that has been
carried out, by using the procedure outlined in clause 12.1 of this specification.
If no air is present in the length under test:
V1
--- = 1
Vp
In order that the above ratio is acceptable, it shall not differ from 1 by more than 6% (i.e.
1.06).
If the air found in the pipeline is within the above established tolerance, then the pressurizing
can continue. If the ratio V1 / Vp exceeds 1.06, the hydrostatic testing cannot go on and
additional pig passages shall be performed to remove the air pockets.
The test shall be repeated as per the above procedure until above estimated tolerances are
satisfied. The pressurizing can then continue, to reach the value of test pressure.
7.9 Testing
After the section has been pressurized and the air volume test has given acceptable results the
test pressure shall be held for a minimum of 24 hours after stabilization. After temperature
and pressure has stabilized, the injection pump shall be disconnected and all connections at
the test heads shall be checked for leakage. The pressure recorders shall then be started with
the charts in a real time orientation for continuous recording throughout the test.
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During the testing period the following measurements shall be recorded :
- every one hour pressure measurements form dead weight testers.

- every two hours the ambient temperature and the pipe temperature at the
thermocouples.
All data shall be recorded on appropriate forms attached to the hydrostatic test procedure
manual. Care shall be taken that the maximum test pressures are not exceeded.
Bleed-off water shall be accurately measured and recorded.
8.0 ACCEPTANCE
8.1 The hydrostatic test shall be considered as passed if pressure has kept a constant value
throughout the test duration, except for change due to temperature effects. Such change shall
be evaluated as described under clause 12.2 of this specification.
The pressure change value as a function of temperature change shall be algebraically added to
the pressure value as read on the meters. The pressure value thus adjusted shall be compared
with the initial value and the test shall be considered as acceptable if the difference is less
than or equal to 0.3 bar. In case of doubt the testing period shall be extended by 24 hours.
8.2 If test section fails to maintain the specified test pressure after isolation, CONTRACTOR shall
determine by search the location of leakage or failure. All leaks and failures within the pipe
wall or weld seam shall be repaired by replacement of entire joint or joints in which leakage or
failure occurs. In circumferential welds the method of repair shall be determined by the
COMPANY. CONTRACTOR shall comply with instructions of the COMPANY whether to replace
a section of the line pipe that includes the line leak or whether to repair the circumferential
weld. This repair should however meet the requirements of 'Specification for Welding Pipelines
and Related Facilities'. Where failure occur in pipeline field bends, bends shall be replaced with
same degree of bends. After completion of repairs, the hydrostatic test shall be repeated in
full, as per this specification.
8.3 The cost of repairs or replacements, followed by refilling and repressurizing the line, due to
poor workmanship, shall be borne by the CONTRACTOR. In the event of leaks or failures
resulting form faulty COMPANY furnished materials, CONTRACTOR shall be reimbursed for
furnishing all labour, equipment, materials, except those materials furnished by the COMPANY,
and transportation necessary to repair and repressurize the section of the pipeline to the
pressure at the time of recognition of leak or line failure. CONTRACTOR shall be entitled for
compensation as per the provisions of the CONTRACT. All work of reinstalling line pipe, to
replace pipe failures shall be done in accordance with the relevant specification included in the
CONTRACT.
8.4 CONTRACTOR shall haul and stockpile all damaged and defective pipes to storage locations
designated by the COMPANY. All cracks and splice resulting from failures shall be coated with
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an application of grease to preserve the characteristics of failures from corrosion. Joint of

failed pipes shall be marked with paint, with a tag indicating failure details, date and location
of failure and pressure at which failure occurred.
9.0 TERMINATION
After the positive results of testing and collection of all data the test shall be terminated upon
written approval given by the COMPANY.
9.1 CONTRACTOR shall dewater the tested line as per the following requirement after test
acceptance.
The dewatering shall be carried out by using four cup pigs and foam pigs driven by
compressed air. The detailed dewatering procedure shall be developed by the CONTRACTOR
in such a way as to provide adequate control of pigs during dewatering. Pigs and equipment
required for dewatering the line shall be furnished by CONTRACTOR and shall be approved in
advance by the COMPANY. Four cup pigs shall first be passed through the line to displace the
water. Foam pigs shall then be passed in order to complete the line dewatering.
CONTRACTOR shall use a number of foam pigs, each in different colors/ numbered for this
purpose. The line shall be considered dewatered when a negligible amount of water is flushed
out by the last foam pig and approval is given by the COMPANY.
9.2 During dewatering, care shall be taken to properly dispose the discharging water in order to
avoid pollution, damages to fields under cultivation and/or existing structures and interference
with the traffic. Before start of dewatering and disposal of hydrotest water, a procedure for
treatment of inhibited water to prevent pollution shall be submitted by contractor to owner/
consultant for review and approval.
9.3 Upon completion of the testing and dewatering operation, any provisional traps for pigs and all
other temporary installation relating to the test shall be removed. Subsequently the individual
sections of the line already tested shall be joined in accordance with the requirements of
relevant specifications issued for the purpose.
10.0 TEST REPORT
A complete report signed by CONTRACTOR and the COMPANY shall be submitted upon
completion of the hydrostatic test for each test section.
This report shall contain as a minimum:
- the cleaning, flushing, filling and testing procedures used;
- schematic layout of cleaning, filling and testing facilities;
- instruments calibration certificates;
- a profile of the pipeline that shows the test sites, all instrument and injection
connections;
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- 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 recording;
- air volume calculations;
- pressure change due to temperature change calculations;
- environmental data;
- depressurization logs and records;
- dewatering procedure and schematic layout of relevant facilities;
- dewatering logs and records;
- records and photograph of all leaks.
11.0 MEASUREMENTS
11.1 Water Amount Measurement
The water volume added to the section to be tested shall be measured during the filling stage
through a positive displacement meter (a turbine meter may also be used). In the calculation,
as per clause 12.1 of this specification, use shall be made of the geometrical volume of the
section in question.
11.2 Pressure Measurement
Pressure shall be measured with a dead weight tester with an accuracy of 0.01 bar that shall
permit readings of at least 0.05 bar.
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During the test the pressure shall be recorded by means of a pressure recorder featuring the
following specifications:
Accuracy : ± 0.1% of the full-scale value
Recording : continuous on tape or disk, graph width 100mm
Feed : 20mm/h for tape diagrams, 7.5°/h for disk diagrams
Recording : to be such as to record pressure between 50% and 90% of the diagram
width.
The pressure recorder shall be checked by means of dead weight tester at the beginning,
during and at the end of the hydrostatic test.
A pressure gauge tested with dead weight tester shall be connected in parallel to the dead
weight tester at the test head.
11.3 Temperature Measurements
Water temperature shall be taken at every 2 hours through the thermocouple that have been
installed on the pipe wall along the section under test on the pipe wall.
Further the temperature measurement shall be taken :
- during the filling operation

- during the thermal stabilization stage
- during the hydrostatic test
The thermocouple’s sensitivity shall enable temperature readings with an accuracy of ±0.2°C.
b) Water temperature shall also be measured on the pump delivery by means of a

recording thermometer (temperature recorder) throughout the filling stage.
The recording thermometer shall have the following features :
Accuracy ± 1% of the scale range
Scale - 10° to + 40° C
Recording: Continuous on tape or disk, diagram within 100mm
Feed : 20mm/h for tape diagrams, 7.5°/h for disk diagrams.
c) Ground temperature shall be taken by measuring pipe temperature at the

thermocouple prior to starting the filling operation.
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d) Environmental temperature shall be recorded from the beginning of pressurization to

the end of the test by means of a recording thermometer featuring the following
characteristics:
Accuracy ± 1% of the scale range
Scale - 0° to + 60° C
Recording: Continuous on tape or disk, diagram width 100mm
Feed : 20mm/h for tape diagrams, 7.5°/h for disk diagrams.
12.0 CALCULATIONS
12.1 The theoritical water amount that is necessary for filling the section to be tested shall be
obtained from the geometrical volume of the section considering the pipe tolerances.
The theoretical water amount that is necessary for pressurizing the section shall be calculated
by means of the following formula:
Vp = (0.884 r i/t +A) x 10-6 x Vt x ∆ P x K
Where:
Vp = computed water amount required to raise by P the pressure in the section to

be tested (m3).
Vt = geometrical volume of the section (m3)
∆ P = Pressure rise (bar)
ri= nominal inner radius of the pipe (mm)
t = nominal pipe thickness(mm)
A = isothermal compressibility value for water at the pressurization temperature in

the P range (bar-1) x 106.
(Refer water compressibility factor vs pressure and temperature chart). For

temperature above 30°C the values may be extrapolated.
K = a dimensionless coefficient that is equal to a value of 1.02 for longitudinally

welded pipe.
12.2 The pressure change due to a water temperature change shall be calculated by the following
formula:
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B
∆P = -------------------------- ∆T
0.884 r i/ t +A
Where,
∆P = pressure change resulting from a temperature change (bar)
∆T algaebrical difference between water temperature at the beginning of the test and
water temperature as measured at the end of the test (°C).
B= value of the difference between the thermal expansion of water at the pressure and
temperature as measured at the end of the test and that of steel (°C-1) x 106
(Refer table – A)
A= Isothermal compressibility value of water as estimated at the pressure and

temperature values obtained at the end of test (bar-1) x 106 (Refer Figure 1)
ri= nominal inner radius of the pipe (mm).
t = nominal thickness of pipe (mm).
13.0 PRECAUTIONS DURING THE TEST
In addition to all that has been expressly described in the procedures for carrying out the
tests, the following additional requirements shall be complied with:
13.1 Provision shall be made for the installation of no-admittance signs to unauthorized personnel
from the roads to the R.O.W.
13.2 Signs stating "PIPE UNDER TEST-KEEP OFF" with local language translation shall be placed
where the pipeline is uncovered, and particularly where the provisional traps and stations are
located. Such areas shall be suitably fenced in such a way as to prevent access of
unauthorized personnel. No unauthorized personnel shall be closer than 40 m to the pipeline
or equipment under test.
13.3 Provisional scraper traps shall be installed in compliance with methods and suitable locations
so that their rupture cannot cause any injuries to the personnel or third parties.
13.4 The test station shall be placed in such a location as to prevent it from being affected by a
catastrophic failure in the test head.
13.5 Once dewatering is over, the sectionalizing valves and other valve assemblies tested
previously, shall be installed at locations shown in the drawings and in accordance with the
procedures contained in the relevant specifications. All thermocouple installed in the pipeline
shall be removed and damaged corrosion coating shall be repaired using COMPANY approved
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materials and procedure.
14.0 PRESERVATION OF PIPELINE
When so stated in the CONTRACT, to preserve/conserve the pipeline for a specified duration,
CONTRACTOR shall completely fill the pipeline with water, with sufficient quantity of corrosion
inhibitors depending upon quality of water and the period of conservation, at a pressure to be
agreed upon with the COMPANY at a later stage. CONTRACTOR shall obtain necessary
approval from the COMPANY of the procedure and the type and quantity of the inhibitors
used before commencement of the works.
TABLE - A
0
C 1 2 3 4 5 6 7 8
Bar
0.981 -98.62 -79.89 -61.81 -44.34 -27.47 -11.14 +4.66 +19.98
10 -95.55 -76.94 -58.99 -41.65 -24.89 -8.67 +7.02 +22.23
20 -92.15 -73.68 -55.86 -38.64 -22.01 -5.92 +9.65 +24.74
30 -88.74 -70.40 -52.72 -35.63 -19.14 -3.16 +12.29 +27.26
40 -85.32 -67.12 -49.58 -32.62 -16.24 -0.41 +14.93 +29.78
50 -81.90 -63.84 -46.43 -29.60 -13.36 +2.36 +17.57 +32.31
60 -78.47 -60.55 42.27 -26.58 -10.46 +5.15 +22.89 +34.85
70 -75.03 -57.25 -40.10 -23.54 -7.56 +7.92 +22.89 +37.39
80 -71.60 -53.96 -36.94 -20.51 -4.65 +10.70 +25.55 +39.94
90 -68.16 -50.66 -33.77 -17.47 -1.73 +13.50 +28.23 +42.50
100 -64.72 -47.35 -30.60 -14.43 +1.18 +16.29 +30.90 +45.05
110 -61.28 -44.05 -27.43 -11.38 +4.10 +19.08 +33.58 +47.61
120 -57.84 -40.74 -24.26 -8.34 +7.02 +21.88 +36.26 +50.18
130 -54.40 -37.44 -21.08 -5.29 +9.95 +24.68 +38.94 +52.75
140 -50.96 -34.13 -17.90 -2.25 +12.87 +27.49 +41.63 +55.32
150 -47.53 -30.83 -14.73 +0.80 +15.79 +30.29 +44.31 +57.89
160 -44.10 -27.53 -11.56 +3.85 +18.72 +33.10 +47.00 +60.46
170 -40.67 -24.23 -8.40 +6.89 +21.64 +35.90 +49.69 +63.04
180 -37.24 -20.94 -5.23 +9.94 +24.56 +38.70 +52.37 +65.62
190 -33.83 -17.65 -2.06 +12.98 +27.48 +41.51 +55.06 +68.19
200 -30.42 -14.37 +1.09 +16.01 +30.40 +44.30 +57.75 +70.77
210 -27.02 -11.09 +4.25 +19.04 +33.31 +47.10 +60.43 +73.34
220 -23.63 -7.82 +7.40 +22.06 +36.22 +49.90 +63.12 +75.90
230 -20.24 -4.56 +10.54 +25.08 +39.13 +52.69 +65.80 +78.48
240 -16.87 -1.30 +13.67 +28.10 +42.03 +55.48 +68.48 +81.05
250 -13.50 +1.94 +16.79 +31.11 +44.92 +58.26 +71.15 +83.61
260 -10.14 +5.17 +19.90 +34.12 +47.81 +61.04 +73.81 +86.81
270 -6.80 +8.39 +23.00 +37.11 +50.69 +63.80 +76.48 +88.73
280 -3.48 +11.60 +26.11 +40.09 +53.56 +66.57 +79.14 +91.29
290 -0.17 +14.80 +29.19 +43.07 +56.43 +69.33 +81.78 +93.83
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300 +3.13 +17.98 +32.27 +46.03 +59.29 +72.06 +84.83 +96.38
DIFFERENCE BETWEEN THE WATER THERMAL EXPANSION FACTOR AND THE STEEL THERMAL
EXPANSION FACTOR ( 0 C -1 ) (10 -6)
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TABLE - A
0
C 9 10 11 12 13 14 15
Bar
0.981 +34.82 +4922 +63.20 +76.78 +89.99 +102.83 +115.34
10 +36.97 +51.26 +65.15 +78.64 +91.75 +104.51 +116.93
20 +39.36 +53.55 +67.33 +80.71 +93.72 +106.39 +118.71
30 +41.76 +55.84 +69.51 +82.79 +95.70 +108.26 +120.49
40 +44.18 +58.14 +71.70 +84.87 +97.68 +110.14 +122.28
50 +46.60 +60.45 +73.90 +86.96 +99.68 +112.04 +124.07
60 +49.02 +62.76 +76.10 +89.07 +102.67 +113.93 +125.88
70 +51.44 +65.08 +78.32 +91.17 +103.68 +115.84 +127.69
80 +53.88 +67.40 +80.53 +93.29 +105.69 +117.76 +129.50
90 +56.32 +69.73 +82.75 +95.41 +107.70 +119.67 +131.32
100 +58.77 +72.07 +84.98 +97.53 +109.73 +121.59 +133.15
110 +61.21 +74.41 +87.22 +99.66 +111.75 +123.52 +134.98
120 +63.67 +76.74 +89.45 +101.79 +113.79 +125.46 +136.82
130 +66.12 +79.09 +91.69 +103.93 +115.83 +127.39 +138.67
140 +68.58 +81.45 +93.93 +106.07 +117.67 +129.34 +140.51
150 +71.05 +83.80 +96.18 +108.21 +119.90 +131.20 +142.37
160 +73.51 +86.15 +18.43 +110.36 +121.96 +133.74 +144.22
170 +75.97 +88.51 +100.68 +112.51 +124.01 +135.19 +146.08
180 +78.44 +90.87 +102.94 +114.66 +126.06 +137.15 +147.94
190 +80.91 +93.23 +105.19 +116.82 +128.12 +139.11 +149.81
200 +83.37 +95.59 +107.45 +118.97 +130.17 +141.07 +151.68
210 +85.84 +97.95 +109.71 +121.13 +132.24 +143.03 +153.55
220 +88.30 +100.31 +111.97 +123.29 +134.29 +144.99 +155.42
230 +90.67 +102.67 +114.23 +125.45 +136.36 +146.96 +157.30
240 +93.22 +105.03 +116.48 +127.60 +138.42 +148.93 +159.18
250 +95.69 +107.39 +118.74 +129.76 +140.48 +150.90 161.05
260 +98.14 +109.74 +121.00 +131.92 +142.54 +152.87 +162.93
270 +100.60 +112.10 +123.25 +134.08 +144.61 +154.84 +164.81
280 +103.05 +114.44 +125.50 +136.24 +146.67 +156.84 +166.69
290 +105.50 +116.79 +127.75 +138.39 +148.73 +158.78 +168.57
300 +107.94 +119.13 +130.00 +140.54 +150.79 +160.75 +170.45
DIFFERENCE BETWEEN THE THERMAL EXPANSION FACTOR THE STEEL THERMAL EXPANSION
FACTOR ( 0 C -1 ) (10 -6)
121 of 911
TABLE - A
0
C 16 17 18 19 20 21 22 23
Bar
0.981 +127.52 +139.41 +151.00 +162.31 +173.37 +184.18 +194.75 +205.08
10 +129.02 +140.83 +152.36 +163.58 +174.56 +185.30 +195.79 +206.07
20 +130.71 +142.42 +153.85 +165.00 +175.90 +186.55 +196.96 +207.16
30 +132.40 +144.02 +155.35 +166.42 +177.23 +187.80 +198.14 +208.26
40 +134.10 +145.62 +156.87 +167.85 +178.58 +189.07 +199.33 +209.37
50 +135.80 +147.24 +158.39 +169.85 +179.93 +190.34 +200.52 +210.49
60 +137.51 +148.86 +159.92 +170.73 +181.29 +191.62 +201.72 +211.61
70 +139.22 +150.49 +161.46 +172.18 +182.66 +192.91 +202.93 +212.74
80 +140.95 +152.11 +163.00 +173.64 +184.03 +194.20 +204.14 +213.88
90 +142.67 +153.75 +164.56 +175.10 +185.41 +195.50 +205.36 +215.03
100 +144.42 +155.40 +166.11 +176.58 +186.80 +196.80 +206.59 +216.17
110 146.15 +157.04 +167.66 +178.05 +188.20 +198.12 +207.82 +217.33
120 +147.90 +158.70 +169.24 +179.54 +189.59 +199.44 +209.06 +218.49
130 +149.65 +160.36 +170.81 +181.02 +191.00 +200.75 +210.31 +219.66
140 +151.40 +162.03 +172.39 +182.51 +192.41 +202.09 +211.56 +220.84
150 +153.16 +163.70 +173.98 +184.00 +193.82 +203.42 +212.81 +222.02
160 +154.93 +165.37 +175.56 +185.51 +195.24 +204.76 +214.08 +223.20
170 +156.69 +167.05 +177.15 +187.02 +196.66 +206.10 +215.34 +224.39
180 +158.47 +168.73 +178.75 +188.53 +198.09 +207.45 +216.61 +225.55
190 +160.24 +170.42 +180.35 +190.05 +199.52 +208.80 +217.89 +226.79
200 +162.01 +172.10 +181.95 +191.57 +200.97 +210.16 +219.17 +227.99
210 +163.80 +173.80 +183.55 +193.09 +202.40 +211.53 +220.46 +229.20
220 +165.58 +175.43 +185.16 +194.62 +203.85 +212.89 +221.74 +230.41
230 +167.36 +177.19 +186.78 +196.14 +205.30 +214.26 +223.04 +231.63
240 +169.16 +178.89 +188.39 +197.68 +206.75 +215.63 +224.33 +232.85
250 +170.94 +180.59 +190.01 +199.21 +208.20 +217.00 +225.63 +234.08
260 +172.73 +182.30 +191.63 +200.75 +209.66 +218.40 +226.93 +235.31
270 +174.53 +184.00 +193.25 +202.29 +211.12 +219.77 +228.24 +236.54
280 +176.32 +185.70 +194.88 +203.83 +212.59 +221.16 +229.55 +237.77
290 +178.11 +187.42 +196.50 +205.37 +214.05 +222.54 +230.86 +239.01
300 +179.90 +189.13 +198.13 +206.92 +215.51 +223.93 +232.18 +240.26
122 of 911
TABLE -A
0
C 24 25 26 27 28 29 30
Bar
0.981 +215.22 +215.14 +234.88 +244.41 +253.79 +263.00 +272.03
10 +216.13 +225.99 +235.66 +245.13 +254.44 +264.59 +272.57
20 +217.15 +226.94 +236.53 +245.94 +255.18 +264.27 +273.18
30 +218.18 +227.88 +237.41 +246.75 +255.93 +264.95 +273.80
40 +219.21 +228.85 +238.30 +247.58 +256.69 +265.64 +274.42
50 +220.25 +229.82 +239.20 +248.40 +257.45 +266.33 +275.07
60 +221.30 +230.79 +240.11 +249.24 +258.22 +267.04 +275.70
70 +222.35 +231.78 +241.02 +250.08 +258.99 +267.75 +276.35
80 +223.42 +232.77 +241.94 +250.93 +259.78 +248.47 +277.01
90 +224.48 +233.76 +242.87 +251.79 +260.57 +269.19 +277.66
100 +225.56 +234.76 +243.79 +252.66 +261.36 +269.92 +278.33
110 +226.64 +235.78 +244.73 +253.53 +262.17 +270.77 +279.01
120 +227.73 +236.79 +245.68 +254.40 +262.98 +271.41 +279.69
130 +228.82 +237.81 +246.63 +255.28 +263.69 +272.16 +280.38
140 +229.92 +238.84 +247.59 +25618 +264.62 +272.92 +281.08
150 +231.03 +239.87 +248.55 +257.07 +265.44 +273.69 +281.78
160 +232.14 +240.91 +249.52 +257.97 +266.28 +274.46 +282.49
170 +233.26 +241.96 +250.49 +258.88 +267.12 +275.23 +283.20
180 +234.38 +243.01 +251.47 +259.79 +267.97 +276.01 +283.92
190 +235.51 +244.06 +252.46 +260.71 +268.82 +276.80 +284.64
200 +236.64 +245.12 +253.45 +261.63 +269.67 +277.59 +285.37
210 +237.77 +246.18 +254.45 +262.50 +270.54 +278.39 +286.11
220 +238.91 +247.26 +255.45 +263.49 +271.40 +279.19 +286.85
230 +240.06 +248.33 +256.46 +264.43 +272.28 +280.00 +287.59
240 +241.21 +249.41 +257.46 +265.37 +273.16 +280.82 +288.35
250 +242.36 +250.49 +258.48 +266.31 +274.04 +281.63 +289.11
260 +243.52 +251.58 +259.49 +267.27 +274.92 +282.46 +289.86
270 +244.68 +252.66 +260.52 +268.23 +275.82 +283.29 +290.64
280 +245.84 +253.76 +261.54 +269.18 +276.71 +284.12 +291.40
290 +247.01 +254.86 +262.57 +270.15 +277.61 +284.95 +292.18
300 +248.18 +255.96 +263.60 +271.11 +278.51 +285.79 +292.95
123 of 911
MECON LIMITED STANDARD TECHNICAL SPECIFICATION OF MAJOR
DELHI WATER CROSSINGS (CONVENTIONAL)
REV 0, EDITION - 1
FOR
MAJOR WATER CROSSINGS
(CONVENTIONAL)
MECON LIMITED
DELHI 110 092

124 of 911
REV 0, EDITION - 1
CONTENTS
SL.NO. DESCRIPTION
0.0 DEFINITION
1.0 SCOPE
2.0 GENERAL
3.0 TRENCHING
4.0 CONTINUOUS CONCRETE COATING
5.0 HYDROSTATIC PRE-TESTING
6.0 INSTALLATION
7.0 BACKFILLING AND BANK PROTECTION
8.0 FINAL HYDROSTATIC TEST
9.0 POST-CONSTRUCTION SURVEY
10.0 FINAL CLEAN-UP
11.0 DOCUMENTATION
125 of 911
REV 0, EDITION - 1
AMENDMENT STATUS

126 of 911
DEFINITION
A major water crossing shall be reckoned the one which will necessitate passing
the gas pipeline across a water body such as perennial river, major irrigation canal,
pond, lake, lagoon, creek etc. using special attention and means. The parameters
required to classify a particular water body as a major water crossing shall
comprise of size, hydrological data, authority/ownership, importance and other
ecological/ environmental factors associated with it, and the authority to classify it
such, shall rest with the COMPANY.
1.0 SCOPE
1.1 This specification covers the minimum requirements for the various activities to be
performed by CONTRACTOR for the construction of pipeline major water crossings by
conventional trenching method. Provisions of this specification are applicable only for
"major water crossings" specifically named as such in the CONTRACT.
and documents included in the CONTRACT between COMPANY CONTRACTOR.
1.3 CONTRACTOR shall, with due care and diligence, execute the work in compliance
with all laws, by-laws, ordinances, regulations etc. and provide all services and
labour, inclusive of supervision thereof, all materials excluding the materials indicated
as "Company supplied Materials" in the CONTRACT, equipment, appliances or other
things of whatsoever nature required in or about the execution of the work, whether
of a temporary or permanent nature.
1.4 CONTRACTOR shall take full responsibility for the stability and safety of all
operations and methods involved in the work.
1.5 CONTRACTOR shall be deemed to have inspected and examined the work area and
its surroundings and to have satisfied himself so far as practicable as to the form and
nature thereof, including sub-surface conditions, hydrological and climatic conditions,
the extent and nature of the work and materials necessary for the completion of the
work, and the means of access to the work area.
1.6 CONTRACTOR shall be deemed to have obtained all necessary information as to

risks, contingencies and all other circumstances, which may influence the work w.r.t.
the above.
1.7 CONTRACTOR shall, in connection with the work, provide and maintain at his own
costs all lights, guards, fencing, watching etc., when and where necessary or
required by COMPANY or by any duly constituted authority for the protection of the
work and properties or for the safety and the convenience of public and/ or others.
1.8 For the purpose of this specification, the following definitions shall hold :
• the words `Shall' and `Must' are mandatory
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• the words `Should', `May' and `Will' are non-mandatory, advisory, or

recommended.
2.0 GENERAL
2.1 All works of the pipeline major water crossing shall be performed in accordance with
the approved construction drawings, procedures, other applicable documents as per
the CONTRACT, good pipeline practice and as directed by COMPANY.
2.2 Before start of the field construction, CONTRACTOR shall submit to COMPANY, for
approval for each major water crossing a complete report containing at the
minimum:
i) installation method
ii) proposed time schedule indicating start and finish dates and detailed break-
up of time period for all critical activities associated with the work.
iii) required work area along with layout and location
iv) equipment to be used (including number and capacity of equipment).
v) manpower deployment during construction
vi) proposed sub-contractors and/ or vendors along with their scope of work.
The description of the installation method as a minimum shall include the following:
a) Study of water currents in relation to the method of launching (on bottom

and on surface).
b) Calculation for stability of pipeline during launching and final test.
c) Buoyancy studies
d) Preparation of fabrication yard and launching areas.
e) Pipeline construction details (handling, stringing, welding, concrete coating

etc.)
f) Pre-test procedure including trial mix, design & tests for concrete coating.
g) Procedure for corrosion coating of field joint
h) Dredging, anchoring program, spoil-deposit and trench survey method

including facilities for COMPANY.
i) Pulling or other installation method and related calculations.

j) Pulling arrangement including launchway and anchoring and breaking device.
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k) Trench correction before launching.
l) Method of positioning and sinking of pipeline.
m) Method of rectification of damages to the pipeline, during launching.
n) Method of backfilling, bank protection and survey.
o) Final test procedure after backfilling.
p) Safety systems during launching, rope tests.
q) Communication.
r) Abandonment and recovery procedures concurred.
s) Necessary permission from concerned authorities for crossing.
COMPANY shall inform CONTRACTOR within 21 days if any objection against the
document and procedure described requires resubmission by CONTRACTOR.
Approval by COMPANY of the methods used by CONTRACTOR shall in no way relieve

CONTRACTOR from the sole responsibility for safe and satisfactory installation of the
crossing.
2.3 CONTRACTOR shall comply with all the conditions and requirements issued by
authorities having jurisdiction in the area where the work is to be performed.
CONTRACTOR shall, at his own responsibility, obtain necessary permits from the
authorities having jurisdiction, for performing his work.
If no public roads exist, CONTRACTOR shall arrange on his own for access to his
work area at no extra cost to COMPANY.
2.4 Pre-construction Surveys
Prior to start of any work, CONTRACTOR shall carry out a survey of the major water
crossings and acquaint himself with site conditions and to collect any data regarding
the water velocity and the tidal variations in the flow pattern and shall verify the
suitability of his equipment and the methods of construction.
3.0 TRENCHING
3.1 Dredging/ Excavating
3.1.1 CONTRACTOR shall dredge or excavate the trench for the water crossing in
conformity with the approved drawings. Dredging of the trench shall be executed as
accurately as possible.
3.1.2 The trench shall be excavated to such depth as required to provide the minimum
129 of 911
cover and the pipeline configuration as specified. The pipeline profile of the crossings
shall be followed as accurately as possible. Before laying, the trench shall be cleaned
and levelled. The trench shall be subject to inspection by COMPANY prior to
installation of the pipe.
3.1.3 Navigational traffic shall not be obstructed, unless permission has been given
thereto. CONTRACTOR shall issue all necessary publications according to the local
regulations. Instructions given by authorities shall be followed accurately and
immediately, so that there in no hindrance to traffic. For stoppage of navigational
traffic public notification, PA system, signal/ sign etc. shall be provided.
CONTRACTOR cannot request a compensation if his work is hampered or delayed

due to weather conditions, any obstacles/ or by any traffic on the spot, where work
is executed.
3.1.4 CONTRACTOR is fully responsible for the execution of the blasting (whenever
permitted) the dredging and excavation work, hopping of the soil, transportation,
dumping on land or in water, all to be executed in agreement with authorities, land
owners and COMPANY.
3.1.5 CONTRACTOR may be obliged to dredge or excavate a trench deeper or wider than
indicated in the drawings in order to properly lay the pipeline in unstable
(underwater) areas, or near and adjacent to the banks of water courses. It shall be
understood that CONTRACTOR is aware of such problems at the time of this bid and
that, when such additional excavation is required, it shall be done by CONTRACTOR
as part of the work and that he will install the necessary provision and/ or temporary
works such as sheet-piling, special filling materials, etc. at no extra cost to
COMPANY.
3.1.6 During, the execution of dredging work of CONTRACTOR, bearings, measurements

and levels shall be taken by or on behalf of COMPANY. CONTRACTOR shall render
assistance for this purpose and make available for COMPANY appropriate survey
boats, fully manned and equipped before the start of excavation work of the water
crossing trench. CONTRACTOR, if so desired by COMPANY, shall make cross profiles
at intervals of not more than 10.0m of the bottom of the water-course along the
surveyed center line of the water crossing. In such a case horizontal measurements
shall be taken by triangulation or taping between known points and shall be made
with such accuracy that the location of each vertical measurement is known within
1.0m. Vertical measurements shall be taken with a sonic recording device, or with
line and rod, as directed by COMPANY and shall be taken with such accuracy that
each depth is known within 0.2m. Vertical measurements shall be taken at points
averaging not more than 5.0m apart and no two measurements shall be more than
7.0m apart. The cross profiles shall extend at least 10m on both sides of the top of
the trench.
All measurements shall be witnessed by COMPANY. The resulting profile, corrected

to the elevation of the undisturbed water-course, shall then be the reference profile.
Said profile shall be plotted on a 1:200 vertical and horizontal scale.
130 of 911
3.1.7 CONTRACTOR shall keep the trench in good condition until the pipe is laid, and no
claim is to be made to the COMPANY by reason of its caving either before or after
the pipe is laid. CONTRACTOR shall do whatever is required to excavate the trench,
install the pipe in it and backfill the trench in accordance with these specifications at
no extra cost to COMPANY.
3.1.8 Immediately before installation of the water crossing in the excavated trench,
CONTRACTOR shall prepare a profile of the trench bottom along the surveyed center
line of the water crossing for comparison with the reference profile. CONTRACTOR
shall also make cross sections of the trench at intervals of not more than 100m. All
profile and cross section measurements shall be taken as specified and shall be
witnessed by COMPANY. These data shall be submitted to COMPANY for approval and
COMPANY will approve or reject the trench excavation as completed within 24 hours
after receipt of the profile and cross sections.
3.1.9 CONTRACTOR shall grade the trench in such a manner as to give the maximum
amount of uniform support to the pipeline when it is lowered or pulled into place. The
maximum unsupported span shall not exceed 10.0m.
3.1.10 In submerged sections, where rock or gravel is encountered in the bottom of the
trench, padding is required. The thickness of the padding under the concrete coated
pipe shall at least be 50 cm and after installation at least 50 cm around the pipe.
Blasting, if any, and padding shall be included in the work.
3.2 Pumping Line
In case CONTRACTOR uses pumping lines to discharge the spoil, he shall take care of
the necessary permits.
Pumping lines, discharges and siphons shall be installed by CONTRACTOR and

removed before the completion of the work. At crossings with existing roads, the
pumping lines shall be led through a casing pipe bored/ jacked under the road or led
through a porch over the road. A stress calculation must then be handed over to
COMPANY. The necessary provisions to embank the dumping area and also the spoil
basins shall be made by CONTRACTOR. CONTRACTOR is responsible for transportation
of the soil and dumping on land and is liable for damage to works of third parties
caused by leakage of pumping lines, etc. CONTRACTOR shall at all time prevent
overflow of pumping water, spoil or sand over embankments, parcels or roads. Further
more, CONTRACTOR shall safeguard COMPANY from claims of compensation by third
parties due to encountered damage.
131 of 911
3.3 Spoil
Spoil which is not dumped on and including spoil acquired after cleaning the water
crossing trench, shall be transported and dumped in places, designated thereto by
agreement between CONTRACTOR and authorities and approved of by COMPANY.
Spoil shall be transported in (split) barges; only those barges shall be used that avoid
spilling during transportation due to incorrect closing of the flaps, etc. Spoil which is
dumped outside the designated places shall be removed by CONTRACTOR at first
notice by COMPANY.
3.4 Dykes, Dams and Weirs
CONTRACTOR shall install temporary provisions in the existing dykes, dams, etc. to
prevent flooding of low areas.
Therefore in general, in existing dykes, dams, etc a double substituting weir must be
installed before start of excavation in the existing dyke or dam. Such a double
substituting weir can be a closed wall of sheet piling, supported by soil. The provisions
shall be such that the underwater profile of the dredged trench, the water movement
caused by ships, etc. cause no slides/ cave-ins of the dyke or dam.
4.0 CONTINUOUS CONCRETE COATING
CONTRACTOR shall provide concrete coating over the pipeline including the bends in
accordance with the specification issued for the purpose (refer specification no.
MEC/S/05/11/03 and approved procedure. CONTRACTOR shall coat the weld joints in
order to arrive at a continuously concrete coated pipeline. However this concrete
coating shall be applied after the hydrostatic pre-test.
5.0 HYDROSTATIC PRE-TESTING
CONTRACTOR shall hydrostatically pre-test the pipe string of each water crossing
before installation as per approved procedure.
Joint coating of the welds shall be done after this pre-test.
The section of the pipeline corresponding to the major water crossing shall, before
installation, be subjected to hydrostatic pre-testing to a combined equivalent stress
of 90% of the SMYS of the pipe material.
After the temperature has been stabilised, the pressure shall be maintained in the
pipeline for at least twenty four (24) hours and recorded by manothermograph. During
the test CONTRACTOR shall check all welds for leakage. Failure, if any, during the test
shall be rectified by the CONTRACTOR. If the same is due to failure on account of any
cause other than defect in material supplied by COMPANY, the repairs shall be done
free of cost, to the satisfaction of COMPANY.
6.0 INSTALLATION
132 of 911
6.1 CONTRACTOR shall submit a detailed scheme for the method he proposes to adopt for
installing the pipeline to COMPANY for approval. CONTRACTOR shall calculate all
stresses in the pipeline while laying and check whether the stresses remain within
permissible limits. A set of all calculations shall be submitted to the COMPANY for
approval.
6.2 CONTRACTOR shall perform all work required to install the water crossings, including
the possible appurtenances indicated in the drawings. The water crossings shall be
installed in such a manner as to comply with the requirements and conditions stated
by the Authorities issuing the permits. CONTRACTOR shall pay special attention to
minimize any damage to embankments and dykes in the vicinity of water crossings.
6.3 The equipment for launching shall be arranged in such a way that the pipeline is laid
without impact or jerking and is not subjected to stresses of any type other than those
which are allowable. Minimum allowed radius of curvature shall be followed,
particularly at the end of the launching way towards the water in the freely suspended
section.
6.4 After the water-crossing section has been installed in place, CONTRACTOR shall fill this
section including the pertaining land sections with water for the final testing.
6.5 CONTRACTOR shall check if the position and depth of the water crossing are in
accordance with the approved drawings, by means of a profile of the pipeline, before
and after the water-crossing section is filled with water. CONTRACTOR shall lower each
pipeline section which is not sufficiently deep by dredging or jetting the underlying
ground.
6.6 The maximum allowed horizontal deviation from the required center line shall be
limited to the following :-
For pipeline dia. upto and including 24" - 300 mm
For pipeline dia greater than 24" - 500 mm
6.7 Prior to backfill the pipeline shall, when laid in the trench, conform to the bottom
contour of the trench grade, so that it will be firmly, uniformly and continuously
supported. COMPANY may employ a diver or use other suitable methods to inspect the
bottom of the trench and/ or after the pipe is installed prior to backfilling of the trench.
CONTRACTOR shall facilitate the work of the diver and shall furnish the necessary
equipment and helpers (other than actual diving equipment) necessary for the diver/
inspector to perform his work.
6.8 If the pipe does not properly fit the trench or does not rest at sufficient depth to satisfy
the minimum requirements of cover as specified in approved drawings, the
CONTRACTOR shall make necessary corrections to either trench or the pipe alignment
or to both so that the pipe, when finally in position in the trench, shall fully meet the
specifications, failing which CONTRACTOR may be asked to remove the pipeline. This
shall be done at no extra to the COMPANY.
6.9 Installation of Parallel Pipelines
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When parallel pipelines are required to be installed for a major water crossing.
CONTRACTOR shall further comply with the following requirements.
6.9.1 Depending on the diameters of the parallel pipelines, the characteristics of the crossing
and the limitations of CONTRACTOR's equipment, CONTRACTOR may propose
installation of the parallel pipelines either together in a combined operation or
separately in a common trench.
6.9.2 If the pipelines are installed together, the minimum clear distance between the parallel
pipelines (measured from the outside diameters of the concrete coated pipes) shall be
300mm. CONTRACTOR shall provide spacers at sufficient intervals along the length of
the pipe section(s), securely fixed to the pipes, or shall propose other suitable
alternative methods, so as to ensure that the stipulated minimum clear distance is
maintained. The spacers may be removed before the trench is backfilled.
CONTRACTOR shall furnish detailed drawings for the pipe assembly showing the
details of spacers/ other arrangements for COMPANY's approval before start of
construction.
6.9.3 If the parallel pipelines are installed separately in a common trench, the minimum clear
distance between the parallel pipelines in the trench shall be 5000mm. CONTRACTOR
shall ensure that this minimum spacing be maintained till the time the trench is
backfilled.
7.0 BACKFILLING AND BANK PROTECTION
7.1 Backfilling of the water-crossing section shall be performed as described in the

following clauses.
7.1.1 The bottom of the waterway shall be reinstated to its original level by backfilling the
trench in a manner and with suitable material and as prescribed and approved by the
authorities and COMPANY. In case material other than the original spoil is required,
this shall be supplied and applied by CONTRACTOR.
Wherever boulders, rock, gravel and other hard object are encountered, they shall not
be placed directly on the pipe. Sufficient earth, and or selected and approved backfill
material shall be backfilled initially around and over the pipe to provide a protective
padding or cushion extending to a minimum thickness of 50 centimeters around the
pipe before backfilling remainder of the trench with excavated or other material.
Wherever required by COMPANY, CONTRACTOR shall cover the (nearly) backfilled

trench with a layer of rock boulders to be approved by COMPANY over a width equal to
the width of the excavated trench with an extra of 5 m on either side at no extra cost
to COMPANY.
7.1.2 Backfilling progress of the trench shall be checked continuously, and a daily progress
report shall be made and handed over to COMPANY.
134 of 911
7.1.3 All embankments and/ or dykes, bed and banks shall be reinstated to their original
state and levels, unless otherwise prescribed in the drawings or by the Competent
authorities or COMPANY.
7.1.4 All remaining spoil-deposits shall be cleaned by CONTRACTOR to the satisfaction of

COMPANY.
7.2 Bank Protection
7.2.1 Trenches in banks of major water crossings shall be backfilled with soil approved by
COMPANY. The fill at the banks shall be tamped firmly and reinforced with sacked
earth, rip-rap, or by other means as directed by COMPANY to the satisfaction of
authorities having jurisdiction thereof. In areas where the backfilled soil is expected to
be of loose type which is prone to flow, the trench shall be backfilled with boulder/
crushed rock of minimum 75mm thickness. The boulder/ crushed rock shall be derived
from solid, stable, non-soluble and approved quality store approved by COMPANY and
pipe shall be provided with adequate padding of soil of a quality approved by
COMPANY. Wherever necessary the boulder/ crushed rock shall be held to the bed by
use of 6.1 wire nets of minimum dia. of 3.2mm, made from steel having tensile
strength of 400 N/mm2 and with a minimum elongation at failure of 12%. The
minimum zinc coating of 275 gm-2 shall be applied on single/ double twisted wire. After
the trench has been backfilled and during the clean up works, the water crossing shall
be cleaned across the whole width of ROW. The existing bed profile shall be
maintained after restorations.
7.2.2 Unless stipulated otherwise by the authorities or by COMPANY, CONTRACTOR shall

protect the banks of the major water crossings by using gravel and boulders filled
embankment mattresses of galvanized iron wire (of specification as in 7.2.1 above) to
be laid over the backfilled, compacted and graded banks. In case slope of the banks is
1:1 or more, bank protection shall be carried out using gabions. Bank protection works
shall be carried out by CONTRACTOR in accordance with the drawings included in the
CONTRACT. All materials required for such works shall be supplied by CONTRACTOR
and all works carried out in accordance with specifications, approved drawings,
instructions of COMPANY and to the complete satisfaction of authorities having
jurisdiction at no extra cost to COMPANY.
The length of the above protection shall be equal to the actual bank excavation edge
including damage and further extending 10 m on either sides, The width of the
restoration on the slope shall be determined by the levels :
• 2m above Highest Water Level, (recordable) or upto the top of bank, whichever
is higher.
• 5m below Low Water Level (recordable) or upto pipe trench level in the bed.
7.2.3 Before final hydrostatic testing, CONTRACTOR shall `prove' the diameter of the
pipeline by passing a gauging (caliper) pig through the pipeline. The gauging pig
shall have a diameter equal to 95% of the internal diameter of the pipe.
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CONTRACTOR shall supply and install all temporary scraper, launchers. Receivers
and other equipment, piping and materials and consumables for the purpose.
8.0 FINAL HYDROSTATIC TEST
The complete water crossing must be tested immediately after the approved backfilling
of the trench. The test procedure shall result in a hoop stress in pipe corresponding to
90% SMYS of the pipe material. After temperature stabilisation pressure shall be
retained in the pipeline for a minimum of twenty four (24) hours and recorded by
manothermograph. The hydrostatic testing shall be carried out in accordance with
approved procedures.
9.0 POST-CONSTRUCTION SURVEY
After laying of the pipeline, CONTRACTOR shall carry out a post-construction survey
jointly with COMPANY. Any defects brought to the notice of CONTRACTOR shall be
promptly corrected by CONTRACTOR at his own expense to the complete satisfaction
of COMPANY.
10.0 FINAL CLEAN-UP
After completion of construction, CONTRACTOR shall clear the site of all balance
material and debris. All balance pipe lengths, in case supplied by COMPANY, shall be
returned to COMPANY's designated stock yard(s). Site shall be cleared to the complete
satisfaction of COMPANY and authorities having jurisdiction. All such works shall be
done at no extra cost to COMPANY.
11.0 DOCUMENTATION
11.1 In addition to the documents specified elsewhere in this specification. CONTRACTOR

shall submit to the COMPANY six copies of each of the following documents / records.
• Complete record of pipes `taken-over' from COMPANY, number of pipe lengths

used, and record of return of balance pipe lengths to COMPANY's designated
stock-yard(s).
• Copies of the permits obtained from authorities having jurisdiction for the
various works.
• Records of Non-destructive testing of welds.
• Clearance certificates from the land owners and authorities having jurisdiction
regarding satisfactory clean-up and restoration of pipeline ROU and work areas.
11.2 After completion of construction CONTRACTOR shall prepare & furnish six sets of
copies and two sets of reproducible of As-built drawing for the crossings.
As-built drawings shall be as a minimum, include the following information.
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• True profile of the bed and banks of the water crossing along the pipeline after
backfilling.
• True profile of the pipeline as installed and the top of cover to top of pipe at
regular intervals.
• Location and angle of sag and over bends.
• Extent of backfill.
• Extent of bank protection.
11.3 All documents shall be in English Language
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MECON LIMITED STANDARD TECHNICAL SPECIFICATION OF PIPELINES
DELHI CROSSING ROADS, RAILROADS, MINOR WATER AND
OTHER CROSSINGS
REV 0, EDITION - 1
FOR
PIPELINES CROSSING ROADS, RAILROADS,
MINOR WATER AND OTHER CROSSINGS

MEC/S/05/28/05
MECON LIMITED
DELHI 110 092

138 of 911
OTHER CROSSINGS
REV 0, EDITION - 1
CONTENTS
SL.NO. DESCRIPTION
1.0 SCOPE
3.0 GENERAL
4.0 ROAD AND RAIL-ROAD CROSSINGS
5.0 CROSSINGS OF BURIED SERVICES
6.0 MINOR WATER COURSE CROSSINGS
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AMENDMENT STATUS

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OTHER CROSSINGS
1.0 SCOPE
1.1 This specification covers the minimum requirement for the various activities to be
carried out by the CONTRACTOR for or about the installation of pipelines crossing
roads, railroads, minor water courses and other services.
The provisions of this specification are not applicable for pipelines crossing water
courses, which are specifically designated as "Major Water Courses" in the CONTRACT.
1.2 This specification shall be road in conjunction with the conditions of all specifications
For the purpose of this specification the following definitions shall hold :
• the words "Shall" and "Must" are mandatory

• the words "Should, "May" and "Will" are non-mandatory, advisory
recommended.
2.1 Reference has been made in this specification to the latest edition (edition enforce at
the time of floating the enquiry) of the following codes, standards and specifications.
a) ASME B 31.4 - Pipeline Transportation Systems for Liquids and

Slurries.
b) ASME B 31.8 - Gas Transmission and Distribution Piping

Pipelines Crossing Railroads and Highways.
c) API RP 102 - Recommended practice for Liquid Petroleum

Pipelines Crossings Railroads and Highways.
d) OISD 226 - Natural Gas Transmission Pipelines and City Gas

Distribution Networks
e) Part 192, Title 49 - Transportation of Natural and Other Gases by

Pipeline.
f) Part 195 - Transportation of liquids by Pipeline.
2.2 In case of conflict between the requirements of above mentioned codes, standards,
specifications and practices, the most stringent requirement shall govern.
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OTHER CROSSINGS
3.0 GENERAL
3.1 Crossing of roads, railroads, buried services, canals and minor water courses with
equipment and/ or personnel is allowed only after acquiring approval from the
authorities having jurisdiction and after making arrangements for safeguarding the
roads, etc. and the buried services with appropriate provisions.
Highways, main-roads and railroads and their verges and banks of water crossings are
not allowed to be used for loading, unloading or stacking of materials and/ or
equipment. For secondary roads, such loading/ unloading is permitted only after prior
approval from the concerned authorities CONTRACTOR is not allowed to close or divert
roads or water courses without prior approval from the COMPANY and the concerned
authorities. CONTRACTOR shall never unnecesarilly hamper the users of the roads,
railroads, buried services and/ or water courses. The water flow shall not be obstructed
in any way.
3.2 COMPANY reserves the right to demand for individual crossings from the
CONTRACTOR a separate detailed report for approval, containing :
• Time schedule
• Working method with equipment
• Test procedure
• Manpower deployment
• Calculations of temporary works
• Soil investigations, etc.
• Approval letter from Competent Authority.
Such works shall be without any extra cost to COMPANY.
3.3 Pipeline crossings for road, railroad, canals and rivers etc., shall be hydrostatically
pretested ex-situ, prior to joint coating, whenever,
• Crossing is executed by boring ;
• Crossing is installed in casing pipe;
• River crossing pipes which are to be continuously concrete weight coated (to
be tested prior to concrete coating);
• Whenever, in COMPANY's opinion, the repair of pipeline at crossing, in case of

a leak during final hydrostatic testing, would require inordinate amount of effort
and/ or time;
• Whenever pretesting is insisted upon by the Authorities having jurisdication

over the utility crossed.
The section of the pipeline for the crossings shall be tested as a single string. Unless
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OTHER CROSSINGS
specified otherwise in the CONTRACT, the test pressure shall be the one resulting in a
hoop stress corresponding to 90% of SMYS of pipe material. Test pressure shall be
retained in the pipeline for minimum period of 4 hours. Test section shall be visually
examined for leaks/ defects, etc.
4.0 ROAD AND RAILROAD CROSSINGS
4.1 The work under crossings shall include necessary clearing, grading and trenching to
required depths and widths, welding of casing (when required) and carrier pipes,
coating, lowering-in, backfilling, clean-up, restoration to the original condition and
further strengthening and protective works, testing, installation of assemblies,
insulators and seals, and temporary works such as sheet pilling, bridges, etc.
The work shall be carried out in accordance with the approved drawings and job
standards, as directed by COMPANY and to the satisfaction of COMPANY and the
authorities having jurisdication over th facility crossed. The work carried out for road
and railroad crossings shall meet the minimum requirements of API RP 1102, latest
edition.
Before the installation work of crossings is started, the CONTRACTOR shall provide
suitable barricades, temporary bridge/ bypass work (especially where roads are open-
cut) with railing, if required by COMPANY for safety of traffic. Adequate traffic warning
signals and/ or traffic lights and suitable diversions shall be provided as directed by
COMPANY/ Authority having jurisdiction over these areas. Such diversions shall not
cross the pipeline where it has already been installed, unless proper safeguarding in
COMPANY's opinion is ensured.
Prior approval from the statutory authorities shall be obtained to lay the pipeline across
highways/ roads either by boring or by open-cut method. Installation of the crossing
shall be by the method (i.e., boring/ open-cut) approved by Authorities having
jurisdiction. Railroad crossings shall always be bored/ jacked.
4.2 Boring/ jacking of carrier pipes for crossings is allowed only if the pipes for boring/
jacking are provided with a suitable corrosion coating and CONTRACTOR remains liable
for the suitability of the pipe and weld-coating of carrier pipes to be bored and for
which coating and method of application are anyhow to be authorised by COMPANY
without prejudice to CONTRACTOR's liability. In all other cases the carrier pipes shall
be cased.
Before start of the boring/ jacking CONTRACTOR shall execute a soil investigation
and determine the ground water table. Based on these investigations CONTRACTOR
shall prepare a construction drawing and submit to COMPANY for approval including
time schedule and soil investigation report. The CONTRACTOR shall submit for
approval of COMPANY the method of boring / trenchless to be carried out,
depending on the nature of soil conditions, nature of crossing, local requirements
etc.
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During the execution of boring the ground water table over the length of the boring
shall be lowered up to at least 0.50 M below bottom of the pipeline. This water table
is to be regularly inspected and maintained by CONTRACTOR and reported to
COMPANY. To safeguard the stability of the borepit, CONTRACTOR shall, if necessary
in COMPANY's opinion, use a closed sheet piling which shall extend at least over
50% of the length in undisturbed soil. The length of the boring shall be in
accordance with the length of the ROW of the crossing (road, railroad, etc.) with
minimum 0.6 m extra on either side.
If the soil conditions and groundwater for a particular boring give reasons for this,
CONTRACTOR is entitled to suggest to COMPANY for a relaxation of one or more of
the following requirements as defined here forth :
• Soil investigation
• Lowering of groundwater table
• Sheet piling
• Length of boring etc.
In approaches to the crossing, CONTRACTOR shall eliminate unnecessary bending of

pipe by conforming to the contour of the ground by gradually deepening the ditch at
such approaches as directed by the COMPANY.
4.3 The bottom of the trench and/ or the pit for at least twelve (12) metres at the
approach to each end of a casing shall be graded and if necessary backfilled with clean
sand and compacted upto atleast 95% Proctor density to an elevation that will provide
sufficient and continuous support to the pipeline so that the pipeline remains correctly
aligned at the casing ends during and after backfilling.
4.4 The diameter of the hole for a bored section shall have a hole diameter as close as
practicable to the outside diameter of the carrier or casing pipe. If excessive void or
too large hole results, or if it is necessary, in the opinion of COMPANY, to abandon the
bored hole, prompt remedial measures such as filling the hole with suitable material
shall be taken to the entire satisfaction of the COMPANY and Authorities having
jurisdiction thereof at no extra cost to COMPANY. Equipment used for installation of
casing pipe shall be of the type approved by COMPANY.
An installation consisting of hydraulic jacks shall be provided with easily readable

pressure gauges (in bar) and sealable pressure limits. Their proper operation shall be
demonstrated before the work is started. COMPANY can request that the maximum
pressing force be limited.
At the front of the pipe there may be a cutting ring which may be 12mm larger than
the outside diameter for the pipe or casing. A lubricating pipe can also be used in
jacking, the nipples of which shall not protrude from the cutting edge. Said
lubricating pipe shall not be fixed to the pipe casing. When jacking, only biologically
degradable lubricants shall be used (e.g. WRC Medlube or an emulsion of bentonite).
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OTHER CROSSINGS
Removal of soil from the pipeline during jacking shall be done mechanically by means
of a standard, locked auger, which has to be safeguarded against jacking ahead of the
pipe.
During jacking the progress of the pipe to be jacked and the cutting capacity of the
auger shall be mutually adjusted, by regulating the speed of the auger, to prevent the
road from bulging (rpm too low) or cave-ins (rpm too high). In any case no more soil
shall be removed than the volume of the pipe. The auger drive shall be provided with a
clutch.
The progress in the work, the readings of the gauge pipes, the jacking pressures
observed, etc., shall be recorded in a log book, to be shown to COMPANY upon
request. All information shall be supplied to COMPANY on completion of the work.
If the jacking fails, the casing shall not be withdrawn. It shall be filled with sand and
plugged at either end. The diameter of the casing pipe shall conform to API RP 1102
recommendations or as directed by the Engineer – in - charge.
COMPANY reserves the right to inspect certain lengths of pipes to assess damages, if
any, to the corrosion coating of the carrier pipe used for boring. CONTRACTOR shall
weld additional lengths of pipe and pull the required extra lengths of COMPANY's
inspection. If during inspection any defects are noticed, CONTRACTOR, in consultation
with COMPANY, shall carry out the remedial measures required.
4.5 While welding of the casing and vent/ drain pipes, internal high or low is not allowed.
Welding of casing and vent/ drain pipes need not be radiographed, however, only
normal visual checks shall be carried out. Before welding, the single length of pipe shall
be inspected in order to check that there is no out of roundness and dents. When such
defects are noticed, these must be completely removed before joining the pipes. If
these defects cannot be repaired, the defective section shall be cut out.
4.6 In the case of crossing where excavation has been authorised, the welding for the
casing pipe and for a continuous section of the pipeline corresponding to the expected
length shall be carried out in the proximity of the crossing. Casing must be laid
immediately after the trenching. Casing pipe must be laid with a single gradient in
order to allow for an easy insertion and, if necessary at a future date, to allow for the
removal or replacement of the pipeline, leaving the casing undisturbed.
4.7 The assembly of vent pipe units as approved by COMPANY shall be carried out by
direct insertion and welding to the ends of the casing pipe before introducing the
carrier pipe. The operation of assembling and extending the vent pipe shall be carried
out in such a way that there is no contact with the carrier pipe. The painting/ coating
of the vent pipes shall be applied before backfilling as per relevant specifications.
4.8 The casing pipe shall be considered ready for installation of the carrier pipe, after
careful inspection and internal cleaning with the removal of soil, mud, stones and other
foreign materials.
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OTHER CROSSINGS
4.9 Insulators, as approved by COMPANY, shall be securely fastened to the pipe with all
bolts and fixtures firmly tightened. The number of insulators and spacing shall be as
shown in the drawings or at 2.5m intervals (whichever is more stringent). At the end of
both sides of the casing, a double set of insulators shall be installed.
4.10 Care must be taken in pushing or pulling carrier pipe into the casing so that the pipe is
aligned correctly in the casing and that the pushing or pulling force is evenly and
constantly applied to avoid damages to the insulators. A nose piece having a diameter
equal to that of the pipe shall be welded on the front and back end of the carrier pipe
to facilitate installation of the carrier pipe properly in the casing and to keep it dry and
clean.
4.11 After installation of the carrier pipe section, the casing and the appurtenances, but
prior to making tie-in welds and backfilling, an electrical test shall be conducted by the
CONTRACTOR in the presence of the COMPANY, to determine the resistance between
the casing and the carrier pipe or the carrier pipe and the soil. These tests shall show
at least a resistance of 100 Kohm/m2. After backfilling and compaction, additional tests
shall be conducted to determine if the casing is electrically shorted to the pipe. If the
installation is found to be shorted, CONTRACTOR shall make the necessary corrections
and repairs at his cost, until a test to the satisfaction of the COMPANY is obtained.
5.0 CROSSINGS OF BURIED SERVICES
5.1 The pipeline under construction may pass above or below the existing buried facilities
such as pipelines, cables, etc. Type of crossing shall be such that a minimum depth of
cover as required in the drawings and specifications are guaranteed. The minimum
clearance required between pipeline and the existing facility shall be 500mm.
5.2 Whenever buried services in the ROW are to be crossed by CONTRACTOR, he shall
safeguard the buried facilities and the required precautions shall be taken as approved
by Owner of the buried services and by COMPANY.
5.3 For buried services to be crossed by boring/ jacking, the relevant provisions of Section
3.0 shall apply.
6.0 MINOR WATER COURSE CROSSINGS
6.1 Minor water crossings are crossings of ditches, canals, water courses, rivers, streams
etc, whether the bed(s) contain(s) water or not, and not being specified as `Major
Water Crossings' in the CONTRACT.
6.2 For minor water crossings a standard drawing or a separate detailed approved drawing
for individual crossing shall be applicable, and all further specifications are applicable.
6.3 Whenever minor water crossings in the ROW are to be crossed, CONTRACTOR shall
install/ temporary bridges to facilitate movement.
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OTHER CROSSINGS
6.4 In crossings of water courses with either moderate flow rate or of torrential nature
with marked and unpredictable flooding, an adequate survey shall be carried out
before starting the work with the object of determining what precautions are necessary
and the most favourable period for executing the work.
6.5 In case of crossings of water courses for which no special methods of laying are
required, a pipe section of a size as per the the approved drawings shall be assembled
and subsequently laid. Bends shall be of cold field type.
Whenever required by COMPANY, CONTRACTOR shall, before start of construction,

execute a soil investigation. Based on this soil investigation he shall prepare
construction drawings, work method and time schedule for approval of COMPANY as
well as concerned local agencies.
The depth of the existing bottom of a minor water course crossing shall be
determined in relation to the adjacent stable ground level by taking the average of
four measurements. Measurement shall be taken with a gauge and with dimensions
60 x 60mm and having a flat bottom. The minimum force to be exerted shall be 360
N (36 kgf).
CONTRACTOR shall take special care to check with the responsible authorities for
special conditions applying to working on, over, under or through minor water
crossings and CONTRACTOR shall comply with any such conditions. Written
arrangements with authorities shall be drawn up in cooperation with COMPANY.
6.7 For crossings beneath the bed of water courses, the pipe section shal be made in such
a way that it conforms to the existing or future bed as indicated in the approved
drawings. In crossings for which an individual drawing has not been prepared, the
minimum cover of the pipeline shall not be less than that indicated in the standard
drawings for a similar type of crossing.
6.8 Whenever the crossing requries a straight section of pipe between the lower bends
coinciding with the river bed, this section shall be laid at a single horizontal level.
6.9 For crossings of ditches, canals, banked channels, etc. by boring, the pipe section shall
be prepared, laid and tested in accordance with the applicable clauses of Section 3.0 of
this specification.
6.10 The CONTRACTOR shall arrange temporary installation of diversions as may be

necessary, to ensure the effective functioning of these water courses crossed, to the
entire satisfaction of the concerned Local Authorities as well as the COMPANY.
6.11 Banks and trenches of minor water crossings shall be backfilled with soil which is to be
approved by COMPANY and shall be thoroughly compacted to prevent soil and bank
erosion as per the drawings and standards to the satisfaction of authorities having
jurisdiction thereof and the COMPANY. Whenever boulders, rock, gravel and other hard
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OTHER CROSSINGS
objects are encountered, they shall not be placed directly on the pipe. Sufficient earth,
sand or selected and approved backfill material shall be backfilled initially around and
over the pipe to provide a protective padding or cushion extending to a minimum
thickness of 30 centimetres around the pipe before backfilling remainder of the trench
with excavated or other material as per approved drawings and standards.
After the trench has been backfilled and during the clean up works, the minor water
crossing shall be cleaned at least across the whole of the ROW.
When directed by the COMPANY, CONTRACTOR shall stabilize and restore the bank
of the water crossings with materials to be supplied by him as follows.
The excavation shall be trimmed in steps-and-berms backfilled with well compacted

solid soil, followed by a minimum 0.25m thick layer of properly shaped boulders (75-
150mm) encased in a net of galvanised iron wire of dia 3mm spaced at a maximum
distance of 50mm to be laid over the backfilled, compacted and graded banks.
The GI wire shall be made from steel having tensile strength of 400 N/mm2 and with a
minimum elongation at failure of 10%. The minimum zinc coating of 200 gm-2 shall be
applied on single/ double twisted wire.
The length of the above protection shall be equal to the actual bank excavation edge
including damage and extending 2m on either sides. The width of this protection on
the slope shall be determined by the following :
• 2m plus the highest water level (recoverable) or upto the top of bank
whichever is higher.
• Up to the bottom of the crossing or 20m below the highest water level
whichever is smaller.
Bank stabilization for certain minor water crossings shall be determined by COMPANY
based on nature of crossing e.g. type of river, canal, major Nala, flood control banks
and other water bodies; type of soil, regulations of local authorities; and any other
socio-economic consideration evaluated by the COMPANY.
6.12 The crossing of any embankments shall be carried out strictly in accordance with
approved drawings.
No drilling work on embankments shall be permitted without prior written approval

from the competent authorities.
148 of 911
MECON LIMITED STANDARD TECHNICAL SPECIFICATION OF PIPING
DELHI FABRICATION AND ERECTION
REV 0, EDITION - 1
FOR
PIPING FABRICATION AND ERECTION

MEC/S/05/28/06
MECON LIMITED
DELHI 110 092

149 of 911
REV 0, EDITION - 1
CONTENTS
SL.NO. DESCRIPTION
1.0 GENERAL
2.0 SCOPE
3.0 BASIS FOR WORK
4.0 FABRICATION
5.0 ERECTION
6.0 WELDING
7.0 ERECTION
8.0 INSPECTION
9.0 PROTECTIVE COATING
10.0 FLUSHING
11.0 HYDROSTATIC TESTING
ANNEXURE-1 - WELDING SPECIFICATION
EXHIBIT-A - ELECTRODE QUALIFICATIONS TEST RECORD

EXHIBIT-B - STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION
EXHIBIT-C - STANDARD PROCEDURE SPECIFICATION NO.
EXHIBIT-D - COUPON TEST RECORD
EXHIBIT-E - WELDER's IDENTIFICATION CARD
EXHIBIT-F - RADIOGRAPHIC PROCEDURE FOR PIPE WELDING
EXHIBIT-G - WELDING SPECIFICATION CHART
ANNEXURE-2 - DESTRUCTIVE TESTING OF WELDED JOINT - BUTT WELDS
ANNEXURE-3 - ULTRASONIC INSPECTION
ANNEXURE-4 - RADIOGRAPHY
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AMENDMENT STATUS

151 of 911
1.0 GENERAL
This specification covers general requirements of fabrication and erection of aboveground and
trench piping systems at site. The specification covers the scope of work of contractor, basis of
work to be carried out by contractor and standards, specifications and normal practice to be
followed during fabrication and erection by the contractor.
2.0 SCOPE
Generally the scope of work of contractor shall include the following:
2.1 Transportation of required piping materials, pipe support and all other necessary piping
materials from Owner's storage point or contractor's storage point (in case of contractor's
scope of supply) to work site / shop including raising store requisitions for issue of materials in
the prescribed format & maintaining an account of the materials received from Owner's stores.
2.1.1 Piping materials include the following but not limited to the same.
a. Pipes (All sizes and schedule)
b. Flanges (All sizes, types & Pressure ratings).
c. Fittings (All sizes, types and schedule)
d. Valves (All sizes, types and Ratings)
e. Gaskets (All sizes, types & Ratings)
f. Bolts, Nuts or M/C Bolts (All types)
g. Expansion Joint / Bellows (All types)
h. Specialty items like online filters, ejectors, sample coolers, steam traps, strainers, air
traps etc.
i. Online instruments like control valve, orifice flange, rotameter, safety valves etc.
2.2 Shop & field fabrication and erection of piping in accordance with documents listed under Cl.
3.0 i.e. 'BASIS OF WORK' including erection of all piping materials enumerated above.
2.3 Fabrication and erection of pipe supports like shoe, saddle, guide, stops, anchors, clips,
cradles, hangers, turn buckles, supporting fixtures, bracket cantilevers, struts, teeposts
including erection of spring supports and sway braces.
2.4 Fabrication
2.4.1 Fabrication of piping specials like special radius bends, reducers, mitres etc.
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2.4.2 Fabrication of plain and threaded nipples from pipes as required during erection.
2.4.3 Fabrication of swage nipples as and when required.
2.4.4 Fabrication of odd angle elbow like 60°, 30° or any other angle from 90/45° elbows as and
when required.
2.4.5 Fabrication of flange, reducing flange, blind flange, spectacle blinds as and when required.
2.4.6 Fabrication of stub-in connection with or without reinforcement.
2.4.7 Grinding of edges of pipes, fittings, flanges etc. to match mating edges of uneven / different
thickness wherever required.
2.5 Modifications like providing additional cleats, extension of stem of valve, locking arrangement
of valves etc. as and when required.
2.6 Preparation of Isometrics, bill of materials, supporting details of all NON-IBR lines upto 2-1/2"
within the unit battery limit and get subsequent approval from Engineer-in-Charge as and
when called for.
2.7 Obtaining approval for drawings prepared by contractor from statutory authority, if required.
2.8 Spun concrete lining of the inside of pipes 3" NB & above including fittings and flanges as
required in accordance with specification.
2.9 Rubber lining inside pipes, fittings, flanges as and when required, in accordance with
specification.
2.10 Radiography, stress relieving, dye penetration, magnetic particle test etc. as required in
specification.
2.11 Performing PMI using alloy analysers as per 'Standard Specification for Positive Material
Identification at Construction Sites, 6-82-0002'.
2.12 Casting of concrete pedestals and fabrication & erection of small structures for pipe supports
including supply of necessary materials.
2.13 Providing insert plates from concrete structures and repair of platform gratings around pipe
openings.
2.14 Making material reconciliation statement and return of Owner's supply left over materials to
Owner's storage.
2.15 Flushing and testing of all piping systems as per standard specification for inspection, flushing
and testing of piping systems (Specification No. MEC/S/05/21/11).
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3.0 BASIS FOR WORK
3.1 The complete piping work shall be carried out in accordance with the following
3.1.1 "Approved for Construction" drawings and sketches issued by MECON to the Contractor - Plans
and/or Isometrics.
3.1.2 "Approved for Construction" drawings and sketches issued by Turn-key bidders to the
Contractor - Plans and/or Isometrics.
3.1.3 Approved Process licensor's standards and specifications.
3.1.4 Drawings, sketches and documents prepared by contractor duly approved by Engineer-in-
Charge' (such as isometrics and offsite piping etc.)
3.1.5 Approved construction job procedures prepared by Contractor as stipulated in 2.16
3.1.6 MECON specifications/documents as below:
a. Process and Instrument Diagram.
b. Piping Materials Specification
c. Piping support standards.
d. Line list / Number
e. Piping support index.
f. Standard specification of NDT Requirement of Piping
g. Welding specification charts for piping classes.
h. Standard specification for Pressure Testing of Erected Piping System.
i. Welding specification for fabrication of piping
j. Any other MECON or OTHER specifications attached with Piping Material Specification
or special condition of contract.
k. Procedure for storage, preservation and positive identification of materials Contractors

works / stores.
3.1.7 Following codes, standards and regulations
a. ASME B 31.3 : Process Piping

b. ASME Sec. VIII : Code for unfired pressure vessel.
c. IBR Regulations
d. IS:823 : Code for procedure for Manual Metal Are Welding
154 of 911
of Mild Steel (for structural steel).

e. NACE Std. : Code for Sour Services material requirements
MR.
Note : All codes referred shall be latest edition.
3.2 Deviations
Where a deviation from the "Basis of Work" and approved job procedure described above is
required or where the basis of work does not cover a particular situation, the matter shall be
brought to the notice of Engineer - in - Charge and the work carried out only after obtaining
written approval from him in each case.
4.0 FABRICATION
4.1 Piping Material
Pipe, pipe fittings, flanges, valves, gaskets, studs bolts etc. used in a given piping system shall
be strictly as per the "Piping Material Specification" for the "Pipe Class" specified for that
system. To ensure the above requirement, all piping material supplied by the Owner /
Contractor shall have proper identification marks as per relevant standards / MECON’s
specifications / Licensors specification. Contractor shall provide identification marks on left over
pipe lengths wherever marked up pipe lengths have been fabricated / erected. Material
traceability is to be maintained for AS., S.S., NACE, LTCS, material for Hydrogen service and
other exotic materials by way of transferring heat number, etc. (hard punching) as per
approved procedure. This shall be in addition to colour coding for all piping materials to avoid
mix-up.
4.2 Fabrication
4.2.1 All fabrication shall be carried out in accordance with piping general arrangement drawings,
(prepared by CONTRACTOR and approved by COMPANY) including this specification and codes
as specified in section 2.0.
4.2.2 CONTRACTOR shall be responsible for working to the exact dimensions as per the approved
drawings. Dimensional tolerances to be adopted during implementation of fabrication work
shall be as per attached sketch "TOLERANCES FOR FABRICATION".
4.2.3 Flange bolt holes shall generally straddle the established centre lines unless other orientation is
required and as called out in approved drawings.
4.2.4 Threading shall be NPT to ANSI B 1.20.1. Threading shall preferably be done after bending,
forging or heat treatment operation. However if it is not possible, precaution shall be taken to
protect threading against deformation. Thread shall be clean cut with no burrs or stripping.
Dies shall be new, sharp and properly designed for piping material. Ends shall be reamed to
remove burrs.
4.2.5 All threaded joints shall be aligned properly. The pipe entering unions shall be true to
centrelines so as to avoid forcing of union coupling during make up. Damaged threads shall be
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cut from the end of run and the pipe shall be rethreaded.
4.2.6 Immediately before testing the piping, all threads of pipe and fittings shall be thoroughly
cleared of cuttings, fuel oil or other foreign matter. The male threads shall be sealed with
thread sealant and the piping made up sufficiently for the thread to seize. Sealant shall be
teflon tape.
4.2.7 Seal welding of threaded connections when specified shall include the first block valve, cover
all threads. The joint shall be cleaned of all cutting oil and other foreign material and made up
dry to full thread engagement. Instrument threaded connections which are frequently
subjected to testing and maintenance shall not be seal welded.
4.2.8 All threaded connections shall be protected from rusting by applying greases or oil when in
operating condition.
4.2.9 When socket weld fittings or valves are used, pipe shall be spaced approximately 1/16" to
avoid bottoming which could result in excessive weld stress.
4.2.10 Where the ends of the piping components being welded have an internal surface misalignment
exceeding 1.6mm, the wall of the component extending internally shall be trimmed by
machining so that the adjoining internal surface will approximately flush.
For the purpose of common understanding the construction job procedure, to be submitted by
the contractor, shall include proposal for
- Maximizing prefabrication, inspection and testing at fabrication shop with minimum

field joints.
- Positive material identification, handling, storage & preservation.
4.3 Dimensional Tolerances
Dimensional tolerances for piping fabrication shall be as per MECON Standard Specification.
The Contractor shall be responsible for working to the dimensions shown on the drawings.
However, the Contractor shall bear in mind that there may be variations between the
dimensions shown in the drawing and those actually existing at site due to minor variations in
the location of equipments, inserts, structures etc. To take care of these variations "Field
Welds" shall be provided during piping fabrication. An extra pipe length of 100 mm over and
above the dimensions indicated in the drawing may be left on one side of the pipe at each of
the field welds. During erection, the pipe end with extra length at each field weld, shall be cut
to obtain the actual dimension occurring at site. Isometrics, if supplied may have the field
welds marked on them. However, it is the responsibility of the Contractor to provide adequate
number of field welds. In any case no extra claims will be entertained from the Contractor on
this account. Wherever errors / omissions occur in drawings and Bills of Materials it shall be
the Contractor's responsibility to notify the Engineer-in-Charge prior to fabrication or erection.
4.4 IBR Piping
4.4.1 Contractor shall be supplied generally with all drawings for steam piping falling under the
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purview of Indian Boiler Regulations duly approved by Boiler Inspectorate. The Contractor
shall carry out the fabrications, erection and testing of this piping as per requirements of
Indian Boiler Regulations and to the entire satisfaction of the local Boiler Inspector. The
Contractor shall also get the approval of IBR inspector for all fabrication and testing done by
him at his own cost. All certificates of approval shall be in proper IBR forms. . .
4.4.2 Approval of boiler inspector on the drawings prepared by the contractor shall be obtained by
the contractor at his own cost.
4.5 Pipe Joints
The piping class of each line specifies the type of pipe joints to be adopted. In general, joining
of lines 2" and above in process and utility piping shall be accomplished by butt welds. Joining
of lines 1-1/2" and below shall be by socket welding / butt welding / threaded joints as
specified in "Piping Material Specifications". However, in piping 1-1/2" and below where socket
welding/ threaded joints are specified butt - welds may be used with the approval of Engineer-
in-Charge for pipe to pipe joining in long runs of piping. This is only applicable for non-
galvanized piping without lining.
Flange joints shall be used at connections to Vessels, Equipment's, Valves and where required
for ease of erection and maintenance as indicated in drawings.
4.6 Butt Welded and Socket Welded Piping
End preparation, alignment and fit-up of pipe pieces to be welded, welding, pre-heat, post-
heating and heat treatment shall be as described in the welding specification and NDT
specification.
4.7 Screwed Piping
In general, Galvanized piping shall have threads as per IS:554 or ANSI B 2.1 NPT as required
to match threads on fittings, valves etc. All other piping shall have threads as per ANSI B 2.1,
tapered unless specified otherwise.
Threads shall be clean cut, without any burrs or stripping and the ends shall be reamed.
Threading of pipes shall be done preferably after bending, forging or heat treating operations.
If this is not possible, threads shall be gauge checked and chased after welding heat treatment
etc.
During assembly of threaded joints, all threads of pipes and fittings shall be thoroughly
cleaned of cuttings, dirt, oil or any other foreign matter. The male threads shall be coated with
thread sealant and the joint tightened sufficiently for the threads to seize and give a leakproof
joint.
Threaded joints to be seal-welded shall be cleaned of all foreign matter, including sealant and
made up to full thread engagement before seal welding.
4.8 Flange Connections
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All flange facings shall be true and perpendicular to the axis of pipe to which they are
attached. Flanged bolt holes shall straddle the normal centerlines unless different orientation is
shown in the drawing.
Wherever a spectacle blind is to be provided, drilling and tapping for the jack screws in the
flange, shall be done before welding it to the pipe.
4.9 Branch Connections
Branch connections shall be as indicated in the piping material specifications. For end
preparation, alignment, spacing, fit-up and welding of branch connections refer welding
specifications. Templates shall be used wherever required to ensure accurate cutting and
proper fit-up.
For all branch connections accomplished either by pipe to pipe connections or by using forged
tees the rates quoted for piping shall be inclusive of this work.
Reinforcement pads shall be provided wherever indicated in drawings/ specifications etc.
4.10 Bending
Bending shall be as per ASME B31.3 except that corrugated or creased bends shall not be
used.
Cold bends for lines 1-1/2" and below, with a bend radius of 5 times the nominal diameter
shall be used as required in place of elbows wherever allowed by piping specifications.
Bending of pipes 2" and above may be required in some cases like that for headers around
heaters, reactors etc.
The completed bend shall have a smooth surface, free from cracks, buckles, wrinkles, bulges,
flat spots and other serious defects. They shall be true to dimensions. The flattening of a
bend, as measured by the difference between the maximum and minimum diameters at any
cross-section, shall not exceed 8% and 3% of the nominal outside diameter, for internal and
external pressure respectively.
4.11 Forging and forming
Forging and forming of small bore fittings, like reducing nipples for piping 1-1/2" and below,
shall be as per ASME B 31.3.
4.12 Mitre Bends and Fabricated Reducers
The specific application of welded mitre bends and fabrication reducers shall be governed by
the Piping Material Specifications. Generally all 90 deg. mitres shall be 4-piece 3-weld type and
45 deg. mitres shall be 3-piece 2-weld type as per MECON Standard unless otherwise
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specified. Reducers shall be fabricated as per directions of Engineer-in-Charge. The

radiographic requirements shall be as per Material Specifications for process and utility
systems and NDT Specification for steam piping under IBR, radiographic requirements of IBR
shall be complied with.
4.13 Cutting and Trimming of Standard Fittings & Pipes
Components like pipes, elbows, couplings, half-couplings etc. shall be cut / trimmed / edge
prepared wherever required to meet fabrication and erection requirements, as per drawings
and instructions of Engineer-in-Charge. Nipples as required shall be prepared from straight
length piping.
4.14 Galvanised Piping
Galvanised carbon steel piping shall be completely cold worked, so as not to damage
galvanised surfaces. This piping involves only threaded joints and additional external threading
on pipes may be required to be done as per requirement.
4.15 Jacketed Piping
The Jacketing shall be done in accordance with MECON Specification or Licensors specification
as suggested in material specification or special condition of contract.
Pre-assembly of jacketed elements to the maximum extent possible shall be accomplished at

shop by Contractor. Position of jumpover and nozzles on the jacket pipes, fittings etc. shall be
marked according to pipe disposition and those shall be prefabricated to avoid damaging of
inner pipe and obstruction of jacket space. However, valves, flow glasses, in line instruments
or even fittings shall be supplied as jacketed.
4.16 Shop Fabrication / Prefabrication
The purpose of shop fabrication or pre-fabrication is to minimise work during erection to the
extent possible. Piping spool, after fabrication, shall be stacked with proper identification
marks, so as facilitate their withdrawal at any time during erection. During this period all
flange (gasket contact faces) and threads shall be adequately fabricated by coating with a
removable rust preventive. Care shall also be taken to avoid any physical damage to flange
faces and threads.
4.17 Miscellaneous
4.17.1 Contractor shall fabricate miscellaneous elements like flash pot, seal pot, sample cooler,
supporting elements like turn buckles, extension of spindles and interlocking arrangement of
valves, operating platforms as required by Engineer-in-Charge.
4.17.2 Spun Concrete Lining
The work of inside spun concrete lining of pipes and specials of diameter 3" and above shall
be done as per material specifications and special condition contract.
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4.17.3 Fabrication of pipes from plate
Pipes shall be fabricated at site as and when required as per the specifications attached and
the actual Piping Material Specification.
5.0 ERECTION
5.1 Cleaning of Piping before Erection
Before erection all pre-fabricated spool pieces, pipes, fittings etc. shall be cleaned inside and
outside by suitable means. The cleaning process shall include removal of all foreign matter
such as scale, sand, weld spatter chips etc. by wire brushes, cleaning tools etc. and blowing
with compressed air/or flushing out with water. Special cleaning requirements for some
services, if any shall be as specified in the piping material specification or isometric or line list.
S.S jacketed piping requiring pickling shall be pickled to remove oxidation and discolouring due
to welding.
5.2 Piping Routing
No deviations from the piping route indicated in drawings shall be permitted without the
consent of Engineer- in-Charge.
Pipe to pipe, pipe to structure / equipments distances / clearances as shown in the drawings
shall be strictly followed as these clearances may be required for the free expansion of piping /
equipment. No deviations from these clearances shall be permissible without the approval of
Engineer-in-Charge.
In case of fouling of a line with other piping, structure, equipment etc. the matter shall be
brought to the notice of Engineer-in-Charge and corrective action shall be taken as per his
instructions.
5.3 Cold Pull
Wherever cold pull is specified, the Contractor shall maintain the necessary gap, as indicated
in the drawing. Confirmation in writing shall be obtained by the Contractor from the Engineer-
in-Charge, certifying that the gap between the pipes is as indicated in the drawing, before
drawing the cold pull. Stress relieving shall be performed before removing the gadgets for cold
pulling.
5.4 Slopes
Slopes specified for various lines in the drawings / P&ID shall be maintained by the Contractor.
Corrective action shall be taken by the Contractor in consultation with Engineer-in-Charge
wherever the Contractor is not able to maintain the specified slope.
5.5 Expansion Joints / Bellows
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Installation of Expansion Joints/Bellows shall be as follows:
 All Expansion joints / Bellows shall be installed in accordance with the specification and
installation drawings, supplied to the Contractor.
 Upon receipt, the Contractor shall remove the Expansion Joints/ Bellows from the
case(s) and check for any damage occurred during transit.
 The Contractor shall bring to the notice of the Engineer-in-Charge any damage done to
the bellows / corrugations, hinges, tie-rods, flanges / weld ends etc.
 Each Expansion Joint / Bellow shall be blown free of dust / foreign matter with
compressed air or cleaned with a piece of cloth.
 For handling and installation of Expansion Joints, great care shall be taken while
aligning. An Expansion Joints shall never be slinged from bellows corrugations /
external shrouds, tie / rods, angles.
 An Expansion Joints / Bellow shall preferably be slinged from the end pipes / flanges or
on the middle pipe.
 All Expansion Joints shall be delivered to the Contractor at "Installation length",

maintained by means of shipping rods, angles welded to the flanges or weld ends or
by wooden or metallic stops.
 Expansion Joints stop blocks shall be carefully removed after hydrostatic testing.
Angles welded to the flanges or weld ends shall be trimmed by saw as per
manufacturer's instructions and the flanges or weld ends shall be ground smooth.
 The pipe ends in which the Expansion Joint is to be installed shall be perfectly aligned
or shall have specified lateral deflection as noted on the relevant drawings.
 The pipe ends / flanges shall be spaced at a distance specified in the drawings.
 The Expansion Joint shall be placed between the mating pipe ends / flanges and shall
be tack welded/bolted. The mating pipes shall again be checked for correct alignment.
 Butt-welding shall be carried out at each end of the expansion joint. For flanged
Expansion Joint, the mating flanges shall be bolted.
 After the Expansion Joint is installed the Contractor shall ensure that the mating pipes
and Expansion Joints are in correct alignment and that the pipes are well supported
and guided.
 The Expansion Joint shall not have any lateral deflection. The Contractor shall maintain
parallelism of restraining rings or bellows convolutions.
 Precautions
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• For carrying out welding, earthing lead shall not be attached with the Expansion
Joint.
• The Expansion bellow shall be protected from arc weld spot and welding spatter.
• Hydrostatic Testing of the system having Expansion Joint shall be performed with
shipping lugs in position. These lugs shall be removed after testing and certification
is over.
5.6 Flange Connections
While fitting up mating flanges, care shall be exercised to properly align the pipes and to check
the flanges for trueness, so that faces of the flanges can be pulled together, without inducing
any stresses in the pipes and the equipment nozzles. Extra care shall be taken for flange
connections to pumps, turbines, compressors, cold boxes, air coolers etc. The flange
connections to these equipments shall be checked for misalignment, excessive gap etc. after
the final alignment of the equipment is over. The joint shall be made up after obtaining
approval of Engineer-in-Charge.
Temporary protective covers shall be retained on all flange connections of pumps, turbines,
compressors and other similar equipments, until the piping is finally connected, so as to avoid
any foreign material from entering these equipments.
The assembly of a flange joint shall be done in such a way that the gasket between these
flange faces is uniformly compressed. To achieve this the bolts shall be tightened in a proper
sequence. All bolts shall extend completely through their nuts but not more than 1/4".
Steel to C.I. flange joints shall be made up with extreme care, tightening the bolts uniformly
after bringing flange flush with gaskets with accurate pattern and lateral alignment.
5.7 Vents and Drains
High point vents and low point drains shall be provided as per the instructions of Engineer-in-
Charge, even if these are not shown in the drawings. The details of vents and drains shall be
as per piping material specifications / job standards.
5.8 Valves
Valves shall be installed with spindle / actuator orientation / position as shown in the layout
drawings. In case of any difficulty in doing this or if the spindle orientation / position is not
shown in the drawings, the Engineer-in-Charge shall be consulted and work done as per his
instructions. Care shall be exercised to ensure that globe valves, check valves, and other uni-
directional valves are installed with the "Flow direction arrow "on the valve body pointing in
the correct direction. If the direction of the arrow is not marked on such valves, this shall be
done in the presence of Engineer-in-Charge before installation.
Fabrication of stem extensions, locking arrangements and interlocking arrangements of valves
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(if called for), shall be carried out as per drawings / instructions of Engineer-in-Charge.
5.9 Instruments
Installation of in-line instruments such as restriction orifices, control valves, safety valves, relief
valves, rotameters, orifice flange assembly, venturimeters, flowmeters etc. shall form a part of
piping erection work.
Fabrication and erection of piping upto first block valve / nozzle / flange for installation of
offline Instruments for measurement of level, pressure, temperature, flow etc. shall also form
part of piping construction work. The limits of piping and instrumentation work will be shown
in drawings / standards / specifications. Orientations / locations of take-offs for temperature,
pressure, flow, level connections etc. shown in drawings shall be maintained.
Flushing and testing of piping systems which include instruments mentioned above and the
precautions to be taken are covered in flushing, testing and inspection of piping. Care shall be
exercised and adequate precautions taken to avoid damage and entry foreign matter into
instruments during transportation, installation, testing etc.
5.10 Line Mounted Eqipments / Items
Installation of line mounted items like filters, strainers, steam traps, air traps, desuperheaters,
ejectors, samples coolers, mixers, flame arrestors, sight glasses etc. including their supporting
arrangements shall form part of piping erection work.
5.11 Bolts and Nuts
The Contractor shall apply molycoat grease mixed with graphite powder (unless otherwise
specified in piping classes) all bolts and nuts during storage, after erection and wherever
flange connections are broken and made-up for any purpose whatsoever. The grease and
graphite powder shall be supplied by the Contractor within the rates for piping work.
5.12 Pipe Supports
Pipe supports are designed and located to effectively sustain the weight and thermal effects of
the piping system and to prevent its vibrations. Location and design pipe supports will be
shown in drawing for lines 2” NB. However, any extra supports desired by Engineer-in-Charge
shall also be installed.
No pipe shoe / cradle shall be offset unless specifically shown in the drawings.
Hanger rods shall be installed inclined in a direction opposite to the direction in which the pipe
move during expansion.
Preset pins of all spring supports shall be removed only after hydrostatic testing and insulation
is over. Springs shall be checked for the range of movement and adjusted if necessary to
obtain the correct positioning in cold condition. These shall be subsequently adjusted to hot
setting in operating condition. The following points shall be checked after installation, with the
Engineer-in-Charge and necessary confirmation in writing obtained certifying that :
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- All restraints have been installed correctly.
- Clearances have been maintained as per support drawings.
- Insulation does not restrict thermal expansion.
- All temporary tack welds provided during erection have been fully removed.
- All welded supports have been fully welded.
6.0 WELDING
Welding of pipelines shall be done as per applicable codes and Annexure-1
7.0 ERECTION
7.1 Pre-fabrication and Field Assembly
Extent of pre-fabrication shall be purely at the discretion of CONTRACTOR keeping in

view the following :-
7.1.1 Field joint shall be decided by CONTRACTOR keeping in view the transportation of pre-
fabricated pieces to site.
7.1.2 There can be some variations in the dimensions and level appearing in the
arrangement drawings and those actually occurring at site due to minor variations in
the location of equipments, structures, cut out etc. Adequate field joints shall be
provided, permitting assembly and erection of pipe work without major modification.
7.2 Supporting
Location and design of pipe supports shown in approved drawings and support
drawings shall be strictly followed.
7.2.1 Supports shall be installed in such a way that they do not contribute to over stressing
of a line.
7.2.2 Fabrication and erection of additional supporting elements and structural fixtures which
in COMPANY's view are required for proper supporting of the system, shall be carried
out by CONTRACTOR at no extra cost.
7.2.3 All temporary supports, elements required for alignment, erection and assembly shall
be removed after completion of work.
7.3 Equipment hook-up
7.3.1 Prior to hook-up, the alignment and trueness of flange faces shall be checked to
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ensure that no undue stresses shall be induced in the system while hooking up.
8.0 INSPECTION
8.1
8.2 CONTRACTOR shall provide all facilities/ assistance to COMPANY for proper execution
of their inspection without any extra charge.
8.3 All piping work shall be subjected to inspection by COMPANY at any time during
fabrication. CONTRACTOR shall furnish to COMPANY detailed work programme
sufficiently in advance, in order to enable COMPANY to arrange for inspection.
9.0 PROTECTIVE COATING
9.1 All above ground piping system shall be applied with protective coating in accordance
with specification for shop & field painting.
9.2 All under ground portion of piping system shall be coated with three layer P.E. coating.
CONTRACTOR shall prepared procedure for epoxy painting of burried pipeline for
approval of COMPANY. Procedure shall include surface preparation, brand and type of
coating to be adopted. Coating of pipes shall not commence without approval of
coating procedure. Total dry film thickness to be achieved shall not be less than 300
microns. Compatible primer and finish coat as recommended by coating manufacturer
shall only be applied. Coating integrity shall be checked by "Holiday detector" over full
length of coated pipe work. Coating to be supplied by CONTRACTOR shall be suitable
for design temperature.
9.3 Once the coating has been accepted by COMPANY, backfiling operation can be started.
In order to protect coated pipe from damage, the excavated trench shall be examined
for stone, rock and any other hard substance detrimental to coating. All such
substances shall be removed before lowering the pipe in the trench. COMPANY may
ask for a 100mm padding of clear sand under and above pipeline in rocky or otherwise
hard soil area. No additional payment on account of padding shall however be
admissible.
10.0 FLUSHING
Completed piping systems shall be flushed by CONTRACTOR with fresh water, to clean
the pipe of all dirt, debris, and foreign material. CONTRACTOR shall prepare a
procedure for flushing of the system for approval of COMPANY. Flushing shall not be
commenced without approval of flushing procedure.
10.1 CONTRACTOR shall perform all activities like dismantling and reinstalling of all
strainers, in line instruments etc. before and after completion of flushing.
10.2 Flushing shall be considered as complete only after inspection and approval by
COMPANY.
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10.3 Disposal of muck and flushing media shall be arranged by CONTRACTOR as directed
by COMPANY, in such a manner that it does not spoil the adjacent installation.
CONTRACTOR shall obtain COMPANY approval regarding the place and method to be
adopted for disposal of debris.
10.4 Record of flushing giving following details shall be submitted by CONTRACTOR to

COMPANY for its approval and records :
a) Date of flushing
b) Identification of line : flushed-line number
11.0 HYDROSTATIC TESTING
11.1 Completed piping system as approved by COMPANY shall be hydrostatically tested in

the presence of COMPANY. The general requirements of hydrostatic testing shall be in
accordance with codes specified in section 2.0.
11.2 CONTRACTOR shall prepare hydrostatic test procedure based on specified codes. The
hydrostatic test shall commence only after approval of procedure by COMPANY.
11.3 Piping system shall be hydrostatically tested to a pressure corresponding to 1.4 times
the design pressure.
11.4 Fresh water shall be used as test media. CONTRACTOR shall locate the source of water
supply and arrange for transportation of water to test site. CONTRACTOR shall arrange
at his own cost the water analysis and confirm that water is suitable for testing. In
case any corrosion inhibitor is to added, the same shall be done after approval of
COMPANY.
11.5 Lines repaired subsequent to hydrostatic test shall be retested using the same
procedure as originally adopted. However COMPANY may waive such retest in case of
minor repairs by taking precautionary measures to ensure sound construction.
11.6 All equipment and instruments used for hydrostatic test shall be approved by
COMPANY before start of tests.
11.7 Pressure gauges shall be installed on line to measure test pressures. In case of longer
lines two or more pressure gauges shall be installed as directed by COMPANY. One
gauge shall be installed at the discharge of the pressurising pump. Pressure gauge
used for hydrostatic testing shall be calibrated with dead weight tester in the presence
of Engineer-in-charge. Range of pressure gauge shall generally be 1.5 times the test
pressure.
11.8 Orifice plates and restriction orifices shall not be installed until hydrostatic testing is
completed. Temporary gaskets shall be used during testing.
11.9 First block valve of pressure instruments shall be half open & plugged at the time of
hydrostatic testing. Temperature connections shall be blanked off during testing.
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11.10 All equipments, in line instruments, relief valves shall be disconnected from piping
system by means of blinds during testing. Control valves shall be replaced by spool
pieces during testing.
11.11 High point vents and low point drain required for testing in addition to those marked in
the drawings shall be provided by CONTRACTOR at his own cost.
11.12 All welded and screwed joints shall be kept clean for detecting leaks during testing.
11.13 Test pressure shall be maintained long enough to facilitate complete inspection of the
system. Minimum duration of test shall be 6 hours unless otherwise specified.
Pressurising equipment shall be isolated immediately after test pressure is attained.
11.14 After successful completion of hydrostatic testing, the piping system shall be
dewatered. All lines shall be completely dried using compressed air. CONTRACTOR
shall make his own arrangement for supply of compressed air. Drying of lines shall be
considered complete on approval by COMPANY.
11.15 Test Records
The records in duplicate shall be prepared and submitted by CONTRACTOR as below :
a) Date of test
b) Identification of pipe tested - line number
c) Test pressure
d) Test results
e) Signature of CONTRACTOR
f) Approval signature by COMPANY.
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ANNEXURE-1
WELDING SPECIFICATION
1.0 GENERAL
This specification shall be followed for the fabrication of all types of welded joints of
carbon steel above ground natural gas, liquid, and slurries service piping systems.
The welded pipe joints shall include the following :
a) All line pipe joints of the longitudinal and circumferential butt welded.
b) Attachments of castings, forgings, flanges.
c) Welded manifold headers and other sub-assemblies
d) Welded branch connections with or without reinforcing pads.
e) Joints in welded/ fabrication piping components.
f) The attachments of smaller connections for vents drain drips and other
instrument tappings.
Any approval granted by the Engineer-in-charge or owner's inspectors shall not relieve
the contractor of his responsibilities & guarantees.
1.1 Applicable Codes & Standards
All welding work, equipments for welding, heat treatment, other auxiliary functions and
the welding personnel shall be as per the requirements of the latest editions of the
following approved standards and procedures :-
i) Code for gas transmission and distribution piping systems. ANSI B31.8.
ii) Code for petroleum refinery piping, ANSI B31.3.
iii) Code for Pipeline transportation system for liquid & Slurries ANSI B31.4.
In addition, the following codes/ specifications referred to in the relevant code of

fabrication shall be followed for the welding/ brazing qualifications, consumable
qualifications and non destructive test procedures.
i) Standard for welding of pipelines and related facilities API-1104.

ii) Material Specifications - Welding rods, electrodes and filler materials -
ASME Sec. - IIC.
iii) Code for non destructive examination ASME Sec-V.
iv) Qualification standard for welding and brazing procedure and welders,
brazers, welding and brazing operators - ASME Sec-I
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In the event of any difference due to the additional requirements mentioned in this
specification, over and above those obligation as per codes, this specification shall be
binding.
1.2 Base Material
a) In general carbon steel is used in this plant. The details of material

specifications are given in the welding Specification Chart.
b) The contractor shall provide the Manufacturer's test certificates for every heat
of the materials supplied by him.
1.3A Filler Materials
a) The Contractor shall provide all the necessary welding electrodes, filler
materials, etc. required for the execution of the work.
b) The welding electrodes/ filler wires supplied by the Contractor shall conform to
the class specified in the welding specification chart. The materials shall be of
the make approved by the Engineer-in-charge.
c) The electrode shall be suitable for the welding process recommended and base
metal used. Unless otherwise specified physical properties of the welds
produced by a electrode recommended for the welding of a particular base
metal shall not be lower than the minimum valves specified for the base metal
and shall correspond to the physical properties of the class of electrode
adopted. The choice of electrode shall be made after conducting the required
tests on the electrodes as per relevant standards, and shall be the sole
prerogative of the Engineer-in-charge.
d) Tungsten electrodes used shall conform to ASME Sec. II C SFA 5.12

specification. Thoriated Tungsten electrodes shall not be permitted due to
possible radiation hazard. Instead, ceriated Tungsten Electrodes (EWCe-2 or
equivalent) shall be used for GTA Welding.
e) Electrode qualification test records should be submitted as per the Exhibit-A

(attached) in respect of the electrodes tested by the contractor, for obtaining
the approval of the Engineer-in-charge.
f) The Contractor shall submit batch test certificate from the electrode
Manufacturers giving details of physical and chemical tests carried out by them,
for each batch of electrodes to be used.
g) All electrodes shall be purchased in sealed containers and stored properly to

prevent deterioration. The electrodes removed from the containers shall be
kept in holding ovens at temperature recommended by the electrode
Manufacture. Out-of-the oven time of electrodes before they are consumed
shall not exceed the limits recommended by the electrodes manufacturer. The
electrodes shall be handled with care to avoid any damage to flux covering.
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h) All low hydrogen type of electrodes shall be rebaked at 350°C for 1 hour
minimum and stored in ovens kept at 80-100°C before use. Recommendations
of the electrode Manufacturer shall be followed if available.
i) The electrodes, filler wires and flux used shall be free from rust, oil, greases,
earth and other foreign matter which can affect the quality of welding.
1.3B SHIELDING & PURGING GAS
a) Argon gas used in GTA welding for shielding purposes shall be 99.995% pure.
The purity of the gas shall be certified by the manufacturer. The rate of flow for
shielding purposes shall be established through procedure qualification tests.
Normally this rate may be 12-20 CFH.
b) Argon gas with a purity level of 99.995% shall be used for purging.
c) When GTAW process alone or a combination of GTAW and SMAW processes is

recommended for the production of a particular joint, the purging shall be
maintained during the root pass and for the first filling pass to minimize
oxidation on the inner side of the pipe, unless otherwise specified in Welding
Specification Chart.
d) Initial purging shall be maintained for sufficient period of time so that at least
4-5 times the volume between the dams is displaced, in order to completely
remove the entrapped air. In no case should the initial purging period be less
than 10 minutes. High gas pressure should be avoided.
e) After initial purging, the flow of the backing gas should be reduced to a point
where only a slight positive pressure prevails. For systems, which have a small
volume (up to 1/2 cubic foot) to be purged, a gas flow rate of 6-CFH is usually
adequate. Systems of larger volume may require higher flow rates and these
should be established during procedure qualification tests.
f) Gas backing (purging) is not required for socket type of welded joints.
g) Dams, used for conserving inert gas during purging, shall be removed after
completion of the welding, and shall be accounted for. Wherever, removal of
dams is not possible after welding, use of water-soluble dams should be made.
1.4 Welding Consumables
The Contractor shall provide at this own expense all the welding consumables
necessary for the execution of the job such as electrodes filler wires, oxygen,
acetylene, etc. and these should bear the approval of the COMPANY.
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1.5 Equipment & Accessories
1.5.1 The Contractor should have the arrangement of sufficient number of welding and
cutting equipments, auxiliaries and accessories of sufficient capacities so as to meet
the target schedule.
1.5.2 All the equipment for performing the heat treatment, including transformers,
thermocouples, flow meters, automatic temperature recorders with suitable calibration
arrangement etc. shall be provided by the Contractor, at his own expense and these
should bear the approval of the COMPANY.
1.5.3 Contractor shall make necessary arrangements at his own expense for providing the
radiographic equipment, radiographic films, and all the equipment/ materials required
for carrying out the dye penetrant/ magnetic particle test for satisfactory and timely
completion of the job.
1.5.4 Redoing of any work necessitated by faulty equipments or operation used by the
Contractor, will be done at his own expense.
1.6 Welding Processes
1.6.1 Welding of various materials under this specification shall be carried out using Shielded
Metal Arc Welding (SMAW) Process with the approval of the Engineer-in-charge.
1.6.2 The welding processes to be employed are given in the welding specification chart. Any
deviation desired by the Contractor shall be obtained through the express consent of
the Engineer-in-charge.
1.6.3 Automatic and semi-automatic welding processes shall be employed only with the
express approval of the Engineer-in-charge. The welding procedure adopted and
consumables used shall be specifically approved.
1.6.4 A combination of different welding processes or a could be employed for a particular

joint only after duly qualifying the welding procedure as per the requirements of code
of fabrication to be adopted and obtaining the approval of the Engineer-in-charge.
1.7 End Preparation
1.7.1 End Preparation
The edges to be welded shall be prepared to meet the joint design requirements by
gas cutting, machining or grinding method. After gas cutting, oxides shall be removed
by chipping or grinding.
1.7.2 Cleaning
a) The ends to be welded shall be properly cleaned to remove paint, oil, greases,
rust, oxides, sand, earth and other foreign matter. The ends shall be
completely dry before the welding commences.
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b) On completion of each run, craters, welding irregularities, slag etc., shall be

removed by grinding and chiseling. Wire brushes used for cleaning stainless
steel joints shall have stainless steel wires and the grinding wheels used for
grinding stainless steel shall be of a suitable type. Separate grinding wheels
and wire brushes should be used for carbon steels and stainless steels.
1.8 Alignment and Spacing
a) Prior to alignment, the contractor shall inspect the pipe ends inside and outside
for damage, dents, laminations etc. Pipe for welding shall be set up correctly
spaced. Temporary attachment of any kind shall not be welded. Every effort
shall be made to reduce misalignment by the use of clamp and rotation of
pipes to the best fit. For pipes of same nominal wall thickness, the off set
should not exceed 1.6mm. Any branch connections sleeve shall be at least
150mm from any other weld. The welds for fitting shall be so located that top
of the weld shall not come within 50mm of any other weld. The use of internal
line up clamps is mandatory for diameters 10" and above. However, in case
where it is impossible to use internal line up clamp, external line up clamp may
be used.
b) Tack welds, for maintaining the alignment, of pipe joints shall be made only by
qualified welders using approved WPS. Since the tack welds become part of the
final weldment they shall be executed carefully and shall be free from defects.
Defective tack welds must be removed prior to the actual welding of the joints.
1.9 Weather Conditions
1.9.1 The parts being welded and the welding personnel should be protected from rain and
strong winds. In the absence of such a protection no welding shall be carried out.
1.9.2 During field welding using GTAW process, particular care shall be exercised to prevent
any air current affecting the welding process.
1.10 Welding
1.10.1 Root Pass
a) Root pass shall be made with electrodes/ filler wires recommended in the
welding specification chart. The preferable size of the electrode is 2.5mm
diameter (12 SWG) but in no case greater than 3.25mm (10 SWG).
b) Uphill welding shall be adopted for welding pipes weld fixed with its axis
horizontal. Downward technique of welding shall not be used for welding of
pipes in horizontal position, unless specifically permitted by Engineer-in-charge
for a particular case.
c) The root pass of but joints should be executed properly so as to achieve full
penetration with complete fusion of the root edges. Weld projection inside the
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pipe shall not exceed .4mm wherever not specified by the applicable code.
d) Any deviations desired from the recommended welding technique and

electrodes indicated in the welding specification chart should be adopted only
after obtaining express approval of the Engineer-in-charge.
e) Welding shall be continuous & uninterrupted during a pass.
f) On completion of each run, craters, welding irregularities, slag etc., shall be

removed by grinding and chiselling.
g) While the welding is in progress care should be taken to avoid any kind of
movement of components, to prevent occurrence of weld cracks.
h) Fillet welds shall be made by shielded metal arc/ GTAW welding process
irrespective of the thickness and class of piping.
i) Peening shall not be used unless specified in the welding specification chart.
1.10.2 Joint Completion
a) Joint shall be completed using the class of filler wires/ electrodes,

recommended in the welding specification chart. Size of the electrode shall not
exceed 4 mm in diameter for stainless steels and alloy steels used for low
temperature applications.
b) Two weld beads shall not be started at the same point in different layers.
b) Butt joints shall be completed with a cover layer that would effect good cover
at the joint edge and a gradual notch free surface.
d) Each weld joints should have a workman like finish.
e) Weld identification mark shall be stamped clearly at each joint, just adjacent to
the weld. Metal stamping shall not be used on the thin wall pipe. Suitable paint
shall be used on thin wall pipes for identification.
f) No painting shall be done until the weld joint has been hydrostatically tested.
1.10.3 Dissimilar Welds
Where welds are to be produced between carbon steels and alloy steels, preheat and
post weld heat treatment requirements shall be those specified for corresponding alloy
steels and filler wire / electrodes shall correspond to ER 70 S-G or AWS E-7016/7018
type. For welds between two dissimilar Cr-Mo low alloy steels, preheat and post weld
heat treatments shall be those specified for higher alloy steel and electrodes used shall
correspond to those specified for steel of lower alloy content. For carbon steel or alloy
steel to stainless welds, use of filler wire / electrodes E/ER-309/E-310/E NiCr Fe-3 shall
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be made. The welding procedure, electrodes / filler wires to be used shall be approved
by the Engineer-in-Charge.
1.11 Heat Treatment
1.11.1 Preheating
a) Preheating requirements for the various materials shall be as per the welding
specification chart attached. No welding shall be carried out without preheating
the joint to 10°C (50°F) when the ambient temperature is below 10 degree.
b) Preheating shall be performed using resistance or induction heating methods.

Preheating by gas burners, utilising any acetylene or oxy-propane gas mixtures,
with neutral flame may also be carried out when permitted by the Engineer-in-
charge.
c) Preheating shall extend uniformly to atleast three times the thickness of the
joint, but not less than 50mm, on both sides of the weld.
d) Preheating temperature shall be maintained over the whole length of the joint
during welding. Temperature indicating crayons or other temperature indicating
devices shall be provided by the contractor to check the temperature.
e) Preheating temperature shall be maintained over the whole length of the joint
during welding. Temperature recorders shall be provided by the Contractor to
record the temperature.
1.11.2 Post Heating
In case of alloy steel materials such as Cr-Mo steels, if the post weld heat treatment is
not performed immediately after welding, the weld joint and adjacent portion of pipe,
at least 50 mm on either side of weld, shall be uniformly heated to 300°c. This
temperature shall be maintained for half an hour minimum, and then wrapped with
mineral wool before allowing it to cool to room temperature. If the Post Heating
temperature specified in the Welding Specification Charts exceeds 300°C, the same
shall be followed. Similarly, if the welding specification chart specifies post-heat time,
the same shall be applicable. Post weld heat treatment as specified in the Welding
Specification Chart shall be carried out later on.
1.11.3 Postweld Heat Treatment
a) Post weld heat treatment, wherever required for joints between pipes, pipes an
fittings, pipe body and supports shall be carried out as per the relevant
specifications, applicable standards and the instructions of the Engineer-in-
charge. In this regard procedure qualification to be done before carrying out
PWHT in production welds.
b) The heat treatment of welded joints shall be carried out as per the
requirements laid down in ANSI B31.8 and welding specification chart.
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c) The contractor shall submit for the approval of the Engineer-in-charge, the
details of the post weld heat treatment procedure, as per Exhibit `B'
attached, that the propose to adopt for each of the materials/ assembly/ part
involved, well before carrying out actual heat treatment.
d) Post weld heat treatment shall be done by using an electric resistance or

induction heating equipment as decided by the Engineer-in-charge.
e) While carrying out local post weld heat treatment, technique of application of
heat must ensure uniform temperature attainment at all points of the portion
being heat treated. Care shall be taken to ensure that width of treated band
over which specified post weld heat treatment is carried out, the temperature
attained is atleast as that specified in the relevant applicable standards/ codes.
f) Throughout the cycle of heat treatment, the portion outside the heated band
shall be suitably wrapped under insulation so as to avoid any harmful
temperature gradient at the exposed surface of pipe. For this purpose
temperature at the exposed surface of the pipes should not be allowed to
exceed 400°C.
g) The temperature attained by the portion under heat treatment shall be

recorded by means of thermocouple pyrometers. Adequate number of
thermocouples should be attached to the pipe directly at the equally spaced
location along the periphery of the pipe joint. The minimum number of
thermocouples attached per joint shall be 1 upto 6" dia, 2 upto 10" dia and 3
upto 12" and above. However the Engineer-in-charge can increase the required
minimum number of thermocouples to be attached if found necessary.
h) Automatic temperature recorders which have been duly calibrated should be

employed. The calibration chart of each recorder should be submitted to the
Engineer-in-charge prior to starting the heat treatment operation and his
approval should be obtained.
i) Immediately on completion of the heat treatment, the post weld heat

treatment charts/ records alongwith the hardness test results on the weld joints
(whenever required as per the welding specification chart), shall be submitted
to Engineer-in-charge for his approval.
j) Each joint shall bear an identification number which shall be maintained in the
piping sketch to be prepared by the contractor. The joint identification number
should appear on the corresponding post weld heat treatment charts. The
same identification numbers shall also be followed for identification for
corresponding radiographic films. The chart containing the identification
numbers and piping sketch shall be submitted to the Engineer-in-charge in
suitable folders.
k) The hardness of the heat affected zone as well as of the weld metal, after heat
treatment, shall be measured using suitable hardness tester and shall not
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exceed the maximum hardness specified in the welding specification chart. The
weld joint shall be subjected to re-heat treatment when hardness measured
exceeds the specified limit, at the contractor's own expenses.
l) The contractor shall arrange for the hardness testing and shall maintain the
records of all joints tested. These records shall be checked by the plant
Owner's inspector.
1.12 Cleaning of the Weld Joints
All weld joints shall be free from adherent weld spatter, slag, dirt or foreign matter.
This can be achieved by brushing.
1.13 Inspection & Testing
1.13.1 General
a) The owner's inspector shall have free access to all concerned areas, where the
actual work is being performed. The contractor shall also offer the Owner's
inspector all means and facilities necessary for carrying out inspection.
b) The owner is entitled to depute his own inspector to the shop or field where
pre-fabrication and erection of pipelines are being done with (but not limited
to) the following objectives :-
i. To check the conformance to relevant standards and suitability of

various welding equipments and the welding performance.
ii. To supervise the welding procedure qualification.
iii. To supervise the welder performance qualifications.
c) Contractor shall intimate sufficiently in advance the commencement of

qualification tests welding works and acceptance tests, to enable the plant
owner's inspector to be present to supervise them.
1.13.2 Welding Procedure Qualifications
a) Welding Procedure Qualification shall be carried out in accordance with the

relevant requirements of API 1104/ ASME Sec-IX or other applicable codes and
other job requirements by the contractor at his expense. The contractor shall
submit the welding procedure specifications in format as per Exhibit-C
(attached) immediately after the receipt of the order.
b) COMPANY's inspector will review, check and approve the welding procedure
submitted and shall release the procedure for procedure qualification tests. The
procedure qualification test shall be carried out by the Contractor under field
conditions at this own expense. A complete set of test results in format as per
Exhibit-D (attached) shall be submitted to the COMPANY's inspector for
approval immediately after completing the procedure qualification test and
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atleast 2 weeks before the commencement of actual work. Standard tests as

specified in the code shall be carried out in all cases. In addition to these tests,
other tests like radiography, macro/ micro examination, hardness testers, dye
penetrant examination, Charpy V-notch etc. shall be carried out on specimens.
It shall be the responsibility of the contractor to carry out all the tests required
to the satisfaction of the COMPANY's Inspector. The destructive testing of
welded joints shall be as per Annexure-2 and ASME Sec-IX.
1.13.3 Welder's Qualification
a) Welders shall be qualified in accordance with the API 1104/ ASME IX and other
applicable codes by the contractor at his expense. The butt weld test pieces of
the qualification test shall meet the radiographic tests requirements as
mentioned in this specification. The COMPANY's inspector shall witness the test
and certify the qualification of each welder separately. Only those welders who
have been approved by the COMPANY's inspector shall be employed for
welding. Contractor shall submit the welder qualification test reports in the
standard format and obtain express approval, before commencement of the
work. No welder shall be permitted to work without the possession of the
identify card. It shall be the responsibility of contractor to carry out
Qualification tests of welders.
b) The welders shall always have in their possession the identification card as
shown in Exhibit-E and shall produce it on demand by the COMPANY's
Inspector. It shall be the responsibility, of the Contractor to issue the identify
cards after it has been duly certified by the COMPANY. If a welder is found to
perform a type of welding for which he is not qualified, he shall be debarred
from doing any further work. All welds performed by an unqualified welder
shall be cut and redone by a qualified welder at the expense of the Contractor.
1.13.4 Visual Inspection
Inspection of all welds shall be carried out by COMPANY as per the latest editions of
the applicable codes and specifications. All finished welds shall be visually inspected for
parallel and axial alignment of the work, excessive reinforcement, concavity of welds,
shrinkage, cracks, under cuts, dimensions of the weld, surface porosity and other
surface defects. Under-cutting adjacent to the completed weld shall not exceed the
limits specified in the applicable standard/ code.
1.13.5 Non-destructive Examination
The non destructive examination shall mainly consist of examination using x-ray
radiography as detailed in Annexure-4.
Radiographic examination of one hundred percent (100%) girth welds will be required
by the COMPANY. Welds shall meet the standards of acceptability as set forth in API
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1104 and as per the requirements laid in subsequent paragraphs.
The CONTRACTOR shall make all the arrangements for the radiographic examination of
work covered by this specification at his expense.
The COMPANY will review all the radiographs of welds and inform the CONTRACTOR
regarding unacceptable welds. The decision of the COMPANY shall be final and binding
in this regard.
All requirements mentioned in the specification shall be arranged and executed by the
CONTRACTOR through his own resources. In addition, for pipes with wall thickness
9.5mm and above, ultrasonic inspection is required in the following cases as per
Annexure-3 of this specification.
a) On the first 100 welded joints corresponding to each automatic (GTAW/

GMAW) welding procedure used.
b) When 20mm or more are cut from the pipe end as supplied, the ends shall be
ultrasonically inspected for an additional length of 20mm to ensure no
lamination exist.
c) When welds are repaired.
d) When in the opinion of COMPANY, ultrasonic inspection is required to confirm

or clarify defects indicated by radiography.
e) When automatic procedure is used at least 10cm on each weld shall be

ultrasonically inspected at COMPANY's discretion.
In addition, ultrasonic inspection may be required for certain critical weldings of the
pipeline (i.e. tie-ins, welding of valves, flanges) randomly selected at COMPANY's
discretion. All fillet and groove welds other than that radiographed shall be subjected
to dye pentrant/ MP inspection. The non destructive test system used for inspecting
welds must be approved by the COMPANY.
Weld quality is judged on the basis of the acceptability criteria mentioned below :
Any weld which as a result of radiographic and / or ultrasonic examination in the

opinion of COMPANY exhibits imperfections greater than the limits stated in API-1104
latest edition or as superseded in this article shall be considered defective and shall so
be marked with an identification paint marker.
In addition to the API-1104 requirements, the welds containing cracks including crater
cracks regardless of size of location are unacceptable.
i. Any amount of inadequate penetration of the root bead as defined by API-1104

is unacceptable.
ii. Any amount of incomplete fusion between the root and bevel as defined by
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API-1104 is unacceptable.
iii. Unrepaired burn through areas are unacceptable.
Contractor shall appoint agency for carrying out the radiography works at site from the
list of agency (ies) enclosed in the bid document.
• The Radiographic Examination procedures to be adopted shall be submitted by

the contractor as per Exhibit-F and shall be got approved from the Owner's
Inspector prior to employment. A person qualified to ASNT Level-II or ASNT
Level-III in Radiographic testing shall prepare the procedure. The Radiography
Procedure shall be established to demonstrate that the required sensitivity can
be consistently achieved under the most unfavorable parameters (e.g. source
to film distance, geometric unsharpness, thickness etc.). The radiographic
technique and procedure adopted shall conform of the requirements mentioned
in Article 2 as well as Article 22 of ASME Sec.V. The IQI sensitivity obtained
shall be equal to or better than the requirements mentioned in Article 2 of
ASME Sec.V. Source side penetrameter shall be used in establishing
radiographic procedure / technique. The acceptance criteria shall be as per the
relevant codes of Fabrication and over riding requirements if mentioned else
where in the technical specifications of the contract. The Contractor shall be
responsible for carrying out Radiography; rectification of defects and re-
radiography of welds repaired/rectified at his cost.
• The extent of Radiography shall be as per specifications to be supplied to the

Contractor. For welds between dissimilar materials, the extent of Radiographic
Examination shall be the more stringent of the two recommended for the
materials being welded. Wherever random Radiography is called for, in a
particular piping class, the dissimilar materials weld joints shall essentially be
included.
• Type of Radiation source and film to be used shall be as per Exhibit-H for
carrying out radiographic examination. However if specifications (as given else
where in the contract) for some critical material require usage of X-Radiation,
then Radiography shall be done using X-Rays only.
• The Contractor shall fulfill all the statutory and owner's safety requirements
while handling X-ray and Gamma-ray equipments.
• In case of random radiography, the joints for Radiography shall be selected by

the Owner's Inspector and the Radiography shall be performed in his presence,
if he instructs the contractor to do so. The contractor shall furnish all the
radiographs, to the Owner's Inspector immediately after processing along with
evaluation by a person qualified to ASNT Level-II in Radiographic testing, inline
with Article 2 of ASME Sec.V. The certificate of ASNT / ISNT Level II
qualification of the NDT personnel shall be submitted to owner's inspector for
his approval prior to start of job.
179 of 911
• The Contractor shall provide the Owner's Inspector, all the necessary facilities
at site such as a dark room with controlled temperature, illuminator (viewer)
suitable for varying densities, a duly calibrated electronic densitometer with
batteries, magnifying glass, tracing papers, ruler, marking pencils etc. to enable
him to review the radiographs.
• Where random radiography is specified, the first weld of each welder shall be
completely radiographed. In the case of pipe of size 6" and below, the first two
welds shall be completely radiographed.
• For each weld performed by a welder found unacceptable, two additional

checks shall be carried out on welds performed by the same welder. This
operation is iterative and the of two additional welds for each weld deemed
unsatisfactory shall be continued till such time that two consecutive welds of
satisfactory quality are found for every defective weld.
• The Contractor shall carry out these additional radiographic testing at his own
expense. To avoid the possibility of too many defective welds by a single
welder remaining undetected for a long period to time, the Contractor shall
promptly arrange for Radiographic Examination so that there is no
accumulation of defective joints.
• Contractor shall quote rates for X-ray as well as Gamma Ray for joints indicated
to be radiographed by X-ray in Table of Exhibit-H.
1.13.6 Check shots
(a) Owner / Engineer- in- charge or his representative shall select 5% of the total
joints radiographed on a day for check shots. Contractor shall carry out check
shots as directed.
(b) Weld profiles of check shots shall be compared with weld profile observed in
the earlier Radiographs. In the event of anyone variation in the check shots
and earlier Radiographs, contractor shall re-shoot the entire lot of joints
radiographed by particular Radiography agency on the particular date. All the
re-shot films shall be compared with the originally submitted films.
1.13.7 Magnetic Particle & Liquid Penetrant Examination
a) Whenever such tests are specified, the tests shall be carried out on joints
chosen by the Owner's inspector, as per ASME Section V article 6 and 7
respectively. The tests are to be performed by a person possessing a valid
ASNT / ISNT Level-II qualification in the method being used.
(b) For austenitic stainless steels and other nonmagnetic materials, liquid (dye)
penetrant test shall be carried out. For carrying out this test, the materials shall
be brought within a temperature limit of 15° to 50°C.
180 of 911
1.13.8 Hardness Test
Hardness requirements for welds shall be as per the Welding Specification Chart / Non
Destructive Examination Specification attached elsewhere in the contract. Hardness
testing shall be carried out by Vickers Hardness Tester during welding procedure
qualification and shall be cross sectional. For production welds, hardness testing shall
be carried out by portable digital hardness testers. Poldi hardness tester shall not be
permitted. Contractor shall produce documentary evidence/calibration certificate to the
Owner's Inspector and obtain approval of the hardness testing equipment.
1.13.9 Proof Tests
Hydrostatic and pneumatic tests shall be performed as per the requirements laid down
in the respective flushing & testing specification/ applicable codes to demonstrate the
soundness of the welds. The tests shall be conducted only after fulfilling the
requirements of visual examination, radiography etc. and after the entire work has
been certified by the Owner's inspector, as fit for subjecting to such test.
1.14 Repairs of Welds
a) Defects ascertained, through the inspection methods, which are beyond

acceptable limits shall be removed from the joint completely by the process of
chipping and grinding.
b) When an entire joint is judged unacceptable, the welding shall be completely

cut and the edges be suitably prepared as per required alignment tolerances.
The welded joint shall again be examined following standard practices.
c) No repair shall be carried out without prior permission of the Owner's inspector.
d) Where random radiography is specified, the test welds of each welder shall be
completely radiographed. In the case of pipes of sizes 6" and below, the first
two welds shall be completely radiographed.
e) For each weld found unacceptable due to a welder's fault, two additional
checks should be carried out on welds performed by the same welder. This
operation is interactive and the procedure of radiographing two additional
welds for each weld deemed unsatisfactory shall be continued till such time
that the two consecutive welds of satisfactory quality are found for every
defective weld.
The contractor shall carry out these additional radiographic testing.
To avoid the possibility of too many defective welds by a single welder

remaining undetected for a long period of time, the Contractor shall promptly
arrange for radiographic examination so that there is no accumulation of
defective joints.
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1.15 Limitations on Repairs
Only one attempt at repair of any region is permitted. Repairs are limited to a
maximum 30% of the weld length. For internal or external repairs which open the weld
root, only 20% of the weld length may be repaired. Repairs opening the root must
only be carried out in the presence of COMPANY. The minimum length of a repaired
area shall be 100mm as measured over the recapped length. Welds containing cracks
shall be cut out and rebevelled to make a joint, COMPANY shall authorise all repairs.
1.16 Weld Rejected by Accumulation of Defects
Where a weld is rejected by the accumulation of defect clause, as defined by API-1104

and this specification, repairs within these limitations are permitted. Defects in the
filling and capping passes shall be repaired preferentially.
1.17 DOCUMENTS TO BE SUBMITTED BY CONTRACTOR (4 COPIES EACH)
a) Electrode and Welding Consumable Qualification Records as per Exhibit-A, for

the Welding Consumables tested and approved for the work.
b) Batch Test Certificates, for the Electrodes used, obtained from the Electrode
Manufacturers.
c) Proposed Heat Treatment Procedure as per Exhibit-B.
d) Heat Treatment Charts.
e) Weld joint hardness test results.
f) Welding Procedure Specifications as per Exhibit-C immediately after receipt of
the order.
g) Welding Procedure Qualification records as per Exhibit-D.
h) Welder Performance Qualification records as per Exhibit-E immediately after
conducting Welder Qualification Tests.
i) Radiography Procedure as per Exhibit-F and other NDT procedures.
j) Radiographic test Report along with Radiographs and other NDT reports.
k) Piping Sketch (Isometric) giving all the details regarding the pipe specifications,
welded joints, joints radiographed magnetic particle, tested, ultrasonic tested,
penetrant tested, joints heat treated, WPS used, welders identification number,
etc.
182 of 911
EXHIBIT-A
Sheet 1 of 4
ELECTRODE QUALIFICATIONS TEST RECORD
A: Tested at Date :
(Site Name)
Test Period :
Manufacturer's Name :
Brand Name :
Batch Number & size Tested :
Classification & Code :
Intended for Welding in positions :
In combination with (if any) :
Code of Reference (used for testing) :
Special requirements (if any) :
B: All - Weld Tensile Test
Pre-heat temperature :
Postweld Heat Treatment Details :
Visual Examination :
Radiographic Examination Results :
Sheet 2 of 4
183 of 911
Tensile Test Results :

-------------------------------------------------------------------------------------------------------------------------
Sl. Identification U.T.S. Yield Point Elongation Remarks
No. Number
-------------------------------------------------------------------------------------------------------------------------
-------------------------------------------------------------------------------------------------------------------------
C: Impact Test Results
Test Temperature : Notch in :
Type of Specimens (Impd, Charpy : Size of Specimens :
-------------------------------------------------------------------------------------------------------------------------
Specimen No. Impact Value Average
-------------------------------------------------------------------------------------------------------------------------
1.
2.
3.
4.
5.
-------------------------------------------------------------------------------------------------------------------------
D: Chemical Analysis Result
Electrode size used :
Batch No.
-----------------------------------------------------------------------------------------------------------------
%C %S %P %Si %Mn %Cr %Ni %Mo
-----------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------
Sheet 3 of 4
184 of 911
E: Fillet Weld Test Results
Welding Positions :
Base Materials :
Size of electrode used :
Visual Inspection Results : 1)

2)
3)
Micro Test Results
Fracture Test Results :
Remarks :
F: Other Test Results
i) Transverse Tensile Test :
In Combination with :
Position of Welding :
Preheat Temperature :
Postweld Heat Treatment :
Radiography :
-----------------------------------------------------------------------------------------------------------------
Identification No. U.T.S. Fracture in Remarks
-----------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------
Sheet 4 of 4
185 of 911
2. Guide Bend Test
-----------------------------------------------------------------------------------------------------------------
Position ID No. Root, Face or Remarks
Side Bend
-----------------------------------------------------------------------------------------------------------------
1
2
3
4
5
-----------------------------------------------------------------------------------------------------------------
3. Any other tests
Conclusions
Approved By :
186 of 911
EXHIBIT-B
Sheet 1 of 2
STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION
Name of the Heat - Treatment :.................................................................

Name of the Project :.....................................Specification
Reference No. ..............
1. General Details
Name of the Equipment : ............................................................................
Name of the Assembly/ Part : .....................................................................
Assembly/ Part Drawing No. : .....................................................................
Material : .................................................................................................
2. Furnace Details
Type of Heating : Gas/ Oil/ Elec. Res./ Induction (Tick Mark)
Capacity (size) : ........................................................................................

Maximum Temp. (°C)
Method of temp. measurement : ...................................................................
Atmosphere Control : .................................................................................
3. Heat Treatment Cycle Details
Charging Temp. °C : ...................................................................................
Rate of Heating, °C/Hr : ..............................................................................
Soaking Temp., °C : ...................................................................................
Soaking Time, Hrs. : ..................................................................................
Rate of Cooling, °C/Hr : ..............................................................................
Mode of Cooling : ......................................................................................
Sheet 2 of 2
187 of 911
4. Other Details, if any : .................................................................................
5. The following documents are to be furnished :

along with these specification :
i) Material Test Certificates
ii) Assembly/ Part Details
188 of 911
EXHIBIT-C
Sheet 1 of 2
STANDARD PROCEDURE SPECIFICATION NO.
for ................................ Welding of .............................. Pipe and Fittings
• Process & type ......................................................................................... (Details of special

machines).
• Material .................................................................................................... (Pipes to which

the procedure applied, grade of steel, type of pipe, Reference Specification).
• Diameter and wall thickness ........................................................................ (Series of dia

and thickness to which procedure is applicable)
• Joint Design .............................................................................................
• Filler Metal and Number of Beads .................................................................
• Electrical or Flame Characteristics ................................................................
• Position .....................................................................................................
• Direction of Weldings .................................................................................. (Uphill,

Downhill, Mixed)
• Number of Welders .....................................................................................
• Time Lapse between passes ........................................................................
• Type of Line-up Clamp ................................................................................
• Removal of Line-up Clamp ........................................................................... (Minimum

percentage of welding carried out before removal of clamps)
• Cleaning ....................................................................................................
• Preheat, Stress Relief .................................................................................
• Shielding Flux ............................................................................................
• Speed of Travel ..........................................................................................
• Sketches and Tabulations (to be attached) ....................................................
• Wire Speed (rate of wire speed and variation range) ........................................
• Minimum No. of passes which must be completed before discontinuing weld.
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Sheet 2 of 2
• Minimum No. of welders required for the first pass and second pass :
Tested : ....................................... Welder ......................................
Approved : ....................................... Welding Supt. ............................
Accepted : ....................................... Chief Engineer ...........................
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EXHIBIT-D
Sheet 1 of 2
COUPON TEST RECORD
Location .............................................................................................................
Date ................................... State ................................ Roll Weld ...................... Fixed position
weld ............................................... welder ................................... Mark
.................................................. Welding Time .......................................... Time of day
............................... M. Temperature ................................ F. Weather Condition
........................................ Wing break used ......................................... Voltage
.................................. Amperage ............................................... Type of welding machine
...................................................... Size ................................... Filler Metal
......................................................................................................... Size of reinforcement
........................................................................................... Pipe kind and Grade
............................................................................................. Wall thickness
........................................................... Dia O.D. ............................
-------------------------------------------------------------------------------------------------------------------------
1 2 3 4 5 6 7
Bead No. ............................................................................................................ Size of electrode

................................................................................................ No. of electrode
..................................................................................................
-------------------------------------------------------------------------------------------------------------------------
1 2 3 4 5 6 7
Coupon Stenciled ................................................................................................ Original

Dimension of Plate .................................................................................. Original area of plate
(inch2) ................................................................................ Maximum Load
................................................................................................... Tensile S/ in. plate area
....................................................................................... Fracture Location
................................................................................................
Procedure Qualifying Test Qualified

Welder Line Test Disqualified
Max. tensile strength ................... min. tensile strength ..........................................
Avg. tensile strength ........................ Remarks on tensile strength ...........................
1. .................................................................................................................
2. .................................................................................................................
3. .................................................................................................................
4. .................................................................................................................
Sheet 2 of 2
191 of 911
Remarks on Bend Tests
1. .................................................................................................................
2. .................................................................................................................
3. .................................................................................................................
4. .................................................................................................................
Remarks on Nick Tests
1. .................................................................................................................
2. .................................................................................................................
3. .................................................................................................................
4. .................................................................................................................
Other Tests ........................................................................................................
( Use back for additional remarks )
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EXHIBIT-E
WELDER's IDENTIFICATION CARD
Name :
Identification :
Date of Testing :
Valid Unit :
Approval of Welding :
Welding Position :
Material :
Diameter :
Wall Thickness :
Type of Welding Consumable :
Approved By : Employer's Signature

with Seal
193 of 911
EXHIBIT-F
Sheet 1 of 1
RADIOGRAPHIC PROCEDURE FOR PIPE WELDING
1. Location
2. Date of Testing
3. Name of Supervised Contractor
4. Material
5. Dia. & Thickness
6. Type of Weld Joint
7. Radiation Source (X-ray, gamma ray)
8. Type of equipment (external/ internal)
9. Intensifying screens and material
10. Filter type and placement mask, diaphragm lead screen etc. adjacent to radiation sources or
specimen.
11. Geometric relationship (source local spot size, max and min source strength, object to film
distance, radiation angle with respect to weld and film).
12. Limit of film coverage
13. Film type and make
14. Exposure Time
15. Processing (time temperature for development stop bath or rinse, fixation, washing, drying
etc.)
16. Density
17. Sensitivity
18. Type of penetrameter
Approval of the COMPANY Signature of CONTRACTOR

with seal
194 of 911
WELDING SPECIFICATION CHART EXHIBIT-G

Sheet 1 of 2
Class :
Material Specification :
Pipes : API 5L Gr. X 60, API 5L Gr. B API 5L Gr. X 42
Fittings : A 105, A234 Gr. WPB. MSS-SP-75, Gr. WPHY42, MSS-S
Flanges : A 105, MSS-SP-44 Gr. F42, MSS-SP as Gr. WPH 60
Other : 44 Gr. F6C
Base Metal of NCL :
Welding Processes : Groove Joints : Butt
Root Pass SMAW Filler Pass SMAW Root Pass SMAW Filler Pass SMAW Filler Joints/ Socket Joints :
SMAW
Welding Materials : Groove Joints : Butt
Root Pass E6010G/ E7010G Filler Pass F7010G/ E8010G/ E8818G

Root Pass E7010/ E7018G/ E8018G Filler Pass F7016/ E7018G/ E80118G
Filler Joints/ Socket Joints : E7016/ E7018/ E7018G/ E8018G
Backing Page Consumable :
Gases : Purging Sheilding
Gas Composition : Purging Sheilding
Preheating : 10 min for all welds, 100°C Post heating
Post weld heat treatment :
Holding temp. : 595-650 C Holding Time : 1 Hr. per inch thk

Rate of heating : 200 C/hr max. Min holding time : 1 hr.
Method of cooling : Controlled Rate of cooling : 200°C/hr max.
Mechanical property requirements :
Sheet 2 of 2
195 of 911
Charpy `V' notch impact test valve :
Normal : 22 J
Average : 27 J
At temperature : 0 °C
Hardness : 300 HV10 (for weld & HAZ)
Code of fabrication : ANSI B31.8; API 1104 and welding specifications.
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TECHNICAL NOTES
1. Welding, heat treatment and non destructive testing shall be carried out in accordance with
the requirement of ANSI B31.4 / ANSI B31.8/ API-1104 and additional requirement specified in
the specification. In case of conflict between code and specification more stringent conditions
shall be applicable.
2. No welding shall be carried out without preheating the joint to 10°C (50 °F) when the ambient
temperature is below 10°C (50 °F).
3. Preheat shall be applied while welding the following material as detailed below :
API 5L Gr. B : Thickness upto 100 °F min.

and inclusive of 12mm
A 105 :
MSS-SP-44 Gr. F60 : Thickness beyond 200 °F
A 234 Gr. WPB : 12 mm
MSS-SP-75-WPHY60
4. For fillet welds complete welding may be carried out using the electrodes recommended for
filler passes.
5. All weldments & HAZ shall meet the hardness requirements of 300 HV10 during procedure
qualification. If the hardness exceeds 300 HV10 the joints shall be heat treated at temp. 1100-
1250 °F for one hour. The heating and cooling rates shall be decided during procedure
qualification subject to a maximum of 200 °C/Hr. Hardness testing shall be carried out by
Vickers hardness tester during welding procedure qualification test only. No hardness test is
required for production welds.
6. The electrodes used shall meet the following additional requirement :
Specification UTS (Min.) (As welded) Impact (As welded)
E7018-G 52.7 kg/mm2 20 ft. lb. at 0°C
E7018-I 52.7 kg/mm2 -
E6010 - -
E6018 - 20 ft. lb. at 0°C
7. All the weldments & HAZ shall meet the impact test requirement of 20 ft. lb at 0°C.
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ANNEXURE-2
1.0 DESTRUCTIVE TESTING OF WELDED JOINT - BUTT WELDS
1.1 Preparation
Having passed the visual and the non destructive inspection, the test weld shall be subjected
to mechanical test.
After satisfactory completion of all visual and non destructive testing the procedure test weld
shall be set aside for a period not less than 24 hours. No further work on the test weld and no
cutting of test specimens from the weld be performed till a period of at least 24 hours has
expired.
Weld specimens, for pipe diameter greater than or equal to 12.3/4" shall be taken from the
positions indicated in Fig. 1 of this specification from areas as free from defects as possible.
For this reason it is necessary to take the previous non destructive tests into account. The
minimum no. of tests to be carried out is given in Table-I of this specification.
The test shall be carried out at laboratories approved by COMPANY. The specimens shall be
prepared in accordance with the figure given in the paragraphs which refer to the individual
test.
Table-I
TYPE AND NUMBER OF TEST SPECIMENS FOR

PROCEDURE QUALIFICATION TEST
Pipe Size, Number of Specimens

Out-side Tensil Tensil Nick Root Face Side Macro Hard- Impa Total
diameter e API e ISO Break Bend Bend Bend ness ct
Inches
Wall Thickness > ½ inch (12.7mm) and under
Under 2 3/8 0 0 2 2 0 0 0 0 0 4
2 3/8 to 4½ 0 0 2 2 0 0 0 0 0 4
incl.
Over 4½ less 2 0 2 2 2 0 2 2 12 24
than 12 3/4
12 3/4 and 2 2 4 4 4 0 2 2 24 44
over
Wall Thickness > ½ inch (12.7mm)
4½ and 0 2 0 0 0 2 0 0 0 4
smaller
Over 4½ less 2 0 2 2 2 0 2 2 12 24
than 12 3/4
12 3/4 and 2 2 4 0 0 8 2 2 24 44
over
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1.2 Tensile Strength
Specimens for pipe diameter over 12 3/4" shall be taken from the position indicated in
Fig. 1 of this specification. Two API type specimen shall be taken for pipe diameter
greater than or equal to 12 3/4".
1.3 Nick-Break Test
1.3.1 Preparation
Specimens for nick-break test with notches thus worked can break in the base metal,
instead of in the fusion zone; therefore an alternative test piece may be used after
authorisation by the COMPANY with a notch cut in the reinforcement of outside weld
bead to a maximum depth of 1.5mm measured from the surface of the weld bead.
1.4 Macroscopic Inspection
1.4.1 Preparation
Specimens shall be taken from the positions indicated in Fig. 1 of this specification and
shall be prepared in accordance with ASTM E2 and E3.
The width of the macrosection has to be at least three times the width of the weld.
The section is to be prepared by grinding or polishing and etching to clearly reveal the
weld metal and heat effected zone.
1.4.2 Method
Specimens shall be carefully examined under the microscope with a magnification of at

least 25 times. The COMPANY may ask for a macrograph with 5 times magnification
for documentation purposes.
1.4.3 Requirements
Under macroscopic examination, the welded joints shall show good penetration and
fusion, without any defect exceeding the limits stated in the evaluation criteria of the
nick break test.
1.5 Hardness Test
1.5.1 Preparation
The prepared macrosection is to be used for hardness testing using the Vickers
method with 100 N (10 kg) load. Indentations are to be made along traverses each
approximately 1mm below the surface at both side of the weld.
In the weld metal a minimum of 6 indentations equally spaced along the traverses are
to be made. The HAZ indentations are to be made along the traverses for
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approximately 0.5mm each into unaffected material, and starting as close to the fusion
line as possible.
One indentation at each side of the weld along each traverse has to be made on
parent metal. Reference is made to fig. 3 of this specification. The indentation are to
be made in the adjacent region as well as on the opposite side of the macrosection
along the specified traverses.
1.5.2 Method
The test shall be carried out in accordance with Recommendation ISO R81, Vickers
hardness, using laboratory type machine controlled as per-recommendation of ISO R
146 and using a diamond pyramid penetrator set at 2.37 rad. (136) with a load of 100
N (10 kg).
1.5.3 Requirements
Hardness value shall not exceed 300 H VI0 . In case of a single reading slightly (+10
HV) higher than the specified limit, further indentations should be made to check if the
high value was an isolated case.
All the hardness values obtained from the heat effected zone shall not exceed 100 HV
with respect to the average hardness of the values obtained for the base metal.
If these additional tests mentioned above give a hardness within the specification limit,
the slightly higher value may be accepted.
1.6 Charpy-V-notch Impact Test
1.6.1 Specimens shall be taken from the position indicated in Fig. 1 of this specification. The
test specimens will be prepared in accordance with ISO R 148. Charpy V-notch
specimens shall have dimensions as given in Fig. 3 of the specification.
Three test specimens shall be taken from each sample and they shall be cut and
worked so that their length is transversal and perpendicular to the weld bead with the
notch position as shown in Fig. 4 of this specification. The notch shall be perpendicular
to the roller surface. The test specimens width shall depend upon the pipe wall
nominal thickness as following :
-------------------------------------------------------------------------------------------------------
Nominal wall thickness in Test Specimens width in
mm mm
-------------------------------------------------------------------------------------------------------
> 12 12
-------------------------------------------------------------------------------------------------------
> 9.5 and ≤ 12 7.5
-------------------------------------------------------------------------------------------------------
≥ 7 and ≤ 9.5 5
-------------------------------------------------------------------------------------------------------
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<7 2.5
-------------------------------------------------------------------------------------------------------
1.6.2 Test Method
The test shall be carried out as indicated in ISO R 148 "Beam Impact Test V-notch.
Test pieces shall be immersed in a thermostatic bath and maintained at the test
temperature for at least 15 minutes. They shall than be placed in the testing machine
and broken within 5 seconds of their removal from the batch.
1.6.3 Requirements
The impact energy shall be greater or equal to :-
-------------------------------------------------------------------------------------------------------
Test Specimens in Average of Minimum
mm Three specimens Single Value
Joule (min) (Note-2) Joules (Note 1)
-------------------------------------------------------------------------------------------------------
10 27 22
7.5 21.5 17.5
5 18.5 15.0
2.5 10.0 8.0
-------------------------------------------------------------------------------------------------------
Note:
1) Only one value is permitted to be lower than average upto the value specified.
1.7 Bend Test Requirements
The bend test specimens shall be made and tested as per the requirements of API-
1104 sixteenth edition - May, 1983 except that the dimensions of Jig for guided bend
test fig. 5 para 2.6 API-1104 shall be modified as follows :
Radius of the plunger °A' =2t

Radius of the die °B' = 3 t + 1.6mm
Width of the die °C' = 50.8
The acceptance criteria shall however be as per para 2.643 and 2.653 of API-1104
sixteenth edition - May, 1983.
Note t = Thickness of Specimen (nominal)
201 of 911
ANNEXURE-3
1.0 ULTRASONIC INSPECTION
In addition to the radiographic inspection ultrasonic inspection is required as per

conditions mentioned in Annexure-1 of this specification.
This section concerns manual ultrasonic inspection. However ultrasonic inspection by

automatic equipment may be used if approved by the COMPANY.
1.1 Equipment and Operators
The CONTRACTOR who carries out the ultrasonic inspection shall have sufficient
qualified personnel, equipment and instrument at his disposal to be able to effect the
tests without hindering or delaying the pipeline assembly operations.
• Calibrate the equipment;

• Perform an operational test under production conditions;
• Interpret the screen picture;
• Evaluate the size and location of reflectors
• Interpret the type of defects detected.
The COMPANY has the option of checking the ability of personnel employed for
ultrasonic testing by means of qualification tests.
The CONTRACTOR appointed to carry out UT inspection shall supply the instruments
necessary for their execution on site.
1.2 Specification for Ultrasonic Testing Procedure
Qualification
Before work begins the CONTRACTOR shall present a specification describing the
proposed U.T. procedure qualification.
This specification shall be state, as an indication only but not limited to the following
information :
• Type of U.T. equipment used

• Type and dimensions of transducers
• Frequency range
• Details for calibration
• Coupling medium
• Inspection technique
• Record details
• Reference to the welding procedure where it is intended to adopt the
specification.
• Temperature range of the joints to be inspected.
1.3 Qualification of Ultrasonic Inspection Procedure
202 of 911
The ultrasonic inspection procedure shall be approved by the COMPANY. Before

inspection begins, the COMPANY may require the qualification test of the ultrasonic
inspection procedure. This specification test consists in testing (under normal operating
conditions) some CONTRACTOR welds made according to the same production
procedure, when there are typical defects the test intends to detect.
1.4 Test Procedure
Circumferential weld shall be inspected from both sides using angled. Probes.
The surface with which the probe comes into contact shall be free of metal spatter,
dirt, iron oxide and scales of any type: therefore it shall be necessary to clean a strip at
least 50mm wide on both sides of the weld with steel - wire brushes and anyhow the
cleaned strip must be atleast wide enough to allow full skip examination.
If during the test, echoes of doubtful origin appear, it shall be necessary to inspect a
convenient area on the pipe surface, close to the weld, with a straight beam
transducer in order to check whether any manufacturing defects are present which
could have interfered with the ultrasonic beam.
By way of an example, the equipment shall include but not be limited to the following :
• Ultrasonic equipment and coupling medium

• Sample sections for calibration of instruments.
• Equipment for cleaning of surface to be examined.
• Rulers calibrated in centimeters for exact location of the position of defects.
The characteristics of the above-listed instruments and equipment shall guarantee:
a) that the required standards of the inspection procedure, as previously

established and approved by the COMPANY, are satisfied.
b) continuous operation
All the instruments and equipment shall be approved by the COMPANY before
being used. The COMPANY has the authority to reject any item which is
considered unsuitable. The decision of the COMPANY is final. The
CONTRACTOR appointed to carry out ultrasonic inspection shall also ensure
the operational efficiency and maintenance of the instruments and equipment,
and shall immediately substitute any item rejected by the COMPANY.
All the instrument and equipment necessary for carrying out ultrasonic
inspection on site shall satisfy the requirements laid down by the public board
of institutions which regulate "safety at work".
1.5 Ultrasonic Instruments
203 of 911
The ultrasonic instruments :
• Shall be each pulse type, able to generate, receive and display, on the screen a
cathode ray tube (CRT) pulse, at frequencies between 1 and 6 mhz. The useful
part of the CRT screen shall be at least 70m wide and at least 50mm high.
• Shall have various amplification, with steps of 1 or 2 dB over a range of a least

60 dB.
• The regulation control shall be accurate to within 1 dB and this accuracy shall
be certified by the instrument manufacturer.
• May be powered by a battery or an electric generator. In the first case, the

autonomy of operation (endurance) of the instrument shall be sufficient to
carry on working without frequent interruptions, and the instrument shall be
equipped with an automatic switch which switches it off when the battery runs
down, in the second case, there must be a voltage stabilising device with a
tolerance of 2 volts.
1.6 Probes
The probes used shall have dimensions, frequencies, and a refraction angle suited to
the type of steel, the diameter the thickness of the pipeline and to the joint design.
1.7 Reference Sample Pieces
The efficiency of the equipment used, the effective refraction angle of the probe, and
the beam output points, shall be checked using a V1 and V2 sample block, IIW type or
the calibration block ASTM E-428.
For the calibration of runs and the regulation of detection sensitivity during the test, a
calibration piece be used. This piece shall be taken from the production material, and
will be at least 150mm long (measured in the direction of the axis), and at least 50mm
wide (measured in the direction of the circumference), (see Fig. 4 of this specification).
In the middle of the inside and the outside surface of the calibration piece a groove
shall be made. The groove will have a rectangular cross-section, a flat bottom and the
following dimensions :-
• Depth : 1 +/- 0.1mm

• Breadth (measured parallel to the 150mm side) : 1 +/- 0.1mm
• Length (measured parallel to the 50mm side) not less than 30mm.
In addition, the calibration piece shall have a hole, 2mm in diameter, passing through
its thickness and positioned so that during calibration the echoes returning from the
two grooves do not interfere with those returning from the hole.
1.6 Calibration
204 of 911
For a precise check of the sound paths necessary for a full inspection of the weld joint,
the probe shall be moved (half skip and full skip distance) until internal and external
notches on the test piece are detected (see Fig. 5 of this specification).
The relevant defect limits the path lengths on the time base. The calibration of
reference sensitivity is obtained by utilising the through drilled test hole in the
thickness of the reference block to draw the distance amplitude correction curve
relevant to the test probe.
Calibration shall be carried out according to the following procedure : place its internal
vertex until the maximum height of echo is displayed on the screen; this echo is
adjusted to 80% of full screen height by means of the sensitivity adjuster set in dB.
Without varying the amplification, the probe placed at full skip distance from the hole
is moved to detect the external vertex the hole until the maximum height of echo is
obtained. The straight line connecting the peaks of the two echoes obtained by the
above procedure, represents the 100% reference level, while the one connecting the
two points at half height of the same echoes represents "50% reference level".
The two straight lines shall be marked on the screen with a pen. Calibration shallbe
repeated each time tests are re-started at intervals not longer than 30 minutes during
normal operations; each time the conditions fixed in advance are altered. This
calibration is applicable provided that the crystal of the probe is 8 x 9mm size. Should
this size of the crystal be different, the value of the sensitivity obtained from the
calibration by a crystal of a different size shall be brought to the value of sensitivity
obtained from the calibration by a 8 x 9mm crystal. The sensitivities of the two
different size probes shall be compared through the echoes obtained on the notch of
the test piece with the probe position at half skip of the distance.
1.9 Regulation of Amplification during Production Testing
The amplification during production testing shall be obtained by adding 2-6 dB

(according to the surface condition of the pipe and its cleanness) to the reference
amplification.
1.10 Qualification of Ultrasonic Testing Operators
Before the inspection begins or during the same inspection, the COMPANY may require
a qualification test for the ultrasonic equipment operators.
1.11 Evaluation of Indications given by Ultrasonic Tests
Each time that echoes from the weld bead appear during production testing, the
instrument amplification shall be altered to coincide with the reference amplifications
and the probe shall be moved until maximum respond is obtained paying attention all
the time to the probetube coupling.
If, under these conditions, the height of the defer echo is equal to or greater than that
of the reference echo, the defect shall be evaluated. If the defect has also been
detected by the radiographic and or visual examination, the dimensions shall be
205 of 911
judged according to the type of examination which detects the greater defects.
Returns which are less than 50% of the reference echo, will not be considered. It
returns are above 50% but lower than 100% of the reference echo, and if the operator
has good reasons to suspect that the returns are caused by unfavorably oriented
cracks, he shall inform the COMPANY. Moreover, when there is a defect to be repaired
such defect shall be removed for a length corresponding to the one where no more
return echo is given.
1.12 Other Equipment
The use of rules calibrated in centimeters, attached if possible to the probe, for the
precise location of the position of welding defects, it recommended. Defect location is
effected by measuring the projection distance between the probe output and the
reflecting surface.
The operators carrying out the tests shall have besides the probing instrument, tools
for cleaning the pipe surface (files, brushes, etc.) as well as the coupling liquid or paste
appropriate for the temperature of the section to be examined.
206 of 911
ANNEXURE-4
RADIOGRAPHY
1.0 SCOPE
This annexure covers the radiographic inspection of all types of welded joints of the
main pipeline. The welded joints shall include the following :
i) Full girth welds on the mainline construction including double jointing of pipe, if
adopted.
ii) Welds for installation of block valves, insulating joints and other appurtenances
and tie-ins.
iii) Welds at scraper launching and receiving barrels
iv) Terminal Piping.
2.0 APPLICABLE STANDARDS
This specification shall apply in conjunction with the following (all latest edition) :
i) API 1104, Standard for welding pipelines and related facilities.
ii) ANSI B31.8, code for Gas Transmission and Distribution Piping Systems.
iii) ANSI B31.4, Code for Pipeline Transportation System for liqud & slurries.
iv) ASTM E94, Recommended practice for Radiographic Testing.
v) ASTM, E 142, Standard Method for Controlling Quality of Radiographic Testing.
vi) The American Society for non-destructive Testing. Recommended Practice No.
SNT-TC-1A Supplement-A.
3.0 PROCEDURE
3.1 The radiographic examination procedure to be adopted shall be submitted by the

CONTRACTOR as per Exhibit-F.
3.2 The procedure of radiographic examination shall be qualified to the entire satisfaction
of COMPANY prior to use. It shall include but not be limited to the following
requirements.
i) Lead foil intensifying screens, at the rear of the film shall be used in all
exposures.
ii) Type 2 and 3 films as per ASTM E-94 shall be used.
207 of 911
iii) A densitometer shall be used to determine film density. The transmitted film
density shall be 2.0 and 3.5 through out the weld. The unexposed base density
of the film shall not exceed 0.30.
iv) Radiographic identification system and documentation for radiographic

interpretation reports and their recording system.
3.3 The CONTRACTOR shall qualify each procedure in the presence of the COMPANY prior
to use.
3.4 The procedure of radiographic examination shall produce radiographs of sufficient

density, clarity and contrast so that defects in the weld or in the pipe adjacent to the
weld, and the outline and holes of the pentrameter are clearly discernible.
3.5 All the girth welds of mainline shall be subjected to 100% radiographic examination.
The CONTRACTOR shall furnish all the radiographs to the COMPANY, immediately after
processing them, together with the corresponding interpretation reports on approved
format. The details of the radiographs alongwith the joint identification number shall
be duly entered in a register and signed by the CONTRACTOR and submitted to the
COMPANY for approval.
3.6 When the radiation source and the film are both on the outside of the weld and located
diametrically opposite each other, the maximum acceptable length of film for each
exposure shall not exceed the values given in Table 4 of API 1104. The minimum film
overlap, in such cases, shall be 40mm. The ellipse exposure technique may be used on
nominal pipe sizes of 2 inch and smaller provided that the source to film distance used
is a minimum of 12 inches.
3.7 Three copies of each acceptable radiographic procedure (as outlined in Specification
no. MEC/S/O5/62/02) and three copies of radiographic qualification records, shall be
supplied to COMPANY. One set of the qualifying radiographs on the job shall be kept
by the CONTRACTOR's authorised representative to be used as a standard for the
quality of production radiographs during the job. The other two sets shall be retained
by COMPANY for its permanent record.
3.8 Three copies of the exposure charts relating to material thickness, kilo voltage, source
to film distance and exposure time shall also be made available to aCOMPANY by the
CONTRACTOR.
3.9 The CONTRACTOR shall, on a daily basis, record for each radiograph (1) radiography
number (2) approximate chainage of weld location, (3) whether or not the welds meet
the specified acceptance standards and (4) the nature and approximate location of
unacceptable defects observed. It must be possible to relate to a particular butt weld
and welder on piping drawing and pipeline alignment drawing.
3.10 Each day's production of processed radiographs shall be properly packaged separately,
identified by at least the (1) date, (2) radiographic unit, (3) job locations, (4) starting
208 of 911
and ending progress survey stations and (5) shall include original and three copies of
the daily radiographic record. The package shall be submitted to the COMPANY daily
when possible, but in no event later than noon of the following day.
3.11 The CONTRACTOR shall provide all the necessary facilities at site, such as a dark room
with controlled temperature, film viewer etc. to enable the COMPANY to examine the
radiographs.
3.12 The CONTRACTOR, if found necessary, may modify the procedure of radiographic
examination suiting the local conditions prevailing. This shall, however, be subject to
the approval of the COMPANY.
3.13 COMPANY shall have free access to all the CONTRACTOR's work facilities in the field.
3.14 Any approval granted by the COMPANY shall not relieve the CONTRACTOR of his
4.0 RADIATION SOURCE
4.1 Radiographic examination shall be carried out using x-radiations. Radiographic

examination by Gamma rays may be allowed, at the discretion of the COMPANY, in
case of inaccessible joints.
4.2 Whenever possible, pipeline welds will be inspected by placing the radiation source
inside the pipe, on the pipeline axis, with a radiation of 6.28 rad. (360°).
If it is impossible to place the radiation source inside the pipe, the weld will be
inspected with the source on the outside. An overlap of at least 40mm at the ends of
each film shall be required to ensure that the first and last location increment numbers
are common to successive films and to establish that no part of a weld has been
omitted.
5.0 LEVEL OF QUALITY
The quality level of radiographic sensitivity required for radiographic inspection shall be
at least equivalent to the values in Figure-6.
6.0 PENETRAMETERS
6.1 The image quality indicator (abbreviation : IQI) shall be used for the qualification of
the welding procedure and during normal line production. Radiographic sensitivity shall
be measured with the wire image quality indicator (Penetrameter). The penetrameter
shall be selected according to DIN 54109 or ISO 1027. For radiographs made with the
source on the outside, a penetrameter shall be placed on each side of the film with the
smaller wire of the penetrameter turned towards the end of the film itself. When a
complete weld is radiographed in a single exposure using a source inside the piping,
four penetrameters approximately equally spaced around the circumference shall be
used. During the procedure qualification, IQI shall be placed both on the source side
and on the film side. The sensitivity obtained with IQI on the source side shall not be
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less than the values shown in Fig. 6 of this specification.
The sensitivity limit may be considered to have been reached when the outline of the
IQI, its identification number and the wire of the required diameter show up clearly on
the radiographs.
The COMPANY may authorise use of types of IQI other than those planned, provided
that they conform with recognised standards and only if the CONTRACTOR is able to
demonstrate that the minimum sensitivity level required is obtained. For this
demonstration, a test shall be carried out comparing the IQI specified and the
CONTRACTOR's to show up the identification number and other details of the proposed
IQI, which must be visible in the test radiograph.
7.0 FILM IDENTIFICATION MARKERS
All films shall be clearly identified by lead numbers, letters, and/ or markers. The image
of the markers shall appear on the films, without interfering with the interpretation.
These markers positions shall also be marked on the part to be radiographed and shall
be maintained during radiography.
8.0 PROTECTION AND CARE OF FILM
8.1 All unexposed films shall protected and stored properly as per the requirements of API
1104 standard and ASTM E 94.
8.2 The exposed and unexposed film shall be protected from heat, light, dust and
moisture. Sufficient shielding shall be supplied to prevent exposure of film to damaging
radiation prior to and following the use of the film for radiographic exposure.
9.0 RE-RADIOGRAPHY
9.1 The weld joints shall be re-radiographed in case of unsatisfactory quality of the
radiographs, at the expense of the CONTRACTOR.
9.2 All the repaired weld joints shall be re-radiographed at no extra cost to the COMPANY
in the same manner as that followed for the original welds. In addition, the repaired
weld area shall be identified with the original identification number plus the letter `R'
to indicate the repair.
9.3 When evaluating repair film, radiographers shall compare each section (exposure) of
the weld with the original film to assure repair was correctly marked and original defect
removed.
9.4 The COMPANY will review prior to any repair of welds, all the radiographs of welds
which contain, according to the CONTRACTOR's interpretation, unacceptable defects.
The final disposition of all unacceptable welds shall be decided by the COMPANY.
10.0 QUALIFICATION OF RADIOGRAPHERS
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10.1 Pipeline radiographers shall be qualified in according with the requirement of API 1104
and to the full satisfaction of COMPANY.
10.2 Certification of all the radiographers, qualified as per 10.1 above, shall be furnished by
the CONTRACTOR to the COMPANY before a radiographer will be permitted to perform
production radiography. The certificate record shall include :
i) Background and experience record

ii) Training course record
iii) Technical examination record
iv) Doctor's report on radiographer's Oaecuer 0-1 acquity eye test.
v) Date of qualification.
10.3 The radiographers shall be required to qualify with each radiographic procedure they
use, prior to performing the work assigned to him in accordance with the specification.
11.0 PRESERVATION OF RADIOGRAPHS
11.1 The radiographs shall be processed to allow storage of films without any discoloration
for at least three years. All the radiographers shall be presented in suitable folders for
preservation alongwith necessary documentation.
11.2 All radiographs shall become property of the COMPANY.
12.0 EQUIPMENT AND ACCESSORIES
12.1 CONTRACTOR shall make necessary arrangement at his own expense, for providing
the radiographic equipment, radiographic films and the accessories for carrying out the
radiographic examination for satisfactory and timely completion of the job.
12.2 For carrying out the mainline radiographic examination the CONTRACTOR shall be
equipped with suitable mobile/ stationary type with rooms. These shall have all the
required facilities for film processing. Film viewer used shall be equipped with the film
illuminator that has a light source of sufficient intensity and can be suitably controlled
to allow viewing film densities upto 4.0 without damaging the film.
13.0 RADIATION PROTECTION
13.1 CONTRACTOR shall be responsible for the protection and personal monitoring of every
man with or near radiation sources.
13.2 The protection and monitoring shall comply with local regulations.
13.3 In view of visual hazards in the handling of radioactive source of material,

CONTRACTOR shall be solely responsible for complying with all rules and regulations
set forth by Atomic Energy Commission or any other Government agencies of India in
this regard and COMPANY shall not be responsible and shall be kept indemnified by the
CONTRACTOR for default(s) of whatever nature by the Contractor. Safety equipment
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as considered adequate by the COMPANY for all necessary personnel shall be made
available for use and maintained for immediate and proper use by the CONTRACTOR.
14.0 DISPLAY OF SAFETY INSTRUCTIONS
14.1 The safety provisions shall be brought to the notice of all concerned by display on a
notice board at prominent place at the work spot. The person responsible for the
"safety" shall be named by the CONTRACTOR.
15.0 ENFORCEMENT FOR SAFETY REGULATIONS
15.1 To ensure effective enforcement of the rules and regulations relating to safety
precautions, the arrangement made by the CONTRACTOR shall be open to inspection
by COMPANY or its representatives.
16.0 FIRST AID INDUSTRIAL INJURIES
16.1 CONTRACTOR shall maintain first aid facilities for its employees and those of its sub-
contractors.
16.2 CONTRACTOR shall make outside arrangements for ambulance service and for
treatment of industrial injuries. Names of those providing these services shall be
furnished to COMPANY prior to start of work and their telephone no. shall be posted
prominently in CONTRACTOR's field office.
16.3 All critical industrial injuries shall be reported promptly to the COMPANY and a copy of
CONTRACTOR's report covering each personal injury requiring the attention of
physician shall be furnished to the COMPANY.
17.0 NO EXEMPTION
17.1 Not withstanding the above there is nothing in these clauses to exempt the
CONTRACTOR from the operation of any other act or rules in force.
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MECON LIMITED STANDARD TECHNICAL SPECIFICATION OF SHOP &
DELHI FIELD PAINTING
REV 0, EDITION - 1
FOR
SHOP & FIELD PAINTING
TECHNICAL SPECIFICATION NO.: MEC/S/05/28/07
MECON LIMITED
DELHI 110 092

0 15.10.2015 FIRST ISSUE
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REV 0, EDITION - 1
CONTENTS
SL. NO. DESCRIPTION
1.0 GENERAL
2.0 SCOPE
3.0 CODES & STANDARDS
4.0 EQUIPMENT
5.0 SURFACE PREPARATION
6.0 PAINT MATERIALS
7.0 PAINTING SYSTEMS
7.1 PRE-ERECTION/ PRE-FABRICATION AND SHOP PRIMING FOR CARBON
STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL,
STEEL STRUCTURES, PIPING AND EQUIPMENT ETC.
7.2 REPAIR OF PRE-ERECTION/ FABRICATION AND SHOP PRIMING AFTER
ERECTION/ WELDING FOR CARBON STEEL, LOW TEMPERATURE
CARBON STEEL & LOW ALLOY STEEL, ITEMS IN ALL ENVIRONMENTS.
8.0 FIELD PAINT SYSTEM FOR NORMAL CORROSIVE ENVIRONMENT (FOR
CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY
STEEL)
9.0 FIELD PAINT SYSTEM FOR CORROSIVE ENVIRONMENT (FOR CARBON
STEEL, LOW TEMPERATURE CARBON STEEL AND LOW ALLOY STEEL)
10.0 FIELD PAINT SYSTEM FOR HIGHLY CORROSIVE AREA (FOR CARBON
STEEL, LOW ALLOY STEEL) EXTERNAL SURFACE OF UNINSULATED
COLUMNS, VESSELS, HEAT EXCHANGERS, BLOERS, PIPING, PUMPS,
TOWERS, COMPRESSORS, FLARE LINES, STRUCTURAL STEEL ETC.
11.0 FIELD PAINT SYSTEM FOR CARBON STEEL STORAGE TANKS
(EXTERNAL) FOR ALL ENVIRONMENTS
12.0 FIELD PAINT SYSTEM FOR CARBON STEEL AND LOW ALLOY STEEL
STORAGE TANK (INTERNAL)
13.0 COATING SYSTEM FOR EXTRNAL SIDE OF UNDERGROUND CARBON
STEEL, PLANT PIPING AND TANKS.
14.0 PAINTING UNDER INSULATION FOR (HOT, COLD & SAFETY) CARBON
STEEL LOW TEMPERATURE CARBON STEEL & STAINLESS STEEL
PIPING AND EQUIPMENT IN ALL ENVIRONMENT
15.0 INTERNAL PROTECTION OF CARBON STEEL WATER BOXES AND TUBE
SHEETS OF COOLERS/ CONDENSERS.
16.0 FIELD PAINTING SYSTEM FOR GI TOWERS/ NON-FERROUS TUBE
SHEET
17.0 STORAGE
18.0 COLOURS CODE FOR PIPING
19.0 IDENTIFICATION OF VESSELS, PIPING ETC.
20.0 PAINTING FOR CIVIL DEFENCE REQUIREMENTS
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REV 0, EDITION - 1
22.0 GUARANTEE
23.0 QUALIFICATION CRITERIA O PAINTING CONTRACTOR.
24.0 PROCEDURE FOR APPROVAL OF NEW PAINT MANUFACTURERS.
ANNEXURE-I- LIST OF RECOMMENDED MANUFACTURES
ANNEXURE-II- LIST OF RECOMMENDED MANUFACTURE’S PRODUCTS.
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REV 0, EDITION - 1
AMENDMENT STATUS

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

or a specific work is to be done it shall be deemed that the same shall be
supplied or carried out by the contractor.
Any deviation from this standard without within deviation permit from appropriate
authority will result in rejection to job.
2.0 SCOPE
Scope of work covered in the specification shall include, but not limited to the
following.
2.1 This specification defines the requirements for surface preparation, selection and
application of paint on external surfaces of equipment, vessels, machinery,
piping, ducts, steels structures, external & internal protection of storage tanks for
all services RCC Chimney & MS Chimney with or without refractory lining and
flare lines etc.
2.2 Extent of Works
2.2.1 The following surface and materials shall require shop, pre-erection and field
painting.
a. All uninsulated C. S. & A.S. equipment like columns, vessels, drums,

storage tanks, heat exchangers, pumps, compressors, electrical panels
and motors etc.
b. All uninsulated carbon and low alloy piping fitting and valves (including
painting of identification marks), furnace, ducts and stacks.
c. All items contained in a package unit as necessary.
d. All structural steel work, pipe, structural steel supports, walkways,

handrails, ladders, platforms etc.
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e. RCC/ MS chimneys with or without refractory lining & Flare lines.
f. Identification colour bands on all piping as required including insulated

aluminium clad, galvanised, SS and non-ferrous piping.
g. Identification lettering/ numbering on all painted surface of equipment/

piping insulated aluminium clad, galvanised, SS and non-ferrous piping.
h. Marking/ identification signs on painted surfaces of equipment/ piping for

hazardous service.
i. Supply of all primers, paints and all other materials required for painting
other than owner’s supply.
j. Over insulation surface of equipments and pipes wherever required.
k. Painting under insulation for carbon steel and stainless steel as specified.
l. Repair work of damaged/ pre-erection/ fabrication shop primer and weld

joints at field.
2.2.2 The following surface and materials shall not be painted unless otherwise
specified:
a. Uninsulated austenitic stainless steel.
b. Plastic and/ or plastic coated materials.
c. Non ferrous materials like aluminium, galvanised “piping”, “gratings” and

“handrails” etc. except G. I. Towers.
2.3 Documents
2.3.1 The contractor shall perform the work in accordance with the following
documents issued to him for executions of work.
a. Bill of quantities for piping, equipment, machinery and structure etc.
b. Piping line list.
c. Painting specifications including special civil defence requirement.
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2.4 Unless otherwise instructed final painting on pre-erection/ shop primed pipes and
equipments shall be painted in the field, only after mechanical completion and
testing on system are completed as well as, after completion of steam purging
wherever required.
2.5 Changes and deviations required for any specific job due to clients requirement
or otherwise shall be referred to MECON for deviation permit.
3.0 CODES & STANDARDS
3.1 Without prejudice to the provision of clause 1.1 above and the detailed
specifications of the contract, the following codes and standards shall be
followed for the work covered by this contract.
IS:5 : Colour coding
IS-101 : Methods of test for ready mixed paint

and enamels.
IS-2379:1990 : Indian standard for pipe line

Identification –Colour code.
ASTM Vol. 6.01 and 6.03 : American standard test methods for
Paints and coatings.
ANSI A 13.1-1981 : Scheme for Identification of piping systems

: American National Standard Institution.
3.2 Surface Preparation Standards:
Following standards shall be followed for surface preparations:
3.2.1 Swedish Standard : SIS-05 5900-1967/ ISO-8501-1-1998

(Surface preparation standards for painting steel surfaces).
This standard contains photographs of the various standards on four different

degrees of rusted steel and as such is preferable for inspection purpose by the
Engineer-in-Charge.
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3.2.2 Steel structure painting Council, U.S.A (surface preparations specifications

(SSPC-SP).
3.2.3 British standard (surface finish or Blast-cleaned for painting) BS:4232
3.2.4 National Associations of Corrosion Engineers, U.S.A. (NACE)
3.2.5 Various International Standards equivalent to swedish Standard for surface

preparation are given in Table-I.
3.3 The contractor shall arrange, at his own cost, to keep a set of latest edition of
any one of the above standards and codes at site.
3.4 The paint manufacturer’s instructions shall be followed as far as practicable at all
times. Particular attention shall be paid to the following:
a. Instructions for storage to avoid exposure as well as extremes of

temperature.
b. Surface preparations prior to painting.
c. Mixing and thinning.
d. Application of paints and the recommended limit on time intervals

between coats.
4.0 EQUIPMENT
4.1 All tools, brushes, rollers, spray guns, abrasive materials hand/ power tools for
leaning and all equipments, scaffolding materials, shot/ wet abrassive blasting,
water blasting equipments & air compressors etc. required to be used shall be
suitable for the work and all in good order and shall be arranged by the
contractor at site and in sufficient quantity.
Mechanical mixing shall be used for paint mixing operations in case of two pack
systems except that the Engineer-in-Charge may allow the hand mixing of small
quantities at his discretion.
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5.0 SURFACE PREPARATION, SHOP COAT, COATING APPLICATION & REPAIR

AND DOCUMENTATION
5.1 General
5.1.1 In order to achieve the maximum durability, one or more of following methods of
surface preparation shall be followed, depending on condition of steel surface
and as instructed by Engineer-in-Charge. Adhesion of the paint film to surface
depends largely on the degree of cleanliness of the metal surface. Proper
surface preparation contributes more to the success of the paint protective
system:
a. Manual or hand tools cleaning.

b. Mechanical or power tool cleaning.
c. Blast cleaning.
5.1.2 Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure
that a clean and dry surface is obtained. The minimum acceptable standard in
case of manual or hand tool cleaning shall be St. 2 or equivalent, in case of
mechanical or power tool cleaning it shall be St. 3 or equivalent, in case of blast
cleaning it shall be Sa 2½ or equivalent as per Swedish Standard SIS-055900-
1967/ ISO-8501-1-1988. Where highly corrosive condition exits, then blast
cleaning shall be Sa3 as per Swedish Standard.
Remove all other contaminants, oil, grease etc. by use of an aromatic solvent
prior to surface cleaning.
5.1.3 Blast cleaning shall not be performed where dust can contaminate surfaces
undergoing such cleaning or during humid weather conditions having humidity
exceeding 85%.
5.1.4 Irrespective of the method of surface preparation, the first coat of primer must be
applied on dry surface. This should be done immediately and in any case within
4 hours of cleaning of surface. However, at times of unfavourable weather
conditions, the Engineer-in-Charge shall have the liberty to control the time
period, at his sole discretion and / or to insist on re-cleaning, as may be required,
before primer application is taken up. In general, during unfavourable weather
conditions, blasting and painting shall be avoided as far as practicable.
5.1.5 The external surface of R.C.C. chimney to be painted be dry and clean. Any
loose particle of stand, cement, aggregate etc. shall be removed by rubbing with
soft wire brush if necessary, acid etching with 10-15% HCL solution about 15
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minutes shall be carried out and surface must be thorought washed with water to
remove acid & loose particles then dry completely before application of paint.
5.2 Procedure of Surface Preparation.
5.2.1 Blast Cleaning
5.2.1.1 Air Blast Cleaning
The surface shall be blast cleaned using one of the abrasives: AL202 particles
2
chilled casts iron or malleable iron and steel at pressure of 7kg/cm at
appropriate distance and angle depending on nozzle size maintaining constant
velocity and pressure. Chilled cast iron, malleable iron and steel shall be in the
form of shot or grit of size not greater than 0.055” maximum in case of steel and
malleable iron and 0.04” maximum in case of chilled iron. Compressed air shall
be free from moisture and oil. The blasting nozzles should be venturi style with
tungsten carbide or boron carbide as the material for liners. Nozzles orifice may
vary from 3/16” to ¾”. On completion of blasting operation, the blasted surface
shall be clean and free from any scale or rust and must show a grey white
metallic lustre. Primer or first coat of paint shall be applied within 4 hours of
surface preparation. Blast cleaning shall not be done outdoors in bad weather
without adequate protection or when there is dew on the metal which is to be
cleaned, surface profile shall be uniform to provide good key to the paint
adhesion (i.e.35to 50µ). If possible vacuum collector shall be installed for
collecting the abrasive and recycling.
5.2.1.2 Water Blast cleaning
Environmental, health and safety problems associated with abrasive blast

cleaning limit the application of air blast cleaning in many installations. In such
case water blast cleaning is resorted to.
Water blast cleaning can be applied with or without abrasive and high-pressure
water blasting. The water used shall be inhibited with sodium chromate/
phosphate. The blast cleaned surface shall be washed thoroughly with
detergents and wiped solvent and dried with compressed Air. For effective
cleaning abrasives are used. The most commonly used pressure for high
pressure water blast cleaning for maintenance surface preparation is 3000 to
6000 psi at 35-45 liters/ minute water volume and pressure upto 10000 psi and
water volume of 45 liters/ minute provide maximum cleaning.
The water blast cleaned surface shall be comparable to SSPC-SP-12/ NACE No.
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5. The operation shall be carried out as per SSPC guidelines for water blast
cleaning. The indicative values for sand injection is
Air : 300 to 400 Cu.ft/ min.

Water : 5-10 liter/ min. with corrosion inhibitor
Sand : 200-400 lbs/ hr.
Nozzle : 0.5" to 1” dia
Special equipments for water blast cleaning with abrasives now available shall
be used.
5.2.2 Mechanical of Power tool cleaning
Power tool cleaning shall be done mechanical striking tools, chipping hammers,
grinding wheels or rotating steels wire-brushes. Excessive burnish of surface
shall be avoided as it can reduce paint adhesion. On completion of cleaning, the
detached rust mill scale etc. shall be removed by clean rags and/ or washed by
water or stream and thoroughly dried with compressed air jet before application
of paint.
5.2.3 Manual or hand tool cleaning
Manual or hand tool cleaning is used only where safety problems limit the
application of other surface preparation procedure and hence does not appear in
the specifications of paint systems.
Hand tool cleaning normally consists of the following:
a. Hand de-scaling and/ or hammering

b. Hand scraping
c. Hand wire brushing
Rust, mill scale spatters, old coating and other foreign matter, shall be removed
by hammering, scrapping tools, emery paper cleaning, wire brushing or
combination of the above methods. On completion of cleaning, loose materials
shall be removed from the surface by clean rags and the surface shall be
brushed, swept, deducted and blown off with compressed air/ steam to remove
all loose matter. Finally the surface may be washed with water and dried for
effective cleaning.
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5.3 Non compatible shop coat primer
The compatibility of finishing coat should be confirmed from the paint

manufacturer. In the event of use of primer such as zinc rich epoxy, inorganic
zinc silicate etc. as shop coat the paint system shall depend on condition of shop
coat, if shop coat is in satisfactory condition showing no major defects, the shop
coat shall not be removed. The touch up primer and finishing coat(s) shall be
identified for application by Engineer-in-Charge.
5.4 Shop coated (coated with primer & finishing coat) equipment should not be
repainted unless paint is damaged.
5.5 Shop primed equipment and surface will only be ‘spot cleaned’ in damaged
areas by means of power tool brush cleaning and then spot primed before
applying one coat of filed primer unless otherwise specified. If shop primer is not
compatible with field primer then shop coated primer should be completely
removed before applications of selected paints system for particular
environment.
5.6 For packaged units/ equipment, shop primer should be as per the paint system
given in this specification. However, manufacturer’s standard can be followed
after review.
5.7 Coating Procedure and Application:
5.7.1 Surface shall not be coated in rain, wind or in environment where injurious
airborne elements exists, when the steel surface temperature is less than 5° F
above dew point when the relative humidity is greater than 85% or when the
temperature is below 40° F.
5.7.2 Blast cleaned surface shall be coated with one complete application of primer as
soon as practicable but in no case later than 4 hrs. the same day.
5.7.3 To the maximum extent practicable, each coat of material shall be applied as a
continuous film uniform thickness free of probes. Any spots or areas missed in
application shall be recoated and permitted to dry before the next coat is applied.
Applied paint should have the desired wet film thickness.
5.7.4 Each coat shall be proper state of cure or dryness before the application of
succeeding coat. Material shall be considered dry for recoating when an
additional coat can applied without the development of any detrimental film
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irregularities such as lifting or loose of adhesion of the under coat. Manufacturer

instruction shall be followed for intercoat interval.
5.7.5 When the successive coat of the same color have been specified, alternate coat
shall be tinted, when practical, sufficiently to produce enough contrast to indicate
complete coverage of the surface. The tinting material shall be compatible with
the material and not detrimental to its service life.
5.7.6 Air spray application shall be in accordance with the following:
a. The equipment used shall be suitable for the intended purpose, shall be
capable of properly atomizing the paint to be applied, and shall be
equipped with suitable pressure regulators and gauges. The air caps,
nozzles, and needles shall be those recommended by the manufacturer
of the equipment for the material being sprayed. The equipment shall be
kept in satisfactory condition to permit proper paint application.
b. Traps or separators shall be provided to remove oil and condensed water

from the air. These traps or separators must be of adequate size and
must be drained periodically during operations. The air from the spray
gun impinging against the surface shall show condensed water or oil.
c. Ingredients shall be kept properly mixed in the spray pots or

containers during application by continuous mechanical agitation.
d. The pressure on the material in the pot and of the air at the gun shall be
adjusted for optimum spraying effectiveness. The pressure on the
material in the pot shall be adjusted when necessary for change in
elevation of the gun above the pot. The atomizing air pressure at the gun
shall be high enough to properly atomize the paint but not so high as to
cause excessive fogging of paint, excessive evaporation of solvent, or
less by overspray.
e. Spray equipment shall be kept sufficiently clean so that dirt, dried paint,
and other foreign materials are not deposited in the paint film.
Any solvents left in the equipment shall be completely removed before

applying paint to the surface being painted.
f. Paint shall be applied in a uniform layer, with overlapping at the edge of

the spray pattern. The spray patterns shall be adjusted so that the paint
is deposited uniformly. During application the gun shall be held
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perpendicular to the surface and at a distance which will ensure that a

wet layer of paint is deposited on the surface. The trigger of the gun
should be released at the end of each stroke.
g. All runs and sags shall be brushed out immediately or the paint shall be
removed and the surface repainted.
h. Areas inaccessible to the spray gun shall be painted by brush: if not

accessible by brush, daubers or sheepking shall be used.
i. All nameplates, manufacturer’s identification tags, machined surface

instrument glass, finished flange faces, control valve items and similar
items shall be masked to prohibit coating disposition. If these surface are
coated, the component shall be cleaned and restored to its original
condition.
j. Edges of structural shapes and irregular coated surface shall be coated

first and an extra pass made later.
k. If spray gun shown choking, immediately dechoking procedure shall be

followed.
5.7.7 Airless spray application shall be in accordance with the following procedure: as
per steel structure paint manual vol. 1 & vol. 2. By SSPC, U.S.A., Air less spray
relies on hydraulic pressure rather than air atomization to produce the desired
spray. An air compressor or electric motor is used to operate a pump to produce
pressures of 1,000 to 6.000 psi. Paint is delivered to the spray gun at this
pressure through a single hose within the gun, a single paint stream is divided
into separate streams, which are forced through a small orifice resulting in
atomization of paint without the use of air. This result in more repaid coverage
with less overspray. Airless spray usually is faster, cleaner, more economical and
easier to use than conventional airspray.
Airless spray equipment is mounted on wheels, and paint is aspirated in a hose

that sucks paint from any container, including drums. The unit shall have in built
agitator that keep the paint uniformly mixed during the spraying. The unit shall
consist of in built strainer. Usually very small quantities of thinning are required
before spray. In case of High Build epoxy coating (two pack), 30:1 pump ratios
and 0.020-0.023” tip size will provide a good spray pattern. Ideally fluid hoses
should not be less than 3/8” ID and not longer than 50ft to obtain optimum
results.
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In case of gun choking, decoking steps shall be followed immediately.
5.7.8 Brush application of paint shall be in accordance with the following:
a. Brushes shall be of a style and quality that will enable proper application
of paint
b. Round or oval brushes are most suitable for rivets, bolts, irregular
surfaces and rough or pitted steel. Wide flat brushes are suitable for
large flat areas, but they shall not have width over five inches.
c. Paints shall be applied into all corners.
d. Any runs or sags shall be brushed out.
e. There shall be minimum of brush marks left in the applied paint
f. Surface not accessible to brushes shall be painted by spray, daubers, or

sheepkin.
5.7.9 Manual application by sling (where 6 O’ clock position of pipe is not

approachable)
A canvas strip (alternatively a tinplate strip) about 450mm wide and 1.5m longs
is hold under the pipe by two men. Liquid coating poured on the sling at each
side of the pipe. The men holding this sling move it up and down and walk slowly
forward while fresh coating is poured on the pipe and they manipulate the sling
so that an even coating is contained all round the bottom. This work shall be
done very carefully and by experienced personnel. There shall not be any
formation of “Whiskers” and holes in the coating. The coating film shall be
inspected by mirror.
5.7.10 For each coat the painter should know the WFT corresponding to the specified
DFT and standardize the paint application technique to achieve the desired
WFT. This is to be ensured in the qualification trial.
5.8 Drying of Coated Surface
5.8.1 No coat shall be applied unit the preceding coat has dried. The material shall be
considered dry for re-coating when another coat can be applied without the
development of any film irregularities such as lifting or loss of adhesion of
undercoats. Drying time of the applied coat should not exceed maximum
227 of 911

specified for it as a first coat; if it exceeds the paint material has possible
deteriorated or mixing is faulty.
5.8.2 No paint shall be force dried under condition which will cause checking, wrinkling
blistering formation of pores, or detrimentally after the condition of the paint.
No drier shall be added to paint on the job unless specifically called for in the
manufacturer’s specification for the paint.
Paint shall be protected from rain, condensation, contamination snow and

freezing until dry to the fullest extent practicable.
5.9 Repair of damaged paint surface.
5.9.1. Where paint has been damaged in handling and in transportation, the repair of
damaged coating of pre-creation/ fabrication shall be as given below.
5.9.2. Repair of damaged inorganic zinc silicate primer after erection/ weldding:
Quickly remove the primer from damaged area by mechanical scraping and
emery paper to expose the white metal. Blasts clean the surfaces possible.
Feather the primer over the intact adjacent surface surrounding the damaged
area by emery paper.
5.9.3 Repair of damaged pre-erection and shop priming in the design temperature of
90° C to 500° C.
- Surface preparation shall be done as per procedure 5.9.2
- One coat of F-9 shall be applied wherever damaged was observed on

pre-erection/ pre-fabrication/ shop primer of inorganic zinc silicate coating
(F-9) shall not be applied if damaged area is not more than 5 x 5 cm.
5.10 PAINT APPLICATION
5.10.1 Shop priming/ pre-erection priming with F9 of F12 shall be done only on blasted
surface.
5.10.2 Shop priming/ pre-erection priming with F-9 or F-12 shall be done only with
airless spray.
228 of 911

5.10.3 For large flat surface field painting shall be done by airless spray otherwise brush
can be used.
5.11 Assessment of Painting Requirement
The paint system to be applied for a specific job shall be arrived as sequentially
as given below :
- Identify the environment from area classification details and chose the
appropriate table.
- Identify the design temperature from the technical documents.
- Identify the specific field paint system and surface preparation

requirement from the above identified table and temperature range.
- Identify the shop priming requirement from Table 7.1 based on

compatibility of the above paint system.
- Identify the need of repair of shop primer and execute as per Table 7.2.
5.12 Documentation.
A written quality plan with procedure for qualification trials and for the actual
work.
Daily progress report with details of weather condition, particular of application
no of coats and type of materials applied, anomalies, progress of work versus
program.
Result of measurement of temperature relative humidity, surface profile, film
thickness, holiday detection, adhesion tests with signature of appropriate
authority.
Particular of surface preparation and paint application during trials and during the
work.
Details of non-compliance, rejects and repairs.
Type of testing equipments and calibration.
Code and batch numbers of paint material used.
229 of 911

TABLE-I (for clause 5.0)

SURFACE PREPARATION STANDARDS
S. DESCRIPTION VARIOUS INTERNATIONAL STANDARDS REMARK

NO. (EQUIVALENT)
SWEDISH SSPC-SP NACE USA BRITISH
STANDARD USA STANDARD
SIS-05-5900 BS-4232:
1967 1967
1. MANUAL OR HAND TOOL CLEANING THIS METHOD IS APPLIED
WHEN THE SURFACE IS
REMOVAL OF LOOSE RUST LOOSE MILL EXPOSED TO NORMAL
SCALE AND LOOSE PAINT, CHIPPING, ATMOSPHERIC CONDITION
SSPC-SP-
SCRAPING, SANDING AND WIRE ST.2 - - WHEN OTHER METHODS
2
BRUSHING, SURFACE SHOULD HAVE A CANNOT BE ADOPTED AND
FAINT METALLIC SHEEN. ALSO FOR SPOT CLEANING
DURING MAINTENANCE
PAINTING.
2. MECHANICAL OR POWER TOOL CLEANING
REMOVAL OF LOOSE RUST, LOOSE MILL
SCALE AND LOOSE PAINT TO DEGREE
SPECIFIED BY POWER TOOL CHIPPING, SSPC-SP-
ST.3 - - -DO-
DESCALING, SANDING, WIRE BRUSHING 3
AND GRINDIN, AFTER REMOVAL OF DUST,
SURFACE SHOULD HAVE A PRONOUNCED
METALLIC SHEEN.
230 of 911


S. DESCRIPTION VARIOUS INTERNATIONAL STANDARDS REMARKS
NO. (EQUIVALENT)
SWEDISH SSPC-SP NACE BRITISH
STANDARD USA USA STANDARD
SIS-05-5900 BS-4232:
1967 1967
3. BLAST CLEANING (AIR & WATER)
THERE ARE FOUR COMMON GRADES OF
BLAST CLEANING
3.1 WHITE METAL SA-3 SSPC-SP- NACE#1 FIRST WHERE EXTREMELY CLEAN
5 QUALITY SURFACE CAN BE EXPECTED
BLAST CLEANING TO WHITE METAL FOR PROLONG LIFE OF PAINT
CLEANLINESS REMOVAL OF ALL VISIBLE SYSTEMS.
RUST, MILL SCALE PAINT & FOREIGN
MATTER 100% CLEANLINESS WITH
DESIRED SURFACE PROFILE.
3.2 NEAR WHITE METAL SA 2 ½ SSPC-SP- NACE #2 SECOND THE MINIMUM REQUIREMENT
10 QUALITY FOR CHEMICALLY RESISTANT
BLAST CLEANING TO NEAR WHITE METAL PAINT SYSTEM SUCH AS
CLEANLINESS, UNIT AT LEAST 95% OF EPOXY, VINYL,
EACH ELEMENTS OF SURFACE AREA IS POLYURETHANE BASED AND
FREE OF ALL VISIBLE RESIDUES WITH INORGANIC ZINC SILICATE
DESIRED SURFACE PROFILE. PAINTS, ALSO FOR
CONVENTIONAL PAINT
SYSTEM USED UNDER FAIRLY
CORROSIVE CONDITIONS TO
OBTAIN DESIRED LIFE OF
PAINT SYSTEM.
231 of 911


S. DESCRIPTION VARIOUS INTERNATIONAL STANDARDS REMARKS
NO. (EQUIVALENT)
SWEDISH SSPC-SP NACE BRITISH
STANDARD USA USA STANDARD
SIS-05- BS-4232:
5900 1967 1967
3.3 COMMERCIAL BLAST FOR STEEL REQUIRED
TO BE PAINTED WITH
BLAST CLEANING UNIT AT LEAST CONVENTIONAL PAINTS
TWO—THIRD OF EACH ELEMENT OF THIRD FOR EXPOSURE TO
SA-2 SSPC-SP-6 No. 3
SURFACE AREA IS FREE OF ALL QUALITY MILDLY CORROSIVE
VISIBLE RESIDUES WITH DESIRED ATMOSPHERE FOR
SURFACE PROFILE. LONGER LIFE OF THE
PAINT SYSTEMS.
3.4 BRUSH-OFF BLAST SA-1 SSPC-SP-7 No. 4
BLAST CLEANING TO WHITE METAL

CLEANLINESS, REMOVAL OF ALL
VISIBLE RUST, MILL SCALE , PAINT &
FOREIGN MATTER, SURFACE PROFILE
IS NOT SO IMPORTANT.
232 of 911

6.0 PAINT MATERIALS
Paint manufacturers shall furnish all the characteristics of paint material

on printed literature, alongwith the test certificate for all the specified
characteristics given in this specifications. All the paint materials shall be
of first quality and conform to the following general characteristics as per
the table 6.1, 6.2 and 6.3.
233 of 911

PAINT MATERIALS
TABLE NO.: 6.1 PRIMERS
S. DESCRIPTION P-2 P-4 P-6

No.
1. Technical Name Chlorinated rubber Zinc Etch primer/ wash Epoxy zinc phosphate
Phosphpate primer primer primer
2. Type and composition Single pack, air drying Two pack polyvinyl Tow component
chlorinated rubber butyral resin medium polyamide cured epoxy
based medium cured with phosphoric resin medium,
plasticised with acid solution pogmented pigmented with zinc
unsaponlfiable with zic tetroxy phosphate.
plasticizer, plgmented choromate.
with Zic phosphate.
3. Volume solids (approx) 40% 7-8% 40%
4. DFT (Dry dilm thickness) per coat (approx) 40-50µ 8-10µ 40-50µ
5. Theoretical covering capacity in M2/ coat/ litre 8-10 8-10 8-10
(approx)
6. Welght per litre in kgs/ litre (approx) 1.3 1.2 1.4
7. Touch dry at 30° C (approx) 30 minutes 2 hrs. After 30 mins.
8. Hard dry at 30° C (approx) Min.: 8 hrs. Min.: 2 hrs. Min.: 8 hrs.
Max.: no limitation Max.: 24 hrs. Max.: 3-6 months
9. Over Coating Interval (approx.) Min : 8 hrs Min : 4.6 hrs Min : 8 hrs
Max : No limitation Max : 24 hrs Max : 3-6 months
10. Pot life (approx) at 30° C for two component Not applicable Not applicable 8 hrs.
paints (approx).
11. Temperature Resistance 60°C Not applicable 80°C
234 of 911

PAINT MATERIALS
TABLE NO.: 6.2 FINISH PAINT
S. DESCRIPTION F-2 F-3 F-6 F-7
No
1. Technical Name Acrylic polyurethane Chlorinated rubber Epoxy-High build High build coaltar
finish paint based finish paint finish paint epoxy coating.
2. Type and composition Two-pack aliphatic Single pack plasticised Tow- pack Tow pack polyamide
isocynate cured chlorinated rubber polyamide/ cured epoxy resin
acrylic finish paint based medium with ployamine cured blended with coal/ tar
chemical and weather epoxy resin medium, suitably
resistant pigments. medium suitable pigmented.
pigmented.
3. Volume solids (approx) 40% 40% 62% 65%
4. DFT (Dry film thickness) per coat 30-40µ 40-50µ 100-125µ 100-125µ
(approx)
5. Theoretical covering capacity in 10-13 8-10 5-6 5-2-6.5
M2/ coat/ litre (approx)
6. Welght per litre in kgs/ litre 1.3 1.2 1.4 1.5
(approx)
7. Touch dry at 30° C (approx) 1 hrs. 30 minutes 3 hrs. 4 hrs.
8. Hard dry at 30° C (approx) Overnight 8 hrs. Overnight 48 hrs.
9. Overcoating interval (approx) Min.: Overnight (12) Min.: Overnight Min.: Overnight Min.: 24 hrs.
hrs. Max.: Unlimited Max.: 5 day Max.: 5 day
Max.: Unlimited
10. Pot life at 30° C for two component 6-8 hrs. Not applicable 4-6 hrs. 4-6 hrs.
paints (approx).
11. Temperature Resistance 80°C 60°C 80°C 125°C
235 of 911

PAINT MATERIALS
TABLE NO.: 6.3 FINISH PAINTS

No
1. Technical Name Self priming type surface tolerant Inorganic Zinc Slicate Heat resistant Heat resistant silicone
high build epoxy coating coating synthetic medium aluminum paint
(Complete rust control coating) based two pack suitable upto 500° C
aluminum paint temperature
suitable upto 250°C
dry temperature
2. Type and composition Two-pack epoxy resin based A two-pack air drying Heat resistant Single pack silicone
suitable pigmented and capable self-curing solvent synthetic medium resin based medium
pigmented and capable of based inorganic zinc based two pack with aluminum flakes.
adhering to manually prepared silicate coating. aluminium paint
surface and old coating suitable upto 250°C
3. Volume solids (approx) 72% 60% 25% 20%

4. DFT (Dry film thickness) per 100-125µ 65-75µ 20-25µ 20-25µ
coat (approx)
5. Theoretical covering capacity 6.0-7.2 8-9 10-12 8-10
in M2/ coat/ litre
6. Welght per litre in kgs/ litre 1.4 2.3 1.2 1.1
(approx)
7. Touch dry at 30° C (approx) 3 hrs. 30 min. 3 hrs. 30 min.
8. Hard dry at 30° C (approx) 24 hrs. 12 hrs. 12 hrs. 24 hrs.
9. Overcoating interval (approx) Min.: 10 hrs. Min.: 8 hrs. at 20°C Min.: 16 hrs. Min.: 16 hrs.
Max.: 6 months and 50% RH. Max.: Unlimited Max.: Unlimited
Max.: Unlimited
236 of 911


No
10. Pot life (approx) at 30° C for 90 min. 4-6 hrs. Not applicable Not applicable
two component paints
(approx).
11. Temperature resistance 80°C 400°C 250° C 500° C
F-14: Specially for mulated polyamine cured coal tal epoxy suitable for-45°C to 125°C for application under insulation
F-15: Two pack cold curved epoxy phenolic coating suitable for 45°C to 125°C for application under insulation
F-16: Epoxy siloxane anser coat 738
237 of 911

PAINT MATERIALS
TABLE NO. 6.4 FINISH PAINTS
Sl. Description F-14 F-15 F-16 F-17

No.
1. Technical name Polyamine cured Two-component Ambient Two component
coal tar epoxy Epoxy phenolic temperature solvent free type
coating cured curing Poly high build epoxy
with polyamine Siloxane coating phenolic /
adduct hardner / High build cold novalac epoxy
system (primer + applied phenolic coating
intermediate inorganic cured with
coat + finish copolymer Polyamine
paint) based aluminum adduct hardner
coating suitable system.
for under
insulation
coating of CS
and SS piping
for high
temperature
service.
2. Type & composition Specially Two pack Amercoat 738 Two component
formulated ambient from Ameron solvent free type
polyamine cured temperature Products, USA / high build epoxy
coal tar epoxy curing epoxy Berger 938 from phenolic /
suitable for phenolic coating Berger Paints novalac epoxy
application system suitable Ltd., or phenolic coating
under insulation for application Intertherm 751 cured with
under insulation CSA from Akzo Polyamine
of CS / SS Nobel coating. adduct hardner
piping. Note : 6 system.
3. Volume Solids 70% 65% 60% 98-100%
(minimum)
4. DFT (Dry Film 125 µm 75 - 100 µm 75 - 100 µm 125- 150 µm
thickness) per coat
(minimum)
5. Theoretical covering 5.5 6.5-8.5 6.0-8.0 6.5-8.0
2
capacity in M / coat
/ litre (minimum)
6. Weight per liter in 1.5 1.7 1.3 1.7
kgs/litre (max paint)
(minimum)
7. Touch dry at 30°C 4 hrs. 2 hrs. 1 hr. 2 hrs.
(maximum)
238 of 911

Sl. Description F-14 F-15 F-16 F-17

No.
8. Hard dry at 30°C 24 hrs. 24 hrs. 16 hrs. 24 hrs.
(maximum) Full cure
30°C (for immersion 168 hrs.(7 days) 168 hrs.(7 days) - 168 hrs.(7 days)
/ high temp. service)
9. Over-coating interval Min. 6 hrs. Min. 36 hrs. Min. 16 hrs. Min. 16 hrs.
Max. 5 days Max. 21 days Max. Not Max. 21 days.
applicable
10. Pot life at 30°C for 4 hrs. 1.5 hrs. 1 hr. 1 hr.
two component
paints (minimum)
11. Temperature -45°C to 125°C -45°C to 125°C Up to 400°C for -45°C to 150°C
Resistance (min.) under insulation under insulation CS & SS under for immersion
(Note : 5) insulation service
Notes:
1. Covering capacity and DFT depends on method of application. Covering
capacity specified above are theoretical. Allowing the loose during the
application, minimum specified DFT should be maintained.
2. All primers and finish coats should be cold cured and air drying unless otherwise
specified.
3. All paints shall be applied in accordance with manufacturer’s instruction for

surface preparation, intervals, curing and application. The surface preparation,
quality and workmanship should be ensured.
4. Technical data sheets for all paints shall be supplied at the time of submission of
quotations.
6.4 List of recommended manufacturers
The paint shall conform to the specifications given above and the best quality in
their products range of the manufacturers listed in Annexure-I.
7.0 PAINT SYSTEM
The paint system should vary with type of environment envisaged in and around
the plants. Three types of environment as given below are considered for
selection of paint system. The paint system is also given for specific
requirements.
239 of 911

Primers & finish coats covered in table nos. 7.0 to 15.0
PRIMERS
P-2 : Chlorinated Rubber Zinc Phosphate Primer
P-4 : Etch Primer/ Wash Primer
P-6 : Epoxy Zinc Phosphate Primer
FINISH COATS/ PAINTS
F-2 : Acrylic- Polyurethane finish paint
F-3 : Chlorinated Rubber Finish Paint
F-6 : High Build Epoxy finish coating
F-7 : High Build Coal Tar epoxy coating
F-8 : Self-priming surface tolerant high build epoxy

coating
F-9 : Inorganic Zinc Silicate Coating.
F-11 : Heat resistant Synthetic medium based

Aluminum paint.
F-12 : Heat resistant Silicone Aluminum paint.
F-14 : Specially formulated polyamine-cured coal for

Epoxy coating
F-15 : Epoxy phenolic coating

F-16 : Epoxy Siloxane Coating : Amercoat 738
F-17 : Two component solvent free type high built epoxy
phenolic / novalac epoxy phenolic coating cured with
polyamine.
240 of 911

TABLE 7.1: PRE-ERECTION/ PRE-FABRICATION AND SHOP PRIMING FOR CARBON STEEL, LOW TEMPERATURE
CARBON STEEL & LOW ALLOY STEEL, STEEL STRUCTURE, PIPING AND EQUIPMENT ETC.
S. No. DESIGN TEMPERATURE IN SURFACE PAINT SYSTEM TOTAL DFT IN REMARKS

°C PREPARATION MICRONS (MIN.)
7.1.1 -90 TO 400 SSPC-SP-10 1 COAT OF F-9 65-75 No overcoating is to

be done
7.1.2 401 To 500 SSPC-SP-10 1 COAT OF F-12 40-50 Finish Coat at Site
7.1.3 -40 to 150 for Structures, hand rails and SSPC-SP-3 1 COAT OF F-9 OR 65-75 OF F-9 For Damaged Area
Grating only 2 COATS OF P-7 @ OR of more than 5 x 5
40µ DFT / COAT 80 (P-7) Cm2.
TABLE 7.2: REPAIR OF PRE-ERECTION/ PRE- FABRICATION AND SHOP PRIMING AFTER ERECTION/ WELDING FOR CARBON STEEL
LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL, ITEMS IN ALL ENVIRONMENT.
S. No. DESIGN TEMPERATURE IN SURFACE PREPARATION PAINT SYSTEM TOTAL DFT IN REMARKS
°C MICRONS (MIN.)
7.2.1 -90 TO 400 SSPC-SP-3 (FOR REPAIR 1 COAT OF F-9 65-75 FOR DAMAGED
ONLY) AREA OF MORE
SSPC-SP-10 THAN 5X5 CM.
7.2.2 401 TO 550 SSPC-SP-3 1 COAT OF F-12 20 FOR DAMAGED
AREA OF MORE
THAN 5X5 CM.
241 of 911

TABLE 8.0: FIELD PAINT SYSTEM FOR NORMAL CORROSIVE ENVIRONMENT (FOR CARBON STEEL, LOW TEMPERATURE
CARBON STEEL & LOW ALLOY STEEL)
ALL NORMAL CORROSIVE AREAS SUCH AS OFF SITES EXTERNAL SURFACE OF UNINSULATED COLUMNS, VESSELS, HEAT
EXCHANGERS, BLOWERS, PIPING, PUMPS, TOWERS, COMPRESSORS, STRUCTURAL STEEL WORKS, RCC CHIMNEY WITH
OR WITHOUT REFRACTORY LINE INSIDE CHIMNEY (ALL ENVIRONMENTS), EXCLUDING TANK TOPS, FLARE LINES, D.M.
PLANTS, INTERIOR OF TANKS ETC. FLARE LINES FOR NORMAL CORROSIVE ENVIRONMENT ALSO TO NE PAINTED AS PER
TABLE 9.0
S. DESIGN SURFACE PAINT SYSTEM TOTAL REMARKS

NO. TEMPERATUR PREPARATIO FIELD PRIMER FINISH PAINT DFT IN
E IN C N MICRONS
(MIN.)
8.1 -90 TO –15 SSPC-SP-10 REPAIR OF PRE-FABRICATION NONE 65-75 No over coating to be
PRIMER 1 COAT OF F-9 @65-75µ done follow repair
DFT/ COAT procedure only on
damaged areas of pre-
erection/ pre-fabrication
primer/ coating F-9
8.2 -14 TO 60 SSPC-SP-10 REPAIR OF PRE-FABRICATION 2 COATS OF F-3 @ 225
PRIMER 1 COAT OF F-9 @ 65-75µ 40 µ DFT/ COAT
DFT/ COAT + 2 COATS OF P-2 @ 40µ 2 X 40 = 80
DFT/ COAT
2 X 40 = 80
8.3 61 TO 80 SSPC-SP-10 REPAIR OF PRE-FABRICATION 1 COATS OF F-6 @ 245
DFT/ COAT + 2 COATS OF P-6 @ 40µ
DFT/ COAT
2 X 40 = 80
242 of 911


NO. TEMPERATUR PREPARATIO FIELD PRIMER FINISH PAINT DFT IN
E IN C N MICRONS
(MIN.)
DFT/ COAT 3 X 20 = 60

DFT/ COAT 2 X 20 = 40
8.6 401 TO 500 SSPC-SP-10 REPAIR AS PER 7.2.2 2 COATS OF F-12 @ 80

20 µ DFT/ COAT
2 X 20 = 40
NOTE 1 : FOR MS CHIMNEY OR WITHOUT REFRACTORY LINING 8.3, 8.4 AND 8.5 SHALL BE FOLOWED.
NOTE 2 : FOR EXTENAL SURFACE OF RCC CHMNEY: 2 COATS OF F-6 @ 100 µ DFT/ COAT TO OBBTAIN 2 X 100=200µ
SHALL BE APPLIED AFTER MAKING SURFACE PREPARATION AS PER GUIDELINES IN 1.5
NOTE 3 : WHEREVER REQUIRED S.NO. 8.3 SHALL BE USED FOR 14°C TO 80°C AND S.NO. 8.2 WILL BE DELETED.
243 of 911

TABLE 9.0: FIELD PAINT SYSTEM FOR CORROSIVE ENVIRONMENT (FOR CARBON STEEL, LOW TEMPERATURE
CARBON STEEL & LOW ALLOY STEEL)
FOR ALL CORROSIVE AREAS ABOVE GROUND WHERE H2S, SO2 FUMES OR SPILLAGE’S OF ACID/ ALKALI/ SALT
ARE LIKELY TO COME IN CONTACT WITH SURFACE SUCH AS EXTERNAL SURFACE OF UNINSULATED COLUMNS,
VESSELS, HEAT EXCHANGERS, BLOWERS, PIPING, PUMPS, TOWERS, COMPRESSORS, FLARE LINES,
STRUCTURAL STEEL ETC.
S. DESIGN SURFACE PAINT SYSTEM TOTAL DFT REMARKS

NO. TEMPERATUR PREPARATION FIELD PRIMER FINISH PAINT IN MICRONS
E IN °C (MIN.)
9.1 -90 TO –15 SSPC-SP-10 REPAIR OF PRE-FABRICATION NONE 65-75 Repair of pre-erection/
PRIMER 1 COAT OF F-9 @ 65-75µ pre fabrication primer
DFT/ COAT shall be done wherever
damage is observed.
9.2 -14 TO 80 SSPC-SP-10 REPAIR OF PRE-FABRICATION 1 COATS OF F-6 225 Surface preparation is
PRIMER 1 COAT OF F-9 @ 65-75µ @ 100µ DFT/ required only for repairing
DFT/ COAT + 1 COATS OF P-6 COAT of damaged pre-erection/
@40 µ DFT/ COAT + 1 COAT OF F-2 fabrication primer
@ 40µ DFT/
COAT
9.3 81 TO 400 SSPC-SP-10 REPAIR OF PRE-FABRICATION 2 COATS OF F-12 105
PRIMER 1 COAT OF F-9 @ 65-75µ @ 20 µ DFT/
DFT/ COAT COAT
2 X 20 = 40
9.4 401 TO 500 SSPC-SP-10 REPAIR 2S PER 7.2.2 2 COATS OF F-12 80
@ 20 µ DFT/
COAT
244 of 911

TABLE 10.0: FIELD PAINT SYSTEM FOR HIGHLY CORROSIVE (FOR CARBON STEEL, LOW TEMPERATURE
CARBON STEEL & LOW ALLOY STEEL) EXTERNAL SURFACES OF UNINSULATED COLUMNS,
VESSELS, HEAT EXCHANGERS, BLOWERS, PIPING, PUMPS, TOWERS, COMPRESSORS, FLARE
LINES, STRUCTURE STEEL ETC.
EXPOSED TO SPILLAGE OR FUMES OF HCL H2S04, SALTY WATER IMPINGEMENT, CHLORIDE ETC.

NO. TEMPERATUR PREPARATION FIELD PRIMER FINISH PAINT DFT IN
E IN °C MICRONS
(MIN.)
10.1 -90 TO –15 SSPC-SP-10 REPAIR OF PRE-FABRICATION NONE 65-75 Repair of pre-erection/
PRIMER 1 COAT OF F-9 65-75µ fabrication primer shall be
DFT/ COAT followed. No over coating is
allowed
10.2 -14 TO 80 SSPC-SP-10 REPAIR OF PRE-FABRICATION 2 COATS OF F-6 345 Surface preparation is
PRIMER 1 COAT OF F-9 @ 65-75µ @ 100µ DFT/ required only for repairing
DFT/ COAT + 1 COATS OF P-6 COAT = 2 X 100= of damaged pre-erection/
@40 µ DFT/ COAT 200 + 1 COAT OF fabrication primer.
F-2 @ 40µ DFT/
COAT
10.3 81 TO 400 SSPC-SP-10 REPAIR OF PRE-FABRICATION 2 COATS OF F-12 105
PRIMER 1 COAT OF F-9 @ 65-75µ @ 20 µ DFT/
DFT/ COAT COAT
2 X 20 = 40
10.4 401 TO 500 SSPC-SP-10 REPAIR AS PER 7.2.2 3 COATS OF F-12 80
@ 20 µ DFT/
COAT
2 X 20 = 40
245 of 911

TABLE 11.0 : FIELD PAINT SYSTEM FOR CARBON STEEL STORAGE TANKS (EXTERNAL) FOR ALL
ENVIRONMENTS.
S. NO. DESIGN SURFACE PAINT SYSTEM TOTAL DFT IN REMARKS

TEMPERATURE IN PREPARATION FILED PRIMER FINISH PAINT MICRONS (MIN.)
°C
1.1 EXTERNAL SHELL. WIND GIRDERS APPARATUSES, ROOF TOPS OF ALL GROUND TANK INCLUDING TOP SIDE OF
FLOATING ROOF OF OPEN TANK AS WELL AS COVERED FLOATING ROOF AND ASSOCIATED STRUCTURAL WORK
ROLLING AND STATIONARY LADDERS, SPIRAL STAIRWAYS, HAND TAILS FOR ALL ENVIRONMENTS FOR GRUDE OIL,
LDO, HSD, ATF KEROSENE, GASOLINE, MOTOR SPIRIT, DM WATER, FIREWATER, RAW WATER, POTABLE WATER, ACIDS,
ALKALIS SOLVENTS AND CHEMICALS ETC.
11.1.1 -14 TO 80 SSPC-SP-10 1 COAT OF F-9 @ 1 COATS OF F-6 285 F-6 should be
65-75µ DFT/ @ 100µ DFT/ suitable for
COAT + 1 COATS COAT + 2 COATS occasional water
OF P-6 @40 µ OF F-2 @ 40µ immersion
DFT/ COAT DFT/ COAT
65 + 40 = 105 2 X 40 = 80
11.1.2 81 TO 500 SSPC-SP-10 1 COAT OF F-9 @ 2 COATS OF F-12 105
65-75µ DFT/ @ 20 µ DFT/
COAT COAT
2 X 20 = 40
11.2 EXTERNAL SURFACE OF BOTTOM PLATE (SOIL SIDE) FOR ALL STORAGE TANKS.
11.2 -14 TO 80 SSPC-SP-10 1 COAT OF F-9 @ 3 COATS OF F - 7 365 F7 should be
65-75µ DFT/ @ 100 µ DFT/ suitable for
COAT COAT immersion service
3 X 100 = 300 of the products
given.
246 of 911

TABLE 12.0 : FIELD PAINT SYSTEM FOR CARBON STEEL AND ALLOY STORAGE TANK: (INTERNAL)
S. NO. DESIGN TEMPERATURE IN SURFACE PREPARATION PAINT SYSTEM TOTAL DFT IN REMARKS
°C FILED PRIMER FINISH PAINT MICRONS (MIN.)
INTERNAL SURFACE OF UNDERSIDE OF FLOATING ROOF, INTERNAL STRUCTURAL OF CONE ROOF, BOTTOM PLATE, ROOF STRUCTURE,
STEEL, LADDERS SUPPORTS FOR STORING GRUIDE OIL, LDO AND HSD (EXCLUDING WHITE OIL PRODUCTS)
12.1 -14 TO 80 SSPC-SP-10 1 COAT OF F-9 @ 65- 3 COATS OF F-7 @ 100µ 365 F7 should be suitable for
75µ DFT/ COAT DFT/ COAT immersion service of the
3 X 100 = 300 products given.
12.2 BARE SHEEL OF INSIDE FLOATING ROOF TANK AND CONE ROOF TANK FOR PRODUCTS MENTIONED IN 12.1
12.2.1 -14 TO 80 SSPC-SP-10 PHOSPHATING 2 COATS OF @10 µ 20
TREATMENT WITH 2 X 10 = 20
PHOSPHATING
CHEMICALS (2
COATS)
12.3 FLOATING CONE ROOF TANKS FOR PETROLEUM PRODUCTS SUCH AS ATF, GASOLINE, NAPHTHA, KEROSENE, MOTOR SPIRIT, INSIDE
OF BOTTOM PLATE, UNDERSIDE OF FLOATING ROOF AND SHELL ABOVE MAXIMUM LIQUID LEVEL AND STRUCTURAL STEEL , LADDERS ETC.
12.3.1 -14 TO 80 SSPC-SP-10 1 COAT OF F-9 @ 65- 3 COATS OF F-6 @ 100µ 365 F-6 should be suitable for
75µ DFT/ COAT DFT/ COAT immersion service of
3 X 100 = 300 petroleum produce like
ATF, Kerosene, petrol etc.
12.4 BARE SHELL OF INSIDE OF FLOATING CONE ROOF TANKS FOR PRODUCTS MENTIONED IN 12.3
12.4.1 -14 TO 80 SSPC-SP-10 1 COAT OF F-9 @ 65- NONE 65-75 No over coating is allowed
75µ DFT/ COAT same as per pre-erection
primer, if any
12.5 INTERNAL PROTECTION IF FIXED ROOF TYPE STORAGE TANKS FOR POTABLE WATER: INSIDE OF SHELL, UNDER SIDE OF ROOF AND ROOF STRUCTURE
INSIDE SURFACE BOTTOM PLATE AND STRURAL STEEL WORKS, LADDERS, WALKWAYS, PLATFORMS ETC.
12.5.1 -14 TO 80 SSPC-SP-10 2 COAT OF F-6 @ 40µ 2 COATS OF F-6 @ 100µ 280 F-6 shall be suitable for
DFT/ COAT DFT/ COAT immersion service.
2 X 40 = 80 2 X 100 = 200
12.6 D. M. (DEMINERALISED WATER) AND HYDROCHLORIC ACID (HCL): INTERNAL SHELL, BOTTOM PLATE AND ALL ACCESSORIES
12.6.1 -14 TO 80 SSPC-SP-10 EBONITE RUBBER LINING AS PER SMMS SPECIFICATION 6-06-204
12.7 EG TANKS (INTERNAL SHELL, BOTTOM PLATE ROOF AND ALL ACCESSORIES)
12.7.1 ALL SSPC-SP-10 3 COATS VINYL CHLORIDE CO-POLYMER 225
AMERCOAT 23 @ 75µ / COAT
247 of 911

S. NO. DESIGN TEMPERATURE IN SURFACE PREPARATION PAINT SYSTEM TOTAL DFT IN REMARKS
°C FILED PRIMER FINISH PAINT MICRONS (MIN.)
12.8 INSIDE PONTOON AND INSIDE OF DOUBLE DECK OF ALL FLOATING ROOFS.
12.8.1 -14 TO 80 SSPC-SP-3 1 COAT OF F-8 @ 1 COATS OF F-6 @ 100µ 200
100µ DFT/ COAT DFT/ COAT
1 X 100 = 100
12.9 INTERNAL SURFACE OF AMINE & SOUR WATER STORAGE TANKS
12.9.1 -14 TO 80 SSPC-SP-10 1 COAT OF F-9 @ 65- 2 COATS OF F-15 @ 75µ 215-225
75µ DFT/ COAT DFT/ COAT
2 X 75 = 150
248 of 911

TABLE 13.0 : COATING SYSTEM FOR EXTERNAL SIDE OF UNDERGROUND CARBON STEEL PLANT PIPING
AND TANKS
S. NO. DESIGN TEMPERATURE SURFACE PREPARATION PAINT SYSTEM TOTAL DFT IN REMARKS
IN °C PRIMER FINISH PAINT MICRONS (MIN.)
13.1 CARBON STEEL PLANT PIPING (UNDERGROUND)
13.1.1 YARD COATING
13.1.1.1 25 TO 60 SSPC-SP-10 1 COAT OF 4mm THICK COALTAR 4mm CTE coating shall
SYNTHETIC FAST COATING WRAPPING confirm to 120/ 5 as
DRYING PRIMER AS PER AWWA-C-203 per BS: 4164
TYPE-B AS PER IN 2 LAYER OF EACH
AWWA-C-203 2mm THICKNESS
(1991)
13.1.2 OVER THE DITCH COATING
13.1.2.1 25 Tto 60 SSPC-SP-10 1 COAT OF 2 LAYERS OF 4 mm
SYNTHETIC FAST COALTAR BASED
DRYING PRIMER TAPE COATING AS
TYPE-B AS PER PER AWWA-C-203.
AWWA-C-203
(1991)
13.2 CARBON STEEL PLANT PIPING (UNDERGROUND)
13.2.1 61 TO 400 SSPC-SP-10 1 COAT OF F-9 @ NONE 65-75
65-75µ DFT/ COAT
13.3 EXTERNAL SIDE OF UNINSULATED UNDERGROUND STORAGE TANKS:
13.3.1 40 TO 80 SSPC-SP-10 1 COAT OF F-9 @ 3 COATS OF F-7 @ 365
65-75µ DFT/ COAT 100µ DFT/ COAT
3 X 100 = 300
13.3.2 -90 TO –41 SSPC-SP-10 1 COAT OF F-9 @ NONE 65-75
81 TO 400° c 65-75µ DFT/ COAT
1 COAT OF
AMERCOAT 738 @ NONE 250
250µ DFT/ COAT
249 of 911

TABLE 14.0 : PAINTING UNDER INSULATION FOR INSULATED (HOT COLD SAFETY CARBON STEEL, LOW
ALLOY STEEL, LOW TEMPERATURE CARBON STEEL & STAINLESS STEEL PIPING,
STORAGE TANKS EQUIPMENTS IN ALL ENVIRONMENT
IN °C MICRONS (MIN.)
PRIMER FINISH PINTS
14.1 INSULATED CARBON STEEL, LOW ALLOY STEEL AND LTCS PIPING AND EQUIPMENT & TANKS
14.1.1 -4 TO 125 SSPC-SP-10 REPAIR OF PRE- 2 COATS OF F-14 @ 315 For other temprature
FABRICATION 125µ DFT/ COAT ranges no painting is
PRIMER F-9 @ 65- required under
2 X 125 = 250 OR 3
75µ DFT insulation.
COATS OF F-15= 3 X
80=240
14.1.2 OPERATING SSPC-SP-10 REPAIR OF PRE- 3 COATS OF F-12 @ 105-115
TEMPERATURE –45 TO FABRICATION 20µ DFT/ COAT
125° C BUT DESIGN PRIMER F-9 @ 65-
3 X 20 = 60
TEMPERATURE 126-400° 75µ DFT
C
14.2 INSULATED STAINLESS STEEL INCLUDING ALLOY-20- PIPING
14.2.1 BELOW 0° C TO ALL ALUMINUM SHEETING WITH ALUMINUM FOIL AND CHLORIDE FREE MINERAL SEALANT If the piping &
MINUS TEMPRATURE CONTAINING BARIUM CHROMATE SHALL BE APPLIED equipments are already
erected then surface
14.2.2 0 TO 120 SSPC-SP-10 ( 15-25µ NONE 2 COATS OF F-14 @ 250 shall be prepared by
SURFACE PROFILE) 125µ DFT/ COAT cleaning with emery
paper and wash/ flush
2 X 125 = 250 OR 3 with chloride free DM
COATS OF F-15= 3 X water followed by
80 = 240 wiping with organic
solvent
250 of 911

IN °C MICRONS (MIN.)
PRIMER FINISH PINTS
14.2.3 121 TO 500 SSPC-SP-10 NONE 3 COATS OF F-12 @ 60 No pre erection
20µ DFT/ COAT primer to be applied
3 X 20 = 60
14.2.4 501 TO 1000 SSPC-SP-10 NONE 1 COAT OF 150 Only Amorcoat 738
AMERCOAT 738 @ from Amoron is
150µ DFT/ COAT available for this
temperature range.
14.2.5 CYCLIC SERVICE-196 TO SSPC-SP-10 NONE 1 COAT OF 150

480 EXCEPTING –45 TO AMERCOAT 738 @
120 150µ DFT/ COAT
14.3 NO PAINTING REQUIRED FOR INSULATED MONEL, IN COLOY AND NICKEL LINES
251 of 911

TABLE 15.0 : INTERNAL PROTECTION OF CARBON STEEL WATER BOXES AND TUBE SHEETS OF
COOLERS/ CONDENSERS WATER BOXES, CHANNELS, PARTITION PLATES, END COVERS AND
TUBE SHEETS ETC.
S. NO. DESIGN SURFACE PREPARATION PAINT SYSTEM TOTAL DFT IN REMARKS

TEMPERATURE IN °C PRIMER FINISH PAINT MICRONS (MIN.)
15.1 Upto 65 SSPC-SP-10 1 COATS OF F-6 @ 2 COATS OF F-7 @ 290 For C. S.
40µ DFT/ COAT 125µ DFT/ COAT
2 x 125 = 250
15.2 Upto 65 SSPC-SP-10 1 COATS OF P-4 @ 2 COATS OF F-7 @ 300 FOR NON
NON FERROUS AND 8µ DFT/ COAT 125µ DFT/ COAT FERROUS
BRASS TUBE 1 COATS OF P-6 @ 2 x 125 = 250 SURFACE
SHEETS 40µ DFT/ COAT
TABLE 16.0 FIELD PAINTING SYSTEM FOR GI TOWERS/ NON-FERROUS TUBE SHEET
S. NO. DESIGN SURFACE PREPARATION PAINT SYSTEM TOTAL DFT IN REMARKS

TEMPERATURE IN °C FILED PAINT FINISH PAINT MICRONS (MIN.)
16.1 Upto 65 SSPC-SP-10 1 COATS OF P-4 @ 2 COATS OF F-2 @ 40µ 130 SHADE AS PER
8-10µ DFT/ COAT + DFT/ COAT DEFENCE
1 COAT OF P-6 @ 2 x 40 = 250 REQUIREMENTS
4µ DFT/ COAT
16.2 Upto 65 SSPC-SP-10 1 COATS OF P-4 @ 2 COATS OF F-7 @ 300
NON FERROUS AND 8µ DFT/ COAT 125µ DFT/ COAT
BRASS TUBE 1 COATS OF P-6 @ 2 x 125 = 250
SHEETS 40µ DFT/ COAT
252 of 911

17.0 STORAGE
17.1 All paints and painting materials shall be stored only in rooms to be
arranged by contractor and approved by Engineer-in-Charge for the
purpose. All necessary precautions shall be taken to prevent fire. The
storage building shall preferably be separate from adjacent building. A
signboard bearing the words “ PAINT STORAGE NO NAKED LIGHT-
HIGHLY INFLAMMABLE” shall be clearly displayed outside.
18.0 COLOUR CODE FOR PIPING
For identification of pipeline, the colour code as per Table 18.1 shall be
used. Paint material for colour-coding shall be as specified in this
standard in clause- 6.0.
18.1 Colour coding scheme for pipe, equipment, machinery & structure:
SR. NO. DESCRIPTION GROUND FIRST SECOND

COLOUR COLOUR BAND COLOUR
BAND
18.1.1 ALL KINDS OF WATER
DRINKING WATER Sea Gree French Blue Signal Red
DE-MINERALISED WATER -do- Gulf Red -
COOLING WATER -do- French Blue -
BOILER FEED WATER -do- Gulf Red -
CONDENSATE -do- Light Brown Signal Red
QUENCH WATER -do- Dark Grey -
WASH WATER -do- Ganary Yellow -
PROCESS WATER -do- Oxide Red -
PROCESS WATER -do- Crimson Red -
FIRE WATER Fire red White -
SEA WATER Sea Green -
18.1.2 STEAM
VERY HIGH PRESSURE STEAM Aluminiumto Signal Red -
(VHP) IS2339
HIGH PRESSURE STEAM (SH) -do- French Blue -
MEDIUM PRESSURE STEAM -do- Gulf Red
(SH) -do- Canary Yellow Canary Yellow
LOW PRESSURE STEAM (SL) -do- Grey
DILUTION STEAM/ PURGE
STEAM
253 of 911

SR. NO. DESCRIPTION GROUND FIRST SECOND

COLOUR COLOUR BAND COLOUR
BAND
18.1.3 COMPRESSED AIR Sky Blue Signal Red -
PLANT AIR -do- Silver Grey -
INSTRUMENT AIR -do- French Blue -
NITROGEN Canary Yello Black -
OXYGEN -do- White -
CO2 -do- Light Grey -
18.1.4 GASES
FUEL GAS AND SOUR GAS Canary Yellow Grey Dark Violet
CHARGE GAS -do- Signal Red French Blue
RESIDUE GAS, LPG -do- Oxide Red White
ACETYLENE -do- Service Brown -
SWEET GAS -do- Grey -
18.1.5 ACIDS AND CHEMICALS

SULFURIC ACID DARK Violet Briliant Green Light Orange
NITRIC ACID -do- French Blue -do-
HYDROCHLORIC ACID -do- Signal Red -do-
ACETIC ACID -do- Silver Grey -do-
CAUSTIC smoke Grey Light Orange -
CHLORINE Canary Yellow Dark Violet -do-
18.1.6 HYDRO CARBONS

NAPTHAS Dark Admiralty Brilliant Green Black
PROPYLENE Grey -do- Smoke Grey
PROPYLENE C.G. (LIQ) -do- -do- Gulf Red
ETHYLENE GLYCOL -do- -do- -
ETHYLENE DICHLORIDE -do- Gulf Red -
BENZENE -do- Canary Yellow -
BUTADIENE -do- Black
ETHANE(LIQ) -do- Light Grey French Blue
PROPYLENE(LIQ) Dark Admiralty Signal Red Black
ETHYLENE(LIQ) Grey Light Grey Black
TAR -do- Signal Grey Brilliant Green
AROMATIC GASOLINE -do- Brilliant Green Canary Yellow
METHANOL (LIQ) -do- White Gulf Red
PYROLYSIS GASOLINE -do- Brilliant Green Black
MIXED C4(LIQ) -do- Signal Green Light Brown
LPG(LIQ) -do- Brilliant Gren Dark Violet
KEROSENE -do- -do- -
DIESEL OIL (WHITE) -do- -do- -
DIESEL OIL (BLACK) Light Brown -
-do-
-do-
254 of 911

18.2 The colour code scheme is intended for identification of the individual
group of the pipeline. The system of colour coding of a ground colour and
colour bands superimposed on it.
18.3 Ground colours as given in Table 18.1 shall be applied throughout the
entire length for uninsulated pipes, on the metal cladding & on surfaces
covered by Clause 2.2.2, ground colour coating of minimum 2m length or
of adequate length not to be mistaken as colour band shall be applied at
places requiring colour bands. Colour band(s) shall be applied at the
following location.
a. At battery limit points
b. Intersection points & change of direction points in piping ways.
c. Other points, such as midway of each piping way, near valves,

junction joints of services appliances, walls, on either side of pipe
culverts.
d. For long stretch/ part piping at 50M interval.
e. At start and terminating points.
18.4 Identification Sign
18.4.1 Flow direction shall be indicated by an arrow in the location stated in Para
a,b,c & d and as directed by Engineer-in-charge.
18.4.2 Colours of arrows shall be black or white and in contrast to the colour on
which they are superimposed.
18.4.3 Product names shall be marked at pump inlet, outlet and battery limit in a
suitable size as approved by Engineer-in-charge.
18.4.4 Size of arrow shall be either of those given in 18.5.
18.5 Colour Bands
255 of 911

18.5.1 As a rule minimum width of colour band shall conform to the following
table:
Nominal Pipe Size Width : L(mm)

3” NB and below 25mm
Above 3” NB upto 6” NB 50mm
Above 8” NB upto 12” OD 75mm
Above 12” OD 100mm
Note: For insulated pipes, nominal pipe size means the outside diameter
of insulation.
Nominal pipe size figures are to be inches.
18.5.2 Colour band(s) shall be arranged in the sequence shown in Table 18.1
and the sequence follows the direction of flow. The relative proportional
width of the first colour band to the subsequent bands shall be 4:1,
minimum width of any band shall be as per Clause 18.5.1.
18.5.3 Whenever it is required by the Engineer-in-charge to indicate that a

pipeline carries a hazardous material, a hazard marking of diagonal strips
of black and golden yellow as epr IS:2379 shall be painted on the ground
colour.
18.6 Wherever it is required by the Engineer-in-charge to indicate that a

pipeline carries a hazardous material, a hazard marking of diagonal strips
of black and golden yellow as per IS:2379 shall be painted on the ground
colour.
19.0 IDENTIFICATION OF VESSELS, PIPING ETC.
19.1 Equipment number shall be stencilled in black or white on each vessel,

column, equipment & machinery (insulated or uninsulated) after painting.
Line number n black or white shall be stencilled on all the pipelines of
more than one location as directed by Engineer-in-charge, size of letters
printed shall be as below :
Column & Vessels - 150mm(high)

Pump, Compressor and other machinery - 50mm (high)
Piping - 40-150mm
256 of 911

19.2 Identification of storage tanks
The storage tanks shall be marked as detailed in the drawing.
20.0 PAINTING FOR CIVIL DEFENCE REQUIREMENTS
20.1 Following items shall be painted for camouflaging if required by the client.
a. All columns
b. All tanks in offsite
c. Large vessels
d. Spheres
20.2 Two coats of selected finishing paint as per defence requirement shall be
applied in a particular pattern as per 20.3 and as per the instructions of
Engineer-in-charge.
20.3 Method of Camouflaging
20.3.1 Disruptive painting for camouflaging shall be done in three colours in the
ratio of 5:3:2 (all matt finish).
Dark Green Light Green Dark Medium Brown

5: 3: 2
20.3.2 The patches should be asymmetrical and irregular.
20.3.3 The patches should be inclined at 30 degree to 60 degree to the

horizontal.
20.3.4 The patches should be continuous where two surfaces meet at an angle.
20.3.5 The patches should not coincide with corners.
20.3.6 Slits and holes shall be painted and dark shades.
20.3.7 Width of patches should be 1 to 2 meters.
257 of 911

21.1 All painting materials including primers and thinners brought to site by
contractor for application shall be procured directly from manufacturers as
per specifications and shall be accompanied by manufacturer’s test
certificates. Paint formulations without certificates are not acceptable.
21.2 Engineer-in-Charge at his discretion may call for tests for paint
formulations. Contractor shall arrange to have such tests performed
including batch wise test of wet paints for physical & chemical analysis. All
costs there shall be borne by the contractor.
21.3 The painting work shall be subject to inspection by Engineer-in-Charge at

all times. In particular, following stage wise inspection will be performed
and contractor shall offer the work for inspection and approval of every
stage before proceeding with the next stage. The record of inspection
shall be maintained in the registers. Stages of inspection are as follows:
a. Surface preparation
b. Primer application
c. Each coat of paint
In addition to above, record should include type of shop primer already

applied on equipment e. g. Red oxide zinc chromate or zinc chromate or
Red lead primer etc.
Any defect noticed during the various stages of inspection shall be

rectified by the contractor to the entire satisfaction of Engineer-in-Charge
before proceeding further. Irrespective of the inspection, repair and
approval at intermediate stages of work. Contractor shall be responsible
for making good any defects found during final inspection/ guarantee
period/ defect liability period as defined in general condition of contract.
Dry film thickness (DFT) shall be checked and recorded after application
of each coat and extra coat of paint should be applied to make-up the
DFT specified without any extra cost to owner, the extra cost should have
prior approval of Engineer-in-Charge.
258 of 911

21.4 Primer Application
After surface preparation the primer should be applied to cover the

crevices, corners, sharp edges etc. in the presence of inspector
nominated by Engineer-in-Charge.
21.5 The shades of successive coats should be slightly different in color in

order to ensure application of individual coats, the thickness of each coat
and complete coverage should be checked as per provision of this
specification. This should be approved by Engineer-in-Charge before
application of successive coats.
21.6 The contractor shall provide standard thickness measurement instrument

with appropriate ranges(s) for measuring.
Dry film thickness of each coat, surface profile guage for checking of
surface profile in case of blast cleaning. Holiday directors and pinhole
detector and positector whenever required for checking in case of
immersion conditions.
21.7 Prior to application of paints on surface of chimneys the thickness of the

individual coat shall be checked by application of each coat of same paint
on M. S test panel. The thickness of paint on test panel shall be
determined by using gauge such as ‘Elkomere’. This thickness of each
coat shall be checked as per provision of this specification. This shall be
approved by Engineer-in-Charge before application of paints on surface of
chimney.
21.8 At the discretion of Engineer-in-Charge, the paint manufacturer must

provide the expert technical service at site as and when required. This
service should be free of cost and without any obligation to the owner, as
it would be in the interest of the manufacturer to ensure that both surface
preparation and application are carried out as per their recommendations.
21.9 Final inspection shall include measurement of paint dry film thickness.
Adhesion Holiday detection check of finish and workmanship. The
thickness should be measured at as many points/ locations as decided by
Engineer-in-Charge and shall be within + 10% of the dry thickness,
specified in the specifications.
259 of 911

21.10 The contractor shall arrange for spot checking of paint materials for Sp.
Gr., flow time (ford cup) and spreading rate.
22.0 GUARANTEE
22.1 The contractor shall guarantee that the chemical and physical properties
of paint materials used are in accordance with the specifications
contained herein/ to be provided during execution of work.
22.2 The contractor shall produce test report from manufacturer regarding the
quality of the particular batch of paint supplied. The Engineer-in-Charge
shall have the right the test wet samples of paint at random, for quality of
same as stipulated in clause 11 above. Batch test report of
manufacturer’s for each batch paint supplied shall be made available by
the contractor.
23.0 QUALIFICATION CRITERIA OF PAINTING CONTRACTOR
Painting contractor who is awarded any job for MECON, projects under
this standard must have necessary equipments, machinery, tool and
tackles for surface preparation, paint application and inspection. The
contractor must have qualified trained and experienced surface
preparation, paint applicator, inspector, and supervisors. The contractor
supervisor, inspector surface perpetrator and paint applicator must be
conversant with the standards referred in this specification the contractors
capacity, capability and competency requirements for the job shall be
quantified in the tender document and shall be assessed by an MECON
team before awarding any job.
24.0 PROCEDURE FOR APPROVAL OF NEW COATING MATERIALS AND

MANUFACTURER’S
Following procedure is recommended to be followed for approval of new

manufacturers.
24.1 The manufacturer should arrange testing of the inorganic zinc silicate
coating materials as per the list of tests given in para 24.5 below from one
of the reputed Government laboratories.
260 of 911

24.2 Samples of coating should be submitted to the Govt. laboratory in sealed

containers with batch no. and test certificate on regular format of
manufacturer’s testing laboratory. The sampling shall be certificate and
sealed by a citifying agency.
24.3 All test panels should be prepared by govt. testing agency colored
photographs of test panels should be taken before and after the test
should be enclosed along with test report.
Sample batch. No. and manufacturer’s test certificate should be enclosed

along with the report. Test reports contain details of observation and
rusting if any, as per the testing code. Suggested government laboratories
are:
RRL, Hayderabad
HBTI, Kanpur
DMSRDE, Kanpur
IIT, Mumbai
BIS Laboratory
UDCT, Mumbai
RITES, Calcutta
PDIL
24.4 Manufacturers should intimate the company, details of sample submitted

for testing name of Govt. testing agency, date, contact personnel of the
Govt. testing agency. At the end of the test the manufacturer should
submit the test report to the company for approval. The manufacturer(s)
shall be qualified based on the result of these tests and other
assessment and the Company’s decision in this regard shall be final and
binding on the manufacturer.
261 of 911

24.5 Tests required for evaluation of acceptance of coating materials for

offshore application.
Test ASTM Test Method
Density D 1475
Dipping properties D 823
Film Characteristics
Drying time D 1640
Flexibility D 1737/ D 522
Hardness D 3363
Adhesion D 2197
Abrasion resistance D 968/ D 1044
DFT/ Coat AS PER SSPC GUIDELINES
Storage Stability D 1849
Resistance to
Humidity for 2000 hrs. D 2247
Salt Spray for 2000 hrs. B 117
Accelerated Weathering D 822
% Zn in DFT G 53
24.6 Coating system for panel test shall be decided after discussion with
MECON.
262 of 911

ANNEXURE-I
LIST OF RECOMMENDED MANUFACTURERS
Indian Vendors
1.0 Asian Paints(I) Ltd.

2.0 Berger Paints Ltd.
3.0 Goodlass Nerlolac Paints Ltd.
4.0 Jenson And Nicholson Paint Ltd & chokuGu Jenson & Nicholson Ltd.
5.0 Shalimar Paints Ltd.
6.0 Sigma Coating, Mumabai
7.0 CDC Carboline Ltd.
8.0 Premier Products Ltd.
9.0 Coromandel Paints & Chemicals Ltd.
10.0 Anupam Enterprises
11.0 Grand Polycoats
12.0 Bombay Paints Ltd.
13.0 Vanaprabha Esters & Glycer, Mumbai
14.0 Sunil Paints and Varnishes Pvt. Ltd.
15.0 Courtaulds Coating & Sealants India (Pvt.) Ltd.
16.0 Mark-chem Incorporated, Mumbai (for phosphating chemicals only)
17.0 VCM Polyurethane Paint (for polyurethane Paint only)
FOREIGN VENDORS FOR OVERSEAS PRODUCTS
1.0 Sigma Coating, Singapore

2.0 Ameron, USA
3.0 Kansai Paint, Japan
4.0 Hempel Paint, USA
5.0 Valspar Corporation, USA
6.0 Courtaulds Coating, UK.
Note: This list subjected to revision based fresh approval which will be intimated to
PDD/ Vendor Cell.
263 of 911

ANNEXURE-II
LIST OF RECOMMENDED MANUFACTURER’S PRODUCTS
S. MANUFACTURER P2 P4 P6 F9
No. NAME CHLORINATED RUBBER ETCH PRIMER/ WASH EPOXY ZINC PH. INORGANIC ZINC
Zp PRIMER PRIMER PRIMER SILICATE PRIMER/
COATING
1. ASIAN PAINTS (I) LTD. ASIOCHL OR HB. ZN.PH APCONYL WP 636 (PC APCODUR HB. APCOCIL 605
PRIMER RO PC 168 335) RO.ZP-PC433
2. BARGER PAINT LTD. LINSOL HIGH BUILD ZP BISON WASH PRIMER EPILUX 610 ZINC ANODE 304
PRIMER
3. AMERON/ GODDLASS - AMERCOAT 187 AMERCOAT 71 DIMET COTE-9
NEROLAC PAINTS
LTD.
4. JENSON & NICHOSON JENSOLAC CHLORINATED J & N ETCH PRIMER EPILAC ZINC -
PAINTS LTD. AND RUBBER HB ZN.PH. PHOSPHATE
CHOKUGU JENSON PRIMER PRIMER
NICHOLSON
5. SHALIMAR PAINTS CHIOROKOTE ZINC TUFFKOTE ETC EPIGUARD 4 ZINC TUFFKOTE ZILICATE TL
LTD. PHOSPHATE PRIMER PRIMER PHOSPHATE
GREY PRIMER GREY
6. SIGMA COATING SIGMA NUCOL UNICOAT SIGMA COVER PRIMER COLTURE CM SIGMASIL MC (7568)
7321 (7413) PRIMER 7412
7. CDC CARBOLINE LTD. - - CARBOLINE 893 CARBOZINC 11
8. PRIMER PRODUCTS - - P-15/3A U17/ 92 ETHYL

LTD. U-16/92 SILICATE INORGANIC
ZINC
9. CORAMANDEL PAINTS COROCLORE CR HB. ZN. CPC WASH PRIMER COROPEX EPOXY -
CHEMICALS LTD. PH. PRIMER ZH. PH. HIGH BILD
PRIMER
264 of 911

COATING
10. ANUPAM ANUCHLOR ZP PRIMER ANUPRIME 291 ANUPAM ANILICOR -
ENTERPRISES A-EZP-500
11. GRAND POLYCOATS GP CHILOROPRIME 601 GP PPRIME 401 - -
12. BOMBAY PAINTS HEMPA TEX HIGHBUILD PENTOLITE WASH HEMPEL’S SHOP GALVASOL 1570
LTD. THEMPEL 4633 PRIMER 8520 PRIMER E-1530
MAKINE PAINTS
13. VANAPRABHA VEGCHLOR HB PRIMER VEG WASH PRIMER VEGPOX 1241 Z/ -
ESTERS & 1143 1181 P
GLYCERIDES,
14. SUNIL PAINTS AND SUNCHLOR HB ZINC SUN WASH SUNPOXY ZINC -
VARNISHED PVT. PHOSPHATE PRIMER PHOSPHATE
LTD. PRIMER
15. COURTAULDS - - INTERGARD 251 INTERZINC
COATING LTD.
16. MARK-CHEM RUST PREVENTIVE
INCOPORATED, LIQUID DRSAIO
(FOR PHOSPHATING
CHEMICAL ONLY)
17. VCM
POLYURETHANE
PAINTS (FOR POLY
EURETHANE PAINTS
ONLY)
18. JOTUN PAINTS EPOXY CQ JOTACOTE – 2
SPECIAL ZINC
265 of 911

COATING
PHOSPHATE
PRIMER
19. KCC PRODUCTS EZ 180(N)
(KOREA)
LIST OF RECOMMENDED MANUFACTURER’S PRODUCTS (Contd….)
S. MANUFACTURER F2 F3 F6 F7
No. NAME ACRYLIC-POLY CHLORINATED HIGH BUILD HIGH BUILD COAL
YURETHANE FINISH RUBBER FINISH FINISH PAINT TAR EPOXY
PAINT PAINT COATING
1. ASIAN PAINTS (I) APCOTHANE CF76 (PC ASIOCHLOR CF 621 APCODUR HB APCODUR CF 300
LTD. 1109) (PC 161) COATING 9466
2. BARGER PAINT LTD. BARGER THANE LINOSOL EPILUX 04 AND 78 EPILUX 555
ENAMEL (81) CHLORINATED HB EPOXY
RUBBER HB COATING
COATING
3. AMERON/ AMERCOAT 450GL AMERCOAT 515 AMER COAT 383 AMERCOAT 78 HB
GODDLASS HS
NEROLAC PAINTS
LTD.
4. JENSON & J & N 993 HB JENSON HB EPILAC 981 EPILAC
NICHOSON PAINTS POLYURETHANE CHLORINATED ENAMEL SOLVENTLESS COAT
LTD. AND CHOKUGU FINISH PAINT. RUBBER FINISH TAR EPOXY
266 of 911

S. MANUFACTURER F2 F3 F6 F7
No. NAME ACRYLIC-POLY CHLORINATED HIGH BUILD HIGH BUILD COAL
YURETHANE FINISH RUBBER FINISH FINISH PAINT TAR EPOXY
PAINT PAINT COATING
JENSON PAINT COATING
NICHOLSON
5. SHALIMAR PAINTS SHALITHANE FINISH CHLORKOTE FINISH EPIGARD KL BIPIGARD’S BLACK
LTD. FINISH HB COAL TAR EPOXY
COATING
6. SIGMA COATING SIGMADOUR HS SIGMA NUCOL SIGMA COVER COLTURIET TCN 300
SEMIGLOSS 7530 FINISH 7308 CM 7456
7. CDC CARBOLINE CARBOLINE 132 - CARBOLINE 191 CARBOMASTIC-14
LTD.
8. PRIMER PRODUCTS U3/ 92 POLYURETHANE CR-71 FINISH PAINT 42B/ 4A HIGH 350B/ 3A, COAL TAR
LTD. BUILD EPOXY EPOXY COATING
9. CORAMANDEL - COROCLORE CR COROPEX EPOXY COROPEX EPOXY
PAINTS CHEMICALS FINISHING HB COATING COAL TAR COATING
10. ANUPAM ANUTHANE ENAMEL ANUCHLOR HB DURACOAT-6000 COROGUARD
ENTERPRISES ENAMEL
11. GRAND POLYCOATS GP COAT 131, 132 GP CHILOROGAURD GP GUARD HP POLYGUARD GE
GP BOND 141 631 234
267 of 911

S. MANUFACTURER’S F2 F3 F6 F7
NO. NAME
12. BOMBAY PAINTS PENTATHANE FP 4510 HEMPATEX HIBUILD HEMPADUR HIGH HEMPADUR 1510
LTD./ PAINTS 4633 BUILD 5520
13. VANAPRABHA VEGTHANE FP 3641 VEGCHLOR FP 3140 VEGPOX- 3265 VEGPOX 4265
ESTERS & VEGPOX 3562
GLYCERIDES,
14. SUNIL PAINTS AND SUNTHANE (ALIPHATIC) SUNCHLOR HB CR LPOXY HB ‘PS LPOXY BLACK P. S.
VARNISHED PVT. COATING 901’ 551
LTD.
15. COURTAULDS INTERTHANE - INTEGARD EM INTERTUF JXA 006/
COATING LTD. SERIES 007/ 010
16. MARK-CHEM
INCOPORATED,
(FOR PHOSPHATE
PAINTS ONLY)
17. VCM PIPCOTHANE
POLYURETHANE ALIPHATIC
PAINTS (FOR POLY POLYURETHANE
EURETHANE PAINTS FINISH PAINT
ONLY)
18. JOTUN PAINTS HARDTOP AS PENGUARD JOTAGUARD 85
19. KCC PRODUCTS KOPOX TOPCOAT EH 173
(KOREA) HB ET 5740
268 of 911

S. MANUFACTURER’S NAME F-8 F-11 F-12

NO. EPOXY MASTIC COATING HEAT RESISTANCE HEAT RESISTANCE SILICON
SURFACE TOLERANT SYNTHETIC MEDIUM AL. PAINT
ALUMINUM PAINT
1. ASIAN PAINTS (I) LTD. APCODOR CF 640 ASIAN HR ALUMINUM HR SILICON ALUMINUM PAINT
PAINT (PC 300) (PC 189)
2. BARGER PAINT LTD. PROTECTOMASTIC FERROLOT HR BARGER HEAT RISISTANT
ALUMINUM PANT SILICON ALUMINUM PAINT
3. AMERON/ GODDLASS AMERLOCK 400 AMERCOAT 878
NEROLAC PAINTS LTD.
4. JENSON & NICHOSON PAINTS - FERROTECT FERRLOTECT SILICON HEAT
LTD. AND CHOKUGU JENSON SYNTHETIC RUBBER RESISTANCE 1000
NICHOLSON H/R ALUMINUM PAINT
4000
5. SHALIMAR PAINTS LTD. EPIPLUS 56 HEAT RESISTING LUSTOTHERM HIGH TEMP
LUSTROL ALUMINUM ALUMINUM PAINT
6. SIGMA COATING SIGMA ETPC ALUMINUM HIGH TEMPERATURE AROSTA FINISH HR
RESISTANT EPOXY
SUSTEM UPTO 200° C
4062
7. CDC CARBOLINE LTD. CARBOMASTIC-15 CARBOLINE 1248 CARBOLINE 4674
8. PRIMER PRODUCTS LTD. HB EPOXY MATIC 150B/
150A
9. CORAMANDEL PAINTS - SILVOTOL HR CPC SILICONE HR ALUMINUM
CHEMICALS ALUMINUM PAINT PAINT
10. ANUPAM ENTERPRISES ANUMASTIC-102 - ANUPAM HEAT GUARD
269 of 911
MECON LIMITED STANDARD TECHNICAL SPECIFICATION OF REPAIR OF
DELHI PIPELINE CORROSION COATING
REV 0, EDITION - 1
FOR
REPAIR OF PIPELINE CORROSION COATING
TECHNICAL SPECIFICATION NO.:MEC/S/05/28/08
MECON LIMITED
DELHI 110 092

270 of 911
REV 0, EDITION - 1
AMENDMENT STATUS

271 of 911
REV 0, EDITION - 1
CONTENTS
SL.NO. DESCRIPTION
1. SCOPE
2. MATERIAL AND EQUIPMENT
3. APPLICATION PROCEDURE
4. INSPECTION/ TEST
5. HOLIDAY INSPECTION
6. DOCUMENTATION
272 of 911

1.0 SCOPE :
This specification covers the minimum requirement of material and equipment,

installation procedure and inspection of repair of damaged polyethylene coatings on
steel pipes.
1.1 The repair shall be carried out using repair patch made of radiation cross linked
Polyolefin backing, coated on the inside with semi-crystalline thermoplastic Adhesive
and filler mastic
1.2 The repair patch shall have thermal indicators to ensure correct heat is being applied
during application.
2.0 MATERIAL AND EQUIPMENT
2.1 CONTRACTOR shall supply all ,equipment and manpower required for a skilful and
adequate application in the field in accordance with the specification.
2.2 The repair material shall be :
• Repair patch shall be cross linked polyolefin with semi-crystalline thermoplastic

adhesive (PERP 80 patch make of Covalence Raychem or equivalent).
• Filler mastic : PERPFILLER of make Covalence Raychem or equivalent.
• PERP melt stick of make Covalence Raychem or equivalent.
• Certified by DIN to meet the requirement of EN12068 stress class CHT 80.
2.3 The material shall not be older than their period of validity at the time of Application by
CONTRACTOR. Deteriorated/decomposed materials shall not be used.
2.4 Material shall be stored in sheltered storages in the manufacturer's original packing and
away from direct sunlight and in accordance with manufacturer's recommendations.
3.0 APPLICATION PROCEDURE
The application procedure to be followed for Holiday type of damage shall be in

accordance with manufacturer’s instructions and minimum requirements specified
below whichever is more stringent.
Preparation : Remove coating from damaged area with knife, scraper or power brush.
Scrap off the damaged area and adjacent coating to remove oil, grease, ruse dirt and
moisture.
273 of 911

Preheating : Preheat the exposed bare metal surface to about 80°C and adjacent pipe
coating to about 60°C with a torch moved back and forth over the surface.
Application of the Filler : Plastic filler shall be applied to all exposed metal surface. The
mastic is heated and smoothed down with a paint scraper to cover all bare metal in a
manner such that all entrapped air is removed.
Application of repair tape : Cut a patch from the tape in a manner such that it extends
50 mm beyond the damaged area, position it over the damaged area, heat until the
temperature sensitive paint on the outside of the patch changes colour. It shall be
smoothed down to confirm with the contour of lap, and shall be freed of any air
bubbles or wrinkles.
For cosmetic type of defects such as minor gauging tearing, scratches which do not
indicate holiday during holiday inspection, following procedure shall be adopted :
The defect area shall be roughened to remove loose polyethylene coating, oil grease,
dirt etc.
This shall be followed by application of repair patch as described above.
4.0 INSPECTION, TEST
A visual inspection shall be carried out for the following:
- Mastic extrusion on ends of the patch shall be examined.

- There shall be no sign of punctures or pin holes or bend failure. The external
appearance of the patch shall be smooth, free from dimples, air entrapment or
void formation.
- The entire repair patch shall have changed colour uniformly.
5.0 HOLIDAY INSPECTION
- The holiday detector used shall be checked and calibrated easily with an
accurate D.C. Voltmeter. The detector electrode shall be in direct contact with
the surface of coating to be inspected.
- The entire surface of the repaired section shall be inspected by means of a full
circle holiday detector approved by company set to a DC Voltage of at least 25
KV. Inspection of repaired patch shall be conducted only after it has cooled
below 50°C.
- No repaired point shall be covered or lowered in the trench until it has been
274 of 911

- Procedure qualification shall be carried out for repair patch. The value for peel
strength to pipe surface and to factory coating carried out as per EN 12068
shall be 0.5 N/mm minimum at 60°C.
6.0 DOCUMENTATION
6.1 Prior to procurement of coating repair materials, Contractor shall furnish four copies of,
but not limited to, the following for qualification of the Manufacturer and material :
i) Complete descriptive technical catalogs describing the materials offered along

with samples of repair coating materials, its properties and installation
instruction as applicable specifically to the project.
ii) Test certificate and results of previously conducted tests from independent
inspection agency.
iii) Reference list of previous supplies of the similar material indicating the project
details such as diameter, quantity, service conditions, year of supply, project
name, contact person and feedback on performance.
Once the Company’s approval has been given, any change in material or Manufacturer
shall be notified to Company, whose approval in writing of all changes shall be
obtained before the materials are manufactured.
6.2 Prior to shipment of materials from the Manufacturer’s works. Contractor shall furnish
six copies of the following :
i) Test Certificates for each batch of materials.

ii) Specific installation instruction with pictorial illustrations.
iii) Specific storage and handling instructions.
6.3 All documents shall be in English Language only.
275 of 911
MECON LIMITED STANDARD TECHNICAL SPECIFICATION OF PIPELINE
DELHI MARKERS
REV 0, EDITION - 1
FOR
PIPELINE MARKERS
MECON LIMITED
DELHI 110 092

276 of 911
DELHI MARKERS
REV 0, EDITION - 1
CONTENTS
SL.NO. DESCRIPTION
1.0 SCOPE
2.0 REFERENCE CODES AND DRAWINGS
3.0 GENERAL
4.0 AERIAL MARKERS
5.0 KILOMETRE MARKERS
6.0 PIPELINE WARNING SIGN
7.0 ROW BOUNDARY MARKERS
8.0 DIRECTION MARKERS
9.0 NAVIGABLE WATERWAY PIPELINE CROSSING WARNING SIGN
REFERENCE DRAWINGS
MECON STANDARD DRAWINGS
MEC/TYP/05/21/10/001 : TYPICAL ROW BOUNDARY

MARKER
MEC/TYP/05/21/10/002 : K.M. POST
MEC/TYP/05/21/10/003 : PIPELINE WARNING SIGN
MEC/TYP/05/21/10/004 : NAVIGABLE WATERWAY PIPELINE
CROSSING WARNING SIGN
MEC/TYP/05/21/10/005 : AERIAL MARKER
MEC/TYP/05/21/10/006 : DIRECTION MARKER
277 of 911
DELHI MARKERS
REV 0, EDITION - 1
AMENDMENT STATUS

278 of 911
DELHI MARKERS

1.0 SCOPE
1.1 This specification covers the minimum requirements for supply, fabrication and
erection of pipeline markers to be installed by CONTRACTOR at various locations along
the route of a cross-country pipeline.
2.0 REFERENCE CODES
Reference has been made in this specification to the latest revision of the following
code :
API RP 1109 : Recommended practice for marking liquid petroleum pipeline

facilities.
3.0 GENERAL
3.1 CONTRACTOR shall supply, fabricate and install the pipeline markers along the pipeline
route. The locations of markers as indicated in the approved drawings shall be treated
for guidance purposes only and the exact location of the markers shall be based on AS
BUILT drainage and as directed by COMPANY.
3.2 The pipeline markers shall be fabricated, painted (Painting shall be in accordance with
the MECON Standard Specification for Shop & Field Painting) and installed in
accordance with the MECON standard drawings included herein. Before start of
fabrication of the markers, CONTRACTOR shall prepare and submit for COMPANY's
approval the detailed scheme for the marker plates as applicable for the project.
3.3 The pipeline markers shall be installed, as far as possible, at locations such that to
cause no hindrance to the regular use of the land or to the traffic.
4.0 AERIAL MARKERS
Aerial markers shall in general be installed along the pipeline at every five (5)
kilometres intervals and at places specified by COMPANY. Refer MECON Standard
Drawing No. MEC/TYP/05/21/10/005 for details.
5.0 KILOMETRE MARKERS
Kilometre markers shall in general be installed along the pipeline between the aerial
markers at every one (1) kilometre interval. Markers shall indicate cumulative distance
in kilometres from the reference station, as directed by COMPANY. A kilometre marker
is not required if the relative length between its location and any pipeline warning sign
is less than 200 metres. Refer MECON Standard Drawing No. MEC/TYP/05/21/10/002
for details.
279 of 911
DELHI MARKERS

6.0 PIPELINE WARNING SIGN
Pipeline Warning Sign shall in general be installed at
• National and State Highway Crossings (2 Nos.)

• Other Road Crossings (1 No.)
• Railway Crossings (2 Nos.)
• Minor Water Crossings (less than 15m width) (1 No.)
• Minor Water Crossings (above 15m width) (2 Nos.)
• Major Water Crossings (2 Nos.)
• Valve Station (1 No.)
• And at any other location as shown in the approved drawings and as directed
by the COMPANY.
Pipeline Warning Sign shall identify the existence of the pipeline and display the name
of the COMPANY, with an emergency telephone number, as shown in MECON Standard
Drawing No. MEC/TYP/05/21/10/003 for details.
7.0 ROW BOUNDARY MARKERS
Right-of-Way boundary markers shall be fabricated and installed as per the drawings at
every 250 metres interval along the entire pipeline route. These shall be installed on
either side of the pipeline alignment to define the ROW boundary limits. These shall
also be installed at pipeline turning points to maintain the continuity of the ROW limits.
Refer MECON Standard Drawing No. MEC/TYP/05/21/10/001 for details.
8.0 DIRECTION MARKERS
Direction markers as shown in MECON Standard Drawing No. MEC/TYP/05/21/10/006

shall be installed to identify the significant turning points of the pipeline during aerial
traverse. One direction marker shall be installed at each turning point, in addition, two
more direction markers shall be installed along the pipeline alignment, one on either
side of the turning point at 200m from the turning point.
9.0 SPECIAL MARKERS
As directed by Company, Special Marker shall be installed at Location where the

following changes takes place :
- Change in pipeline diameter and wall thickness.

- Change in type of pipe.
- Change in class locations for pipeline conveying gas.
The above data may be provided on other types of marker (except RoU boundary
marker), if the relative distance between the two does not exceed 100 m.
280 of 911
DELHI MARKERS

10.0 NAVIGABLE WATERWAY PIPELINE CROSSING WARNING SIGN
The Navigable Waterway Pipeline Crossing Warning Sign shall be fabricated in

accordance with MECON Standard Drawing No. MEC/TYP/05/21/10/004. Such Warning
Sign shall be installed one on each bank of navigable water courses at the pipeline
crossing location, in lieu of the Pipeline Warning Sign described in clause 6.0 of this
specification.
281 of 911
MECON LIMITED STANDARD TECHNICAL SPECIFICATION OF FLUSHING
DELHI AND TESTING OF PIPING SYSTEMS
REV 0, EDITION - 1
FOR
FLUSHING AND TESTING OF
PIPING SYSTEMS
MECON LIMITED
DELHI 110 092

282 of 911
REV 0, EDITION - 1
CONTENTS
SL. NO. DESCRIPTION
1.0 SCOPE
2.0 REFERENCES
3.0 INSPECTION
4.0 FLUSHING
5.0 TESTING
5.1 EXTENT OF TESTING
5.2 GENERAL REQUIREMENT/TEST PREPARATION FOR TESTING
5.3 TESTING MEDIA, TEST PRESSURE AND TEST PRESSURE GAUGES.
5.4 TESTING PROCEDURE
5.5 COMPLETION OF TESTING
5.6 TEST RECORDS
283 of 911
REV 0, EDITION - 1
AMENDMENT STATUS

284 of 911
MECON LIMITED STANDARD TECHNICAL SPECIFICATION OF COLD
DELHI INSULATION OF VESSELS, PIPING AND EQUIPMENT

1.0 SCOPE
This specification covers the general requirements for Inspection, flushing and testing
of piping systems. However testing of steam lines falling under IBR shall also be
governed by Indian Boiler Regulations.
Flushing and testing of all piping system shall be witnessed by the Consultant
Representative / Engineer-in- Charge.
2.0 REFERENCE
ASME B31.3-2004 : Process Piping
IBR : Indian Boiler Regulations
3.0 INSPECTION
During various stage and after completion fabrication and erection, the piping system
shall be inspected by the Consultant Representative / Engineer- in - Charge to ensure
that :
- Proper piping material has been used.

- Piping has been erected as per drawings and the instruction of the engineer- in
charge.
- All supports have been installed correctly.
- Test preparations mentioned in this specification have been carried out.
4.0 FLUSHING
Flushing of all lines shall be done before pressure testing.
Flushing shall be done by ‘fresh potable water’ or ‘dry compressed air, wherever water
flushing is not desirable’ to clean the pipe of all dirt, debris or loose foreign materials.
Required pressure of water, flushing shall meet the fire hydrant pressure or utility water
pressure. For air flushing the line, system will be pressurised by compressed air at the
required pressure which shall be 50 psi maximum. The pressure shall then be released
by quick opening of a valve, already in the line for this purpose. This procedure shall be
repeated as many times as required till the inside of the pipe is fully cleaned.
In line instruments like control valves, orifice plates, rotameters, safety valves and
other instruments like thermowells which may interfere with flushing shall not be
included in the flushing circuit.
285 of 911

From all permanent strainers the screens/meshes shall be removed before flushing.
Screens/meshes shall be reinstalled after flushing but before testing.
During flushing temporary strainers shall be retained. These shall be removed, cleaned
and reinstalled after flushing, but, before testing.
In case an equipment such as column, vessel, exchanger etc. forms part of a piping
circuit during flushing, this shall be done with the approval of Engineer- in - Charge.
However equipment thus included in the circuit, shall be completely cleaned and dried
with comprss4ed air, after flushing is completed.
During flushing discharged water/air shall be drained at the place directed the
Engineer- in - Charge. If necessary, proper temporary drainage shall be provided by
the contractor.
Care shall be taken during flushing so as not to damage/spoil work of other agencies.
Precautions shall also be taken to prevent entry of water/foreign matter into equipment,
electric motors, instruments, electrical installations etc. in the vicinity of lines being
flushed.
The contractor shall carry out all the activities required before, during and after the
flushing operation, arising because of flushing requirements, such as but not limited to
the following.
Dropping of valves, specials, distance pieces, online instruments and any other piping
part before flushing. The flanges to disengaged for this purpose shall be envisaged by
the contractor and approved by the Engineer-in-Charge. These flanges shall be
provided with temporary gaskets at the time of flushing.
After flushing is completed and approved, the valve, distance pieces, piping specials
etc. shall be re-installed by the contractor with permanent gaskets. However, flanges of
equipment nozzles and other places where isolation is required during testing, only
temporary gaskets shall be provided.
Records in triplicate shall be prepared and submitted by the Contractor for each piping
system for the flushing done in the proforma provided / approved by EIC.
5.0 TESTING
Pressure testing, in general shall be as per clause 345 of ASME B31.3, unless
otherwise specified, herein. Lines carrying highly hazardous / poisonous fluids must
have a sensitive leak test. For IBR lines, ‘IBR Regulations’ shall also be followed.
286 of 911

5.1 Extent of testing
With the exclusion of instrumentation. piping system fabricated or assembled in the

field shall be tested irrespective of whether or not they have been pressure tested prior
to site welding of fabrication.
To facilitate the testing of piping systems, vessels and other equipments may be
included in the system with the prior approval of Engineer-in-charge, if the test
pressure specified is equal to or less than that for the vessels and other equipments.
Pumps, compressors and other votary equipments shall not be subjected to field test
pressures.
Lines which are directly open to atmosphere such as vents, drains, safety valves,
discharge need not be tested, but all joints shall be visually inspected wherever
necessary such lines shall be tested by continuous flow of fluid to eliminate the
possibility of blockage. However, such lines if provided with block valve shall be
pressure tested upto the first block valve.
Seats of all vales shall not be subjected to a pressure in excess of the maximum cold
welding pressure of the valve. Test pressure applied to vales shall not be grater than
the manufacturer is recommendation nor less than that required by the applicable
code. Where desirable set pressure is less than test pressure, test shall be made
through an open valve.
Instruments in the system to be tested, shall be excluded from the test by isolation or
removal, unless approved otherwise by the Engineer-in-charge. Restrictions which
interfere with filling, venting and drawing such as orifice plates etc. shall not be installed
unless testing is complete.
Control valves shall not be included in the test system. Where by-passes are provided
test shall be performed through the by-pass end/or necessary spool shall be used in
place of the control valve.
Pressure gauges which are part of the finished system, but cannot withstand test
pressure shall not be installed until the system has been tested. Where piping systems
to be tested are directly connected at the battery limits to piping for which the
responsibility tests with other agencies, the piping to be tested shall be isolated from
such piping by physical disconnection such as valves or blinds.
5.2 General Requirement/Test preparation for Testing
Test shall be carried out with permanent gaskets installed unless specified otherwise or
287 of 911

instructed by the Engineer-in- charge.
No pressure test shall be carried out against close valve unless approved by the
Engineer-in-charge.
The Engineer-in-charge shall be notified in advance by the contractor, of the testing

sequence and programme, to enable him to be present for witnessing the test. The
contractor shall be fully responsible for making arrangements with the local boiler
inspector to witness the tests for steam lines falling under IBR. IBR certificates for
these tests shall be obtained in the relevant IBR forms and furnished to the
Engineer-in-charge. Before testing, all piping shall be cleaned by flushing to make it
free from dist loose scale, debris and other loose foreign materials.
All piping systems to be hydrostatically tested shall be vented at the high points and
the systems purged of air before the test pressure is applied.
Wherever in the line any void is existing due to any reasons, for absence of control
valve, safety valve, check valves etc. it shall be filled with temporary spools.
All joints welded, screwed or flanged shall be left exposed for examination during the
test. Before pressuring the lines, each weld joint shall be cleaned by wire brush to free
it from rest and any other foreign matter.
Where a system is to be isolated of a pair of companion flanges, a blank shall be

inserted between the companion flanges. Minimum thickness of the blank shall be
designed in accordance with applicable design code.
Open ends of piping system where blanks cannot be used, such as pumps,
compressors, turbines or wherever equipment or pipe spool have been receivered or
disconnected prior to hydrostatic testing, shall be blinded – off by using standard blind
flanges of same rating as the piping system being tested.
Pressure gauges used in testing shall be installed as close as possible to the lowest
point in the piping system to be tested, to avoid overstressing of any of the lower
portion of the system. For longer lines and vertical lines, two or more pressure gauges
shall be installed at locations selected by the Engineer-in-charge. For lines containing
check valves any of the following alternatives shall be adopted for pressure testing.
Wherever possible pressurise up-stream side of valve.
Replace the valve by a temporary spool and re-install the valve after testing.
Provide blind on valve flanges and test the upstream and downstream of the line
separately and remove the blind after testing. All these flanges, temporary gaskets
shall be provided during testing and shall be replaced by permanent gaskets
288 of 911

subsequently. For check valves in lines 1-1/2" and below, flapper or seat shall be
removed during testing (if possible). After completion of testing the flopper/ seat shall
be refitted.
Pipelines when hydrostatically tested shall be provided with additional temporary

supports during testing as directed by Engineer-in-charge.
Piping which is spring or counter – weight supported shall be temporarily supported,

where the weight of the fluid would overload the support. Retaining pins for spring
supports shall be removed only after testing is completed and test fluid is completely
drained.
When testing any piping system, air or steam of approximately 2 kg/cm2 (g) may be
used as preliminary test to detect missing gaskets etc. as this avoids the necessity of
purging the gas to make repairs. However, this method may not be used for this
purpose, if the steam temperature is more than the design temp. of the line.
For jacketed pipes testing of core pipes shall be done on individual pieces where the
pipe is continuously packed, before it is jacketed. The outer jacket shall be tested
separately as a system for piping with discontinuous jacketing, the core pipe and the
jacket shall be tested as separate system.
5.3 Testing Modes, Test pressure and Test Pressure Gauges
5.3.1 Testing Modes
In general all pressure test shall be hydrostatic using iron free water, which is clean
and free of silt. Maximum clorine content in water for hydrostatic testing for MS piping
shall be 15-20 ppm. Air shall be used for testing only if water would cause corrosion of
the system or overloading of supports etc. in special cases as directed by
Engineer-in-charge.
If operating fluid in the line is much lighter than testing fluid, the additional weight of
testing fluid may render piping supports (as designed) inadequate. This will call for
additional temporary supports. The typical examples are flare and vapor lines. It is
preferable that hydrostatic testing is avoided in such systems and instead pneumatic
testing may be specified.
Where air/water tests are undesirable substitute fluid such as gas, oil, methanol etc.
shall be used as the testing medium, with due consideration to the hazards involved.
These test fluids shall be specified in the line list given to the contractor.
5.3.2 Test Pressure
289 of 911

The hydrostatic/pneumatic test pressure shall be as indicated in the line list or as per
the instruction of Engineer-in-charge.
The selection of the piping system for one individual test shall be based on the
following: -
Test pressure required as per line list.
Maximum allowable pressure for the material of construction of piping depending upon
the above requirements and based on construction progress, maximum length of
piping shall be included in each test.
5.3.3 Test Pressure Gauge
All gauge used for field testing shall have suitable range so that the test pressure of the
various system falls in 35% to 65% of gauge scale range. Pressure gage shall be
minimum of 150 mm. Size of Bourdon shall not be less than 75% of nominal diameter
of dial range. Gauge shall be of a good quality and in first class working condition.
Prior to the start of any test or periodically during the field test programmes, all test
gauges shall be calibrated using a standard dead weight gauge tester or other suitable
approved testing apparatus. Any gauge having an incorrect zero reading or error of
more than ± 2% of full scale range shall be discarded. The Engineer-in-charge shall
check the accuracy of master pressure gauge used for calibration.
5.4 Testing Pressure
5.4.1 Hydrostatic Test
All vents and other connections used as vents shall be kept open while filling the line
with test fluid for complete removal of air. For pressurising and depressurising the
system, temporary isolating valves shall be provided if valves, vents, drains do not exist
in the system.
Pressure shall be applied only after the system/line is ready and approved by the
Engineer-in-charge.
Pressure shall be applied by means of a suitable test pump or other pressure source
which shall be isolated from the system as the desired test pressure is reached and
stabilised in the system.
A pressure gauge shall be provided at the pump discharge for guiding the system to
the required pressure.
290 of 911

The pump shall be attended constantly during the test by an authorised person. The
pump shall be isolated from the system wherever the pump is to be left unattended.
Test pressure shall be maintained for a sufficient length of time to permit through
inspection of all joints for leakage or signs of failure. Any joint found leaking during a
pressure test, shall be re-tested to the specified pressure after repair. Test period shall
be maintained for a minimum of four hours.
The pump and the piping system to be tested are to be provided with separate
pressure indicating test gauges. There gauges are to be checked by the standard test
gauge before each pressure test.
Care shall be taken to avoid increase in the pressure due to atmospheric variation
during the test.
5.4.2 Air Test
When testing with air, pressure shall be supplied by means of a compressor. The
compressor shall be portable type with a receiver after cooler & oil separator.
Piping to be tested by air shall have joints covered with a soap and water solution so
that the joints can be examined for leaks.
All other activities shall be same as per hydro testing procedure (specified above).
5.5 Completion of Testing
After the hydrostatic test has been completed, pressure shall be released in a manner
and at a rate so as not to endanger personnel or damage equipments.
All vents and drains shall be opened before the system is to be drained and shall
remain open till all draining is complete, so as to prevent formation of vacuum in the
system. After draining lines/systems shall be dried by air.
After testing is completed the test blinds shall be removed and equipment/piping
isolated during testing shall be connected using the specified gaskets, bolts and nuts.
These connections shall be checked for tightness in subsequent pneumatic tests to be
carried out by the contractor for complete loop/circuit including equipments (except
rotary equipments).
Pressure tests shall be considered complete only after approved by the

Engineer-in-charge. Defects, if any, noticed during testing shall be rectified
immediately and retesting of the system/line shall be done by the contractor at his cost.
291 of 911

5.6 Test Records
Records in triplicate shall be prepared and submitted by the contractor for each piping
system, for the pressure test done in the proforma provided / approved by the
Engineer-in-charge.
292 of 911
MECON LIMITED STANDARD TECHNICAL SPECIFICATION OF CASING
DELHI INSULATORS AND END SEALS
REV 0, EDITION - 1
FOR
CASING INSULATORS
AND END SEALS
MECON LIMITED
DELHI 110 092

293 of 911
REV 0, EDITION - 1
CONTENTS
PART-A CASING INSULATIONS
1.0 SCOPE
2.0 FUNCTION
3.0 DESIGN
4.0 MATERIAL
PART-B CASING END-SEALS
1.0 SCOPE
2.0 FUNCTION
3.0 DESIGN
4.0 MATERIAL
PART-C SUPPLEMTARY REQUIREMENTS
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REV 0, EDITION - 1
AMENDMENT STATUS

295 of 911
PART-A CASING INSULATORS
1.0 SCOPE
This specification covers the minimum requirements of design, material,

manufacture and supply of casing insulators intended to be used for cased
pipeline crossings.
2.0 FUNCTION
Pipeline insulators shall be used to support the carrier pipe inside the casing
pipe and electrically isolate the carrier pipe from the casing pipe at the cased
crossings.
The casing insulators shall:
- Resist cold flow and will not soften at design temperature.
- Resist corrosion
- Resist mechanical damage while being pulled into the casing.
- Have high electrical insulating value and low water absorption, thus
preventing leakage and maintain electrical isolation between carrier
and casing pipes
- Have high compressive strength in order to assure a permanent

support to the carrier pipe.
3.0 DESIGN
Casing Insulator shall be made of HDPE, modular type, offering a high impact
strength and low coefficient of friction. Each Casing Insulator element shall
represent a flexible section containing a toothed male butt strap at one end
and an approximately toothed male slot on the other end. No metallic parts or
attachments would be considered in the casing insulator element assembly.
The design of casing insulator should allow for onsite adjustments for any
variances within the allowable O.D. range of pipeline and should grip the
firmly without any chances of horizontal movement or breakage of the
insulator rings during installation. The insulator rings should be fastened on to
the carrier pipe with the appropriate tool to be provided by the casing
insulator manufacturer.
The number of segments shall be two for pipe diameters up to 12”

(generally). For larger diameters, the number of segments may be more than
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two, but their number shall be kept minimum.

The skid height shall be such that it is slightly less than the value obtained by
following formula.
Manufacturer shall obtain prior approval from COMPANY on casing insulators

drawings/designs.
4.0 MATERIAL
Casing insulators shall be made of injection moulded high density

polyethylene or other material equivalent or superior as approved by
COMPANY and shall meet the following specifications:
Description Value Standard

Yield Strength >22 N/mm2 UNI EN ISO 527-2
Tensile Strength >16 N/mm2 UNI EN ISO 527-2
Elongation at Break >400% UNI EN ISO 527-2
Hardness shore D 64 ASTM D 2240
Dielectric Strength >37 kV/mm ---
UVL Stabilization Good ---
Moisture Vapor Very low ---
Transmission Rate (MVTR)
Density at 23 C 960 kg/m3 ISO 1183/A
Melting Point 136 C ISO 11357-3
Manufacturer shall furnish material test certificates of the components used in

the assembly of casing insulations as per the requirements of clause 4.0 of
this specification.
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PART-B CASING END-SEALS
1.0 SCOPE
This specification covers the minimum requirements of design, material,

fabrication and supply of casing end-seals intended to be used for pipeline
cased crossings.
2.0 FUNCTION
Casing end seals are intended to be used for sealing the annular space
between casing pipe and carrier pipe at casing ends so as to prevent ingress
of moisture and water.
3.0 DESIGN
The seal shall be suitable for the casing and carrier pipe diameters as
applicable for each case.
The casing end-seal shall be flexible to cater for the expansion and
contraction of carrier and casing pipes and shall be able to tolerate both
angular and concentric misalignment of casing pipe without loss of sealing
efficiency.
The design of the casing end-seal shall permit easy installation of the seal to
the cased pipeline crossing.
It shall provide moisture-proof seals when installed for the entire anticipated
life of the buried pipeline.
Manufacturer shall obtain prior approval from COMPANY on casing end seals
design/drawings.
4.0 MATERIAL
The casing end-seal shall be made of head shrink high density radiation
cross linked polyethylene with an adhesive having a melt point suitable for the
pipeline service temperature and ambient temperatures foreseen during
construction. End-seals material shall be resistant to heat, cold, vibration,
impact, abrasion, corrosive fluids, disbonding, organic and bio-deterioration.
Manufacturer shall confirm compatibility of end seals with carrier pipe coating.
Casing end seals shall meet following minimum property requirements:
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Property Minimum Value Test Method
a) Backing (Sleeve and closure patch)
Tensile strength 2200 psi ASTM D-638
Ultimate Elongation 400% ASTM D-638
Heat Shock No visual cracks, ASTM D-2671

flow or drips
(at 225°C, 4 hours)
b) Adhesive
Ring and Ball softening 90°C ASTM E-28

point
Lap Shear 60°C - 25 psi ASTM D-1002

23°C - 250 psi
(2 inch/min)
c) System (as applied)
Peel strength 5 pli ASTM

(To casing and carrier (10 inch/min.) D-1000
pipe and closure patch)
Manufacturer shall furnish material test certificates of the components used in

the assembly of casing end-seals as per the requirements of this specification.
PART-C SUPPLEMENTARY REQUIREMENTS
1.0 The Manufacturer shall replaces, at no extra cost, any material not
conforming to the material and performance requirements of this
specification.
2.0 Manufacturer shall submit detailed specification of the materials used in the
assemblies, along with instructions for handling, use and installation of the
material for COMPANY approval prior to procurement.
3.0 Manufacturer shall submit all the documents, test reports, records and other
information in six copies to the COMPANY for record after approval as per
clause 2.0 above.
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MECON LIMITED STANDARD TECHNICAL SPECIFICATION OF FIELD JOINT
DELHI COATING (ONSHORE PIPELINES)
REV 0, EDITION - 1
FOR
FIELD JOINT COATING
(ONSHORE PIPELINES)

MEC/S/05/28/13
MECON LIMITED
DELHI 110 092

300 of 911
REV 0, EDITION - 1
CONTENTS
SL. NO. DESCRIPTION
1.0 SCOPE
2.0 REFERENCE DOCUMENTS
3.0 MATERIAL AND EQUIPMENT
5.0 INSPECTION
6.0 TESTING
7.0 REPAIRS
8.0 DOCUMENTATION
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REV 0, EDITION - 1
AMENDMENT STATUS

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1.0 SCOPE
This specification covers the minimum requirements of materials, equipment and

installation of field joint anti-corrosion coating of underground onshore factory coated
pipelines with either three layer polyethylene or fusion bonded epoxy (FBE) coating by
heat shrink wraparound sleeves conforming to DIN EN 12068 – “Cathodic Protection –
External Organic Coatings for the Corrosion Protection of Buried or Immersed Steel
Pipelines used in Conjunction with Cathodic Protection – Tapes and Shrinkable
Materials” and the requirements of this specification. Unless modified / replaced by
this specification, all requirements of DIN EN 12068 shall remain fully applicable and
complied with.
This specification shall be read in conjunction with the conditions of all specifications
and documents included in the Contract between Company and Contractor. Unless
specified otherwise, all sections of this specification shall apply to all specifications
referred in this specification.
Reference has been made to the latest edition (edition enforce at the time of floating
the enquiry) of the following standards, codes and specifications:
a) ASTM D-149 : Standard Test Methods of Dielectric Breakdown voltage

and Dielectric Strength of solid electrical insulating
materials at commercial frequencies.
b) ASTM D-257 : Standard Test Methods for D-C Resistance or

conductance of insulating materials.
c) ASTM D-570 : Standard Method of Test for Water Absorption of

Plastics.
d) ISO 8502-3 : Preparation of Steel Stubstrates before Application of

Paints and Related Products – Part-3 – Assessment of
Dust on Steel Surfaces Prepared for Painting (Pressure
Sensitive Tape Method).
e) ISO:8503-1 : Part-1 : Specification and definitions for ISO surface

profile comparator for the assessment of abrasive blast
cleaned surfaces.
f) ISO:8503-4 : Part-4 : Methods for calibration of ISO surface profile

comparator and for the determination of surface profile –
Stylus instrument procedure.
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g) SIS-055900 : Pictorial surface Preparation Standard for Painting Steel

Surfaces.
h) SSPC-SP 1 : Steel Structure Painting Council.
In case of conflict between the requirements of this specification and that of above
referred documents, the requirements of this specification shall govern.
The Contractor shall be familiar with the requirements of these documents and shall
make them readily available at the site to all personnel concerned with carrying out the
works specified in this specification.
3.0 MATERIALS AND EQUIPMENT
3.1 Contractor shall supply joint coating materials, all equipment and manpower required
for a skillful and adequate application of coating in the field in accordance with the
specifications.
Contractor shall submit and demonstrate to Company proposed materials and works
procedures for applying field coating and repair procedures for same. These
proposed procedures and all materials, equipment and tools used in the work shall
be subject to Company’s approval.
3.2 Field Joint Corrosion Coating Material
Field joint anti-corrosion coating material shall be either heat shtrinktable wraparound
sleeve or cold applied tape suitable for a maximum operating temperature of (+) 65°C
(Tmax) and shall conform to designation EN 12068 – C HT 60 UV. In addition the field
joint anti-corrosion coating shall comply the requirements specified in para 3.3 of this
specification.
3.2.1 Heat Shrinkable Wraparound Sleeve
Heat shrinkable wrap around sleeve shall consist of radiation cross-linked thermally
stabilised, ultraviolet resistant semi-rigid polyolefin backing with a uniform thickness of
high shear strength thermoplastic/copolymer hot melt adhesive. The joint coating
system may consist of a solvent free epoxy primer applied to the pipe surface prior to
sleeve application. The backing shall be coated with thermochrome paint which will
change colour when the desired heat during shrinking is attained. The wraparound
sleeve shall be supplied in pre-cut sizes to suit the diameter and the requirements of
overlap.
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The total thickness of heat shrinkable wraparound sleeve in the as applied condition
shall be as follows :
Pipe Size Thickness (mm)

(Specified Outside Diameter) On Pipe Body On Weld Bead
(Min.) (Min.)
4” (114.3 mm) to 10” (273.0 mm) 2.0 mm 1.6 mm
12” (323.9 mm) to 18” (457.2 mm) 2.2 mm 1.8 mm
20” (508.0 mm) to 30” (762.0 mm) 2.5 mm 2.0 mm
≥ 32” (812.8 mm) 3.0 mm 2.5 mm
The heat shrink wraparound sleeve shall have the required adhesive properties when
applied on various commercial pipe-coating materials. The pre-heat and application
temperatures required for the application of the shrink sleeve shall not cause loss of
functional properties of the pipe coating.
Heat shrinkable wraparound field joint coating system manufactured by M/s Covalence
and M/s Canusa are acceptable for the supply of field joint coating materials. The
Contractor shall propose the specific grade of field joint coating system meeting the
requirements of this specification from these manufacturers. In case the Contractor
proposes to supply heat shrinkable wraparound sleeve from any other manufacturer,
then the Contractor shall propose only those coating systems that have been
previously used for pipelines of size same or higher than the size indicated in tender,
for a length of 50 km and above in a single project for similar operating conditions.
3.2.2 Cold Applied Tapes
Cold applied tape system shall comprise of primer, an inner wrap and an outer wrap.
The inner and outer wraps shall be asymmetric 3-ply tape with co-extruded
polyethylene carrier film and butyl rubber adhesive layers on both sides. The inner
layer of butyl rubber adhesive of inner wrap shall have a thickness of min. 1.0 mm. The
inner and outer wraps are to be spirally wrapped with 55% overlap, equivalent to two
layers each providing a total minimum thickness of 3.0 mm on the pipe body and 2.5
mm on the weld.
The Contractor shall propose only those cold applied tape coating systems that have
been previously used in pipelines of size 16" and above and a length of 50 km and
above in a single project for similar operating conditions.
3.3 Functional Requirements of Field Joint Coating
3.3.1 Properties of the PE backing and the as applied joint corrosion coating shall be as
follows:
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Sl. Property Unit Requirement Test

No. Method
i) Tensile Strength @+25°C N/mm2 ≥12 DIN EN
12068
ii) Ultimate Elongation % @+ % ≥250 DIN EN
25°C 12068
iii) Dielectric withstand KV with kv ≥30 ASTM D
1000 Volts/sec 149
iv) Water absorption % ≤0.05 ASTM D
@+ 25°C for 24 hours 570
v) Volume Resistivity @+25°C Ohm-cm ≥1015 ASTM D
257
vi) Resistance to thermal aging % Change in DIN 30672
at 100°C elongation ≤ 250
3.3.2 Functional Properties of Joint Coating System (As applied)
As applied field joint coating system shall comply the requirements of DIN EN 12068.
Table 1 and 2 corresponding to designation DIN EN 12068 – C HT 60 UV, except as
modified below :
a) Cathodic Disbondment Resistance at Tmax i.e. 60°Cshall be 20mm when

tested as per Annexure K of DIN EN 12068. Test shall be carried out at (+)
60°C.
b) Peel Strength shall be as follows :
Peel Strength Unit Requirement for Test

Mech Resistance Method as
Class C per DIN EN
(Minimum) 12068
Inner to Inner + @23°C N/mm 1.5
Outer to Inner @Tmax N/mm 0.3
Annexure-B
Outer to Outer @23°C N/mm 1.5
@Tmax N/mm 0.3
To Pipe Surface @23°C N/mm 3.5
@Tmax N/mm 1.0
Annexure-C
To Factory @23°C N/mm 3.5
Coating @Tmax N/mm 1.0
Notes
(Tmax shall be (+) 60°C)
Contractor shall obtain prior approval from Company regarding the manufacturer of the
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joint coating material. Complete technical details alongwith test certificates complying
with the requirements of clause 3.2.1 and 3.2.2 shall be submitted to Company for this
purpose. The Contractor shall furnish test certificates from an independent DIN
recognized / approved laboratory for all the properties required for the specified EN
designation of field joint coating and the requirements of this specification.
3.3 The materials shall not be older than their period of validity at the time of application by
CONTRACTOR. Deteriorated/ decomposed material shall be disposed of and replaced
by CONTRACTOR at his own expense.
CONTRACTOR shall ensure that the coating materials supplied by him are properly
packed and clearly marked with the following :
- Manufacturer’s name
- Material qualification
- Batch number
- Date of manufacturing and date of expiry.
3.4 CONTRACTOR shall ensure that the manufacturer has carried out all quality control
tests on each batch and manufacturer shall provide test certificates to certify that the
supplied materials meet the manufacturer’s specifications as indicated in the purchase
order and as approved by COMPANY. Certificates and data sheets certifying the
qualities of the coating materials shall be submitted by CONTRACTOR to COMPANY
prior to application. COMPANY reserves the right to have the materials tested by an
independent laboratory.
3.5 Materials shall be stored in sheltered storage in the manufacturer’s original packing
and away from direct sunlight and in accordance with manufacturer’s instructions.
3.6 CONTRACTOR shall provide and maintain mobile facilities which contains all
necessary equipment and its spares for cleaning, coating repairs, inspection and tests.
3.7 CONTRACTOR shall furnish sufficient number of the following equipment and the
required spares as a minimum for inspection and test purpose for each crew.
a) Fully automatic full circle adjustable holiday detector with a visible and audible
signal system for inspection of coatings.
b) Thickness gauge for measuring thickness.
c) Contact type temperature recording thermometer (Digital Pyrometer with flat
probe type contact).
d) Roughness profile measuring (Stylus) instrument
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4.1 General
4.1.1 The application procedure shall be in accordance with manufacturer’s instruction and
the minimum requirements specified below whichever are the most stringent and
shall be demonstrated to and approved by the Company. Manufacturer’s expert
shall supervise the application and shall be available at site upon request during
qualification of application procedure and during construction at Contractor’s cost.
4.1.2 Operators for coating application shall be given necessary instructions and training
before start of work, by the Contractor. To verify and qualify the application
procedures, all coating applied during the qualification test, shall be removed for
destructive testing until the requirements stated in sections “Inspection” and
“Testing” of this specification are met.
4.1.3 Oil, grease and salt shall be removed from steel surface by wiping with rags soaked
with suitable solvents such as naphtha or benzene. Kerosene shall not be used for
this purpose. Solvent cleaning procedure according to SSPC-SP1 shall be followed.
4.1.4 Each field joint shall be blast cleaned using a closed cycle blasting unit or an open
expendable blasting equipment. With the first equipment type, steel or chilled shot
and iron grit shall be used and Garnet material with the second one (in case the
authority having jurisdiction have no objection, the contractor may adopt sand
blasting instead of garnet material). During blast cleaning the pipe surface
temperature shall be simultaneously more than 5° and more than 3°C above ambient
Dew Point, while the ambient Relative Humidity shall not be greater than 85%. Prior
to surface cleaning the surface shall be completely dry. The surface shall be
cleaned to a grade Sa 2½ in accordance with Swedish Standard SIS-055900 with a
roughness profile of 50-70 microns. Surface roughness profile shall be measured
using an approved profile comparator in accordance with ISO 8503-1 and shall be
calibrated prior to the start of the work in accordance with ISO:8503-3 or ISO:8503-
4. The blast cleanliness shall be checked on every joint and the roughness profile
shall be checked 1 every 10 joints.
Dust grit or foreign matter shall be removed from the cleaned surface by an industrial
vacuum cleaner. The dust contamination allowed shall be of a rating max 2 as per
ISO:8502-3. The frequency of checking for dust contamination shall be 1 every 10
joints.
Blast cleaned field joint shall be coated within 2-4 hours according to the conditions
below :
- Relative Humidity (RH) > 80% - 2 Hours
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- Relative Humidity (RH) 70-80% - 3 Hours

- Relative Humidity (RH) < 70% - 4 Hours
Pipes delayed beyond this point or pipes showing any visible rust stain shall be blast
cleaned again.
4.1.5 The field joint surface shall be inspected immediately after blast cleaning and any
feature of the steel surface such as weld spatter, scabs, laminations or other
imperfections considered injurious to the coating integrity made visible during blast
cleaning shall be reported to the Company Representative and on permission from
Company Representative, such defects shall be removed by filing or grinding. Pipes
affected in this manner shall be then re-blast cleaned if the defective area is larger
than 50 mm in diameter.
4.1.6 The ends of existing pipe protective coating shall be inspected and chamfered.
Unbounded portions of the coating shall be removed and then suitably trimmed.
Portions where parent coating is removed shall be thoroughly cleaned as specified.
The adjacent chamfered areas of the line pipe coating shall be cleaned and abraded,
to expose a clean uniform fresh surface of uncontaminated factory applied coating.
4.1.7 All steel joint surfaces shall be thoroughly examined before the application of the
coating in order to ensure the surface are free of soil, grease, rust, mud, earth or any
other foreign matter. All these substances shall be removed before coating, to the
procedures herein described.
4.1.8 Protection coating shall be applied on the joints immediately after the completion of
cleaning operation.
4.2 Application of Heat Shrink Wraparound Sleeves
In addition to the general requirements stated above, following shall be taken into
account :
4.2.1 The wrap around sleeves shall be of a size such that a minimum overlap of 50mm is
ensured (after shrinking) on both sides of yard applied corrosion coating of the pipes.
In cases where carrier pipe is installed by direct boring/jacking, the overlap on the mill
coating for the leading edges of the joints shall be minimum 200mm. When this extra
overlap is achieved by providing an additional patch of heat shrink tape/wraparound, it
shall be applied in such a manner that the square edge of the patch on the joint
coating is in the direction opposite to the direction of boring/jacking.
4.2.2 Before centering the wraparound sleeve, the bare steel surface shall be preheated
with torch moved back and forth over the surface or by induction heating. The
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minimum preheat temperature shall be as recommended by manufacturer and shall

be checked by means of contact type temperature recording thermometer (Digital
Pyrometer with flat probe type contract) to check this, approved temperature
indicates shall be used. Temperature indicating crayons shall not be used. Pre-heat
temperature shall be checked on every joint. Care shall be taken to ensure that the
entire circumference of the pipe is heated evenly. Temperature measuring
instruments shall be calibrated immediately before the start of the works and
thereafter at intervals recommended by the manufacturer of the instrument.
4.2.3 Application of heat shrink wrap around sleeve Upon pre-heating the pipe surface
shall be applied with two pack epoxy primer of wet film thickness 200 microns or as
per manufacturer’s recommendation whichever is higher, to cover the exposed bare
metal of the welded field joint and 10mm min. onto the adjacent pipe coating if
recommended by the manufacturer. The wet film thickness of the primer shall be
checked or every joint with a wet film thickness gauge prior to installation of sleeve.
Thickness gauge shall be calibrated once per shift.
4.2.4 Immediately after application of epoxy primer, the wraparound sleeve shall be
entirely wrapped around the pipe within the stipulated time recommended by the
manufacturer. Sleeve shall be positioned such that the closure patch is located to
one side of the pipe in 10 or 2 O’clock position, with the edge of the undergoing layer
facing upward and an overlap of min. 50mm. Gently heat by appropriate torch the
backing and the adhesive of the closure and press it firmly into place.
4.2.5 A heat shrinking procedure shall be applied to shrink the sleeve in such a manner to
start shrinkage of the sleeve beginning from the center of the sleeve and heat
circumferentially around the pipe. Continue heating from the center towards one end
of the sleeve until recovery is completed. In a similar manner, heat and shrink the
remaining side. Shrinking has been completed when the adhesive begins to ooze at
the sleeve edges all around the circumference.
The complete shrinking of the entire sleeve shall be obtained without undue heating
of existing pipe coating and providing due bonding between pipe, sleeve and pipe
coating. The installed sleeve shall not be disturbed until the adhesive has solidified.
The coatings mentioned are for undergrounds installations.
For HDD Joint Coating fiber glass reinforced heat shrinkable sleeve certified to
Stress class C60 type CANUSA-TBK or COVALENCE / DlRAX shall be used.
Directional drilling kit, multilayer sleeve system or equivalent to be approved by
Owner / Engineer.
Only coating material C-60 Class as per EN 12068 and DVGW certified (wrapping
tape and heat shrinkable material) will be accepted for all material to be coated.
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For the buried valve station (moulded piece, valves, elbows etc) Thermoset plastic
coatings may be used. They will be of type S50 certified as per DIN 30671 & DIN
30677.
Underground bare valves if any will be coated with above material.
At the point of transition from the aboveground pipe to underground pipe special
coating material FIBAROLL or equivalent to be used over the coated part of U.G.
pipe and painted part of A.G. Pipe end over lapping shall be at least 500 mm inside
the ground and 500 mm on painted AG line. Minimum thickness shall be 1.5 mm.
The application of the material will be as per supplier's specification.
Wherever Thrust Boring (Jacking) method is carried out, for mechanical protection of
coating of carrier pipe extra layer of hard cold applied tapes C-70 class as per DIN
30675-1 or solvent free PUR (1000 microns) as per DIN 3067712 Ep-50 types shall
be applied. Surface preparation (sand blasting) of PE layer shall be appropriate as
per applicator's recommendations. The type & thickness of coating must got
approved by Owner / Engineer prior to coating.
4.3 Application of Cold Applied Tapes
In addition to general requirements stated above following shall be taken care of:-
4.3.1 Cold applied joint protection tapes shall be of the type which can be applied by spirally
wrapping on the pipe.
4.3.2 Immediately after the completion of surface preparation the approved primer of wet
film thickness 150 microns or as per manufacturer’s recommendation whichever is
higher to cover the exposed bare metal of the welded field joint and 10mm min. onto
the adjacent pipe coating if recommended by the manufacturer. Any dirt on the
primed surface shall be removed. If the primer is damaged, the damaged area shall
be cleaned and re-primed.
4.3.3 Approximately 100mm of tape interleaving paper shall be peeled back and tape shall
be applied with the adhesive side to the pipe. Whilst continuously removing the
interleaving paper, the tape shall be spirally applied to provide a minimum of 55%
overlap. Sufficient tension shall be applied to ensure good conformity, avoiding air
pockets and also continuously smooth out as the wrapping proceeds. The wrapping
shall start and finish to give a minimum of 50mm overlap on to the adjoining yard
applied coating. Outer wrap shall also be applied in similar method.
In the cases where carrier pipe is installed by direct boring/jacking, the overlap on the
mill coating for the leading edges of the joints shall be minimum 200mm. The direction
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of spiral wrapping in these cases shall be such that the square edge of the wrapping
with the joint coating is in the direction opposite to the direction of boring/jacking.
4.4 Pre-Qualification of Field Joint Coating System
The field joint coating system materials and the procedures proposed by the Contractor
shall be pre-qualified during the sleeve installation start-up phase. Five joints (5) shall
be coated with the requirements of this specification and then inspected and tested in
accordance with the requirements of this specification with respect to the following :
i) Surface preparation cleanliness, roughness profile and dust contamination

ii) Pre-heat temperature (as applicable)
iii) Primer thickness
iv) As applied coating thickness
v) Holiday detection
vi) Peel test at (+) 23°C & (+) 60°C on pipe surface & factory applied coating and
at over laps (as applicable). If required to achieve the temperature of (+) 60°C,
suitable thermal blanket may be used.
vii) Visual appearance and void after installation on the body, area adjoining the
weld and area adjoining the factory applied coating. (To establish voids
adjoining the weld and factory coating a strip of 50 mm wide and 200 mm long
shall be stripped and examined).
Company Representative shall witness the tests and inspection. Regular application of
field joint coating shall commence only upon successful completion of the pre-
qualification testing.
After successful completion of the pre-qualification testing as above, the entire field
joint coating shall be removed, the pipe surface re-blasted and field joint coating re-
applied as per the requirements of this specification.
5.0 INSPECTION
5.1 A visual inspection shall be carried out for the following:

- Mastic extrusion on either ends of the sleeve shall be examined. (applicable
for heat shrink wraparounds).
- There shall be no sign of punctures or pinholes or bend failure. The external
appearance of the sleeve shall be smooth, free of dimples, air entrapment or
void formation.
- Weld bead profile shall be visible through the sleeve.
- The entire closure patch shall have changed colour uniformly (applicable for
heat shrink wraparounds).
5.2 Holiday Inspection
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The holiday detector used shall be checked and calibrated daily with an accurate DC
voltmeter. The detector electrode shall be in direct contact with the surface of coating
to be inspected.
The entire surface of the joint section shall be inspected by means of a full circle
holiday detector approved by Company set to a DC voltage of at least 25 kV.
Inspection of the sleeves shall be conducted only after the joint has cooled below 50°C.
(applicable for heat shrink wraparounds).
5.3 No field joint shall be covered or lowered in the trench until it has been approved by the
Company.
5.4 As-applied Coating Thickness
Coating thickness shall be checked by non-destructed methods for each field joint.
Average thickness of the as-applied coating on pipe body shall be established based
on measurement at min. eight locations i.e. four measurement on either sides of the
girth weld at 3, 6, 9, & 12 O’clock positions. To establish the minimum thickness on
the girth weld, four measurement shall be taken on apex on the weld at 3, 6, 9 & 12
O’clock positions. All such measurements shall be recorded. Company
Representative reserves the right to ask for additional measurement at any location
on the field joint coating, whenever doubt arises.
6.0 TESTING
6.1 Company reserves the right to remove and test one out of every 50 joint coatings or
one joint coating out of every day’s production whichever is stringent. Contractor shall
provide all assistance in removing and testing of field joint coatings.
6.2 From each test sleeve, one or more strips of size 25mm x 200 shall be cut
perpendicular to the pipe axis and slowly peeled off.
The required peel strength shall meet the requirements of clause 3.2.4.2 (ii) as
applicable for 23°C or 60°C whichever is feasible. This test shall be conducted
between wrapping & metal and mill coating & between layers at overlap with joint
coating (wherever applicable). After removal of strip the bulk of adhesive shall remain
adhered to the pipe showing on bare metal, otherwise, test shall be considered failed.
The adhesive layer that remains on the pipe surface shall generally be free of voids
resulting from air or gas inclusion. In case the peel strength test at a different
temperature than that specified in warranted due to the ambient site conditions, then
the peel strength shall comply the recommendation of the manufacturer. Manufacturer
shall be asked to furnish peel strength values corresponding to various expected
temperatures, prior to start of the works.
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6.3 If the sleeve taken away for test does not meet the requirements of clause 6.2 the
adjacent two sleeves shall also be removed and inspected.
If the adjacent two sleeves are acceptable the test rate shall be increased to one
sleeve in every twenty five until Company's Representative is satisfied. The test rate
can then be reduced as per clause 6.1.
If either or both of the adjacent two sleeves do not meet the requirements of clause
6.2, the field coating shall be stopped. (Refer clause 7.0).
6.4 Company Representative reserve the right of 100% removal of sleeves if he is not
convinced that the requirements of clause 6.2 are achieved.
6.5 Coating thickness shall be checked by non-destructive methods for each fields joints.
7.0 REPAIRS
7.1 If a field joint is detected to be unacceptable after testing as per section 6.0 of this
specification the Contractor shall, at his own cost :
- determine the cause of the faulty results of the field coating.
- mobilize the expert of manufacturer, if required.
- test to the complete satisfaction of the Company, already completed field
coatings.
- stop field coating until remedial measures are taken against the causes of
such faults, to the entire satisfaction of the Company.
7.2 Contractor shall replace all joint coating found or expected to be unacceptable a per
section 6.0 of this specification.
7.3 Contractor shall, at his own cost repair all areas where the coating has been removed
for testing by the Company.
7.4 After the coating work on welded joints, fittings and repairs to the coating have been
completed the coating as a whole shall be tested with a spark-tester before lowering or
jacking the pipeline.
7.5 Company shall be entitled to check the coating on buried pipelines or parts of pipelines
with equipment such as the "Pearson Meter" and the resistance meter. If Coating
defects are establish, the Contractor shall be responsible for excavations at such
points, repairing the coating, spark testing and backfilling the excavation without extra
charge.
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8.0 DOCUMENTATION
8.1 Prior to procurement of coating materials, Contractor shall furnish the following
information for qualification of the Manufacturer and material:
i. Complete descriptive technical catalogs describing the materials offered

along with samples of corrosion coating materials, its properties and
application instruction as applicable specifically to the project.
ii. Test certificates and results of previously conducted tests, for all properties
listed in clause 3.2.4 of this specification.
iii. Reference list of previous supplies, in last 5 years, of the similar material
indicating the project details such as diameter, quantity, operating
temperature, years of supply, project name, contact person and feed back on
performance.
Once the Company’s approval has been given, any change in material or
Manufacturer shall be notified to Company, whose approval in writing of all changes
shall be obtained before the materials are manufactured.
8.2 Prior to shipment of materials from the Manufacturer’s Works Contractor shall furnish
the following documents:
i. Test certificates/ results as per Manufacturer’s Quality Control Procedure for

each batch of materials.
ii. Specific application instructions with pictorial illustrations.
iii. Specific storage and handling instructions.
8.3 All documents shall be in English Language only.
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MECON LIMITED STANDARD TECHNICAL SPECIFICATION OF VENTS,
DELHI DRAINS AND WELLS
REV 0, EDITION - 1
FOR
VENTS, DRAINS AND WELLS

MEC/S/05/28/15
MECON LIMITED
DELHI 110 092

316 of 911
REV 0, EDITION - 1
CONTENTS
SL. NO. DESCRIPTION OF DRAWING DRAWING NO.
1. Vent & Drain for Line 2” & above MEC/SD/05/28/15/01
2. Wells Installation 1½ Dia Taps MEC/SD/05/28/15/02 (Sheet 1 of 2)
3. Wells Installation 1½ Dia Taps MEC/SD/05/28/15/02 (Sheet 2 of 2)
4. Vent & Drain for lines 1½” & below MEC/SD/05/28/15/03
5. Pressure Tapping MEC/SD/05/28/15/05
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AMENDMENT STATUS

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MECON LIMITED STANDARD TECHNICAL SPECIFICATION OF BLASTING
DELHI
REV 0, EDITION - 1
FOR
BLASTING
MECON LIMITED
DELHI 110 092

324 of 911
DELHI
REV 0, EDITION - 1
CONTENTS
Sl.No. Description
1.0 SCOPE
3.0 GENERAL
4.0 MATERIALS
5.0 PERSONNEL
6.0 STORAGE OF EXPLOSIVES
7.0 PREPARATION OF EXPLOSIVES
8.0 PREPARATION OF PRIMERS
9.0 CHARGING OF HOLES
10.0 ELECTRICAL FIRING
11.0 VIBRATION RECORDING
12.0 MISFIRES
13.0 DISPOSAL OF DETERIORATED EXPLOSIVES
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AMENDMENT STATUS

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1.0 SCOPE
 This specification covers the minimum requirements for materials, personnel, transportation,
storage and use of explosives for grading of Right of Use (ROU) and excavation of trenches
for onshore pipeline installation in rocky terrain.
 This specification does not cover the construction or operation of permanent magazines.
Reference has also been made to the latest edition of the following standards, codes and
specifications. The edition enforce at the time of floating the enquiry shall be termed as
latest edition.
a) BS-5607 : Safe use of Explosives in the Construction Industry
b) IS4081 : Safety Code for Blasting and Related Drilling Operations
c) NFPA-495 : Manufacture, Transportation, Storage & Usage of Explosive

Materials.
d) Safety Rules of Chief Controller of Explosives, Nagpur
3.0 GENERAL
 The Contractor shall acquaint himself and comply with all the applicable local laws and
regulations concerning storing, handling and the use of explosives. All such laws,
regulations and rules etc., as enforced from time to time shall be binding upon the
Contractor. National / Local Laws and Regulations shall take precedence over this
specification in the event of conflict. All conflicts shall be brought to the notice of the
Company.
 The requirements stated herein however in no way relieve the Contractor of his
responsibility of carrying out safe blasting operations. The Contractor shall be solely
responsible for damages and claims thereof.
 The use of explosives requires an approval from the Chief Controller of Explosives and/or
his authorized Inspector. It shall be the responsibility of the Contractor to obtain all such
permits and. approvals and comply all requirements regarding the safe storage, handling
and use of explosives. All expenses incurred in this regard shall be to Contractor's account.
 Contractor shall inform the Company in writing at least four (4) weeks prior to planned use
of explosives.
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 Contractor shall notify the Company prior to any blasting in the proximity of overhead power
lines, roads, communication lines, pipelines, utility services or other services and structures
above and below ground. Before, starting blasting operations, local authorities and owners
of utilities shall be consulted to check on the presence of services, which could be damaged
and their approval obtained to undertake blasting operations. The distances to nearest
structures (houses, offices, factories) or service shall also be taken into consideration when,
planning blasts so that ground vibration and air-over pressure is kept within acceptable
levels as given in section 11.0 of this specification
 Contractor shall prepare an Explosives Handling and Usage Procedure for the information of
the Company, which shall include the following:
- Detailed procedure and calculations.

- Nature of blasting operations, including hole diameter, depth and presence of
cavities
- Rock characteristics
- Type of explosives
- Temperature likely to be encountered in use
 Unless specified otherwise, blasting shall not be allowed within 20 m of any above ground or
underground structure, pipelines or other facilities. However, in case it is necessary to carry
out blasting operation within 20 m from any under ground or above ground structures,
pipelines or other facilities, the blasting may be allowed, at discretion of Company, subjected
to the following :
a) Minimum clear distance from the facility is 5 m.
b) Contractor demonstrates the blasting technique proposed by him doesn't result in

any damage to the existing facility. (Contractor shall carry out mock demonstration
as per the direction of Company Representative for this purpose).
c) Contractor fulfils the conditions laid out by the Owner of the existing facilities.
d) Contractor fulfils the requirements laid-out by National / Local Laws and Regulations
and other statutory/regulatory Authorities.
In case of presence of overhead power lines/cables, specific approvals shall be obtained by

Contractor from the concerned Authorities having jurisdiction over it.
4.0 MATERIALS
 All materials such as explosives, detonators; fuses, tamping materials etc. that are proposed
to be used by the Contractor in blasting operations, shall be as approved for use in the
Country.
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 All electric detonators used in the blast shall be of the same electrical sensitivity and be
produced / procured from the same manufacturer.
 The detonators used shall be capable of giving effective blasting of the explosives.
Damaged explosive materials shall be destroyed by a responsible person as per
manufacturer's instructions or returned to the manufacturer.
 No explosive material shall be abandoned.
 All blasting materials and testing equipment shall be regularly tested for correct
performance. The intervals between test shall be decided after consideration of the local
factors, but tests shall always be carried out if the blasting materials and / or test equipment
have been subjected to abnormal conditions, or following any misfires. Guidelines /
recommendations of the manufacturer shall be adhered to.
 All packaging and other waste materials gathered together during blasting operation shall be
burnt after the blast has been fired. The burning site shall be chosen at a safe distance with
due respect to prevailing wind strength and direction, at least 100 meters from explosives
stores and other premises. A minimum of two fire extinguishers shall be on hand during
burning activities.
5.0 PERSONNEL
 Excavation by blasting will be permitted only under personal supervision of competent and
licensed persons and by trained workmen.
 The storage of explosives shall be in the charge of a person approved by the Company.
Company may, if necessary, ask police inquiries being made as to his reliability,
antecedents etc.
6.0 STORAGE OF EXPLOSIVES
 The Contractor shall build a magazine for storing the explosives. The site of the magazine,
its capacity and design shall be subject to approval by the Company and the Inspector of
Explosives before the fabrication is taken up. As a rule the explosives should be stored in a
clean, dry, well ventilated, bullet proof and fire proof building, at an isolated site. Adequate
security shall be provided to ensure no unauthorized entry into the magazine. A notice shall
be hung next to magazine entrance prohibiting entry of unauthorized persons.
 Contractor shall comply with National / Local Regulations and specifications for truck
mounted mobile explosives store. Mobile stores shall only carry ONE DAY's Explosives
requirements and shall be parked overnight inside the compound at the authorized
magazine.
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 All safety precautions and necessary equipment for maintenance, operation of mobile
stores, as required by local authorities or regulatory bodies shall also be installed / provided
on the Mobile Store.
 A careful and day-to-day account of all explosives shall be kept by the Contractor in a
register and in an approved manner. The register shall be produced by the Contractor, for
the inspection of the Company / Inspector of Explosives when so required by the later.
Any loss, damage or theft shall be reported immediately to the necessary local authorities
and to the Company.
 The magazine shall on no account be opened during or on the approach of a thunderstorm

and no person shall remain in the vicinity of the magazine during such period.
 Magazine-shoes without nails shall, at all times, be kept in the magazine, and a wood-tub or
cement trough, filled with water shall be fixed near the door of the magazine.
 Persons entering the magazine must put on the magazine-shoes and shall comply to
following:
I) not to put their feet on the clean floor unless they have magazine-shoes on.
II) not to allow the magazine-shoes to touch the ground outside the clean floor.
III) not to allow any dirt or grit to fall on the clean floor.
 No matches or inflammable material shall be allowed in the magazine. Light shall be

obtained from an electric storage battery lamp.
 No person having articles of steel or iron on him shall be allowed to enter the magazine. No
tools or implements other than those of copper, brass, gun metal or wood shall be allowed
inside the magazine.
Oily cotton. rags, waste and articles liable to spontaneous ignition, shall not be allowed
inside the magazine.
 Boxes of explosives shall not be thrown down or dragged along the floor and shall be
stacked on wooden trestles. Open boxes of explosives shall never be exposed to the direct
rays of the sun. Empty boxes or loose packing materials shall not be kept inside the
magazine.
 The magazine shall have a lightning conductor, which shall be got tested periodically, by an
officer authorized by the Company, the testing fee shall be to the Contractor's account.
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 The magazine shall be inspected periodically by an officer representing the Company, who
will see that all the rules are strictly complied with. He will notify all omissions etc. to the
Contractor, who shall rectify the defects within a period of 3 days from the date of receipt of
the notice, failing which the Company may take whatever actions it considers suitable.
7.0 PREPARATION OF EXPLOSIVES
 Contractor shall submit the following procedures for INFORMATION of the Company as a
minimum.
- Loading of explosives
- Drilling of new holes and extending existing holes
- Handling of explosives at site
- Tamping explosives into holes,
- Machines, tools and cables required
- Initiation of blasting
- Safety of personnel
- Vibration control
- Blast pattern and shot size establishment
- Misfires
- Emergency procedures
 Trial blasts in conjunction with vibration recording shall be carried out for each rock and
trench type, in order to assess rock breakability and vibration levels. These trial blasts shall
be carried out prior to actual trench blasting of the pipeline route. Contractor shall conduct
trial digs as directed by Company in order to check suitability of the blasting pattern and to
measure vibration levels to ensure vibration levels are below the allowable maximum.
 "Weight per Distance Tables" shall be drawn up from these trials.
 The detonators shall never be forced into the primer cartridge. It shall be inserted in a hole
made by a wooden, copper, brass or aluminium pricker. The detonator shall be firmly
embedded in the primer so that it is not pulled out of place during loading.
 Detonators shall be activated electrically. In proximity of electric over-head power lines,

Contractor may use non-electric system with the approval of Company. Fly rock shall be
minimized by the use of approved blast mats and by careful selection of shot size and drill
hole configuration.
 Use of explosives is prohibited in areas exposed to flammable gasses or dust.
 Explosive and detonators shall be carried in separate boxes, tightly closed, and transported
separately. For the conveyance of primers special containers shall be used.
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 Explosives shall be stored and used chronologically to ensure that the ones received earlier
are being used first.
 A make-up house shall be provided at each working place in which cartridges shall be made
up by experienced men as required. The make-up house shall be separated from other
buildings. Only electric storage battery lamps shall be used in this house.
 No smoking shall be allowed in the make-up house.
8.0 PREPARATION OF PRIMERS
The primers shall not be prepared near open flames or fires. The work of preparation of
primers shall always be entrusted to the qualified and approved personnel. Primers shall be
used as soon as possible after they are ready.
9.0 CHARGING OF HOLES
 The work of charging shall not commence before all the drilling work at the site is completed
and the Company has satisfied itself to that effect by actual inspection.
 The lead wires shall be kept away from conductors or sources of stray current. While
charging, open lamps/flames shall be kept away.
 Only wooden tamping rods without any kind of metal on them shall be used.
 Only one cartridge shall be inserted at a time and gently inserted to the required depth with
the tamping rod. The sand, clay or other tamping material used for filling the hole completely
shall not be tamped too hard.
 Blasting shall not take place after sunset or before sunrise unless specific approval is first
obtained by Contractor from local authorities and the Company.
 The site of blasting operations shall be prominently demarcated by red danger flags. The
order of fire shall be given only by the Supervisor-In-Charge of the work and this order shall
be given only after giving the warning signal three times, so as to enable all the labor,
watchmen etc. to reach safe shelter and after having ascertained that nobody is within the
danger zone.
 A buegle with a distinctive note shall be used to give the warning signals. The buegle shall
not be used for any other purpose. All the labor shall be made acquainted with the sound of
the buegle and shall be strictly warned to leave their work immediately at the first warning
signal and to take safe shelters, and not to leave the shelters until the all clear signals have
been given.
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 All the roads and footpaths leading to the blasting area shall be watched. All the escape
routes shall have been clearly marked.
10.0 ELECTRICAL FIRING
 Only the Supervisor-In-Charge shall keep the key of the firing apparatus and shall keep it
always with himself.
 Special apparatus shall be used as source of current for the firing operations. Power lines
shall not be tapped for the purpose.
 The firing cable shall have a proper insulating cover so as to avoid short circuiting due to
contact with water, metallic parts or rock.
 The use of earth as a return line shall not be permitted.
 The firing cable shall be connected to the source of current only after ascertaining that
nobody is in the area of blasting.
 Before firing, the circuit shall be checked by a suitable apparatus.
 After firing, whether with or without an actual blast, the contact between the firing cable and
the source of current shall be cut off before any person is allowed to leave the shelter.
 During storms, charging with electrical detonators shall be suspended. The charges already
placed into the holes shall be blasted as quickly as possible after taking all the safety
precautions and giving necessary warning signals. If this is not possible, the site shall be
abandoned till the storm has passed.
11.0 VIBRATION RECORDING
 Contractor shall use Company approved vibration recording system capable of

measurement in three axes (tri-axial). The device shall have an accuracy of 0.0025 mm and
a resonance of2 Hz.
- The device shall measure both frequency and amplitude of vibration.
 All the measurement devices shall be calibrated by an APPROVED certification body.
 Particle velocity shall not exceed the following:
• Areas beyond 500 m of proposed pipeline centreline
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DELHI

- 50 mm/sec at a surface distance of 15 m from trench centreline.
• Areas with existing buried or above ground facilities within 500 m of proposed
pipeline centreline.
- 20 mm/sec at a surface distance from the trench centre line towards the
nearest existing facilities.
 The particle velocity levels are provided for the guidance only, Contractor shall be
responsible and liable for any injury to life or damage to property/facilities.
 Air-over pressure/sound levels shall be limited to 100 db in inhabited areas.
12.0 MISFIRES
 If it is suspected that part of the blast has failed to fire, or is delayed, sufficient time shall be
allowed to lapse before entering the danger zone. When fuse and blasting caps are used, a
safe time should be allowed and then the Supervisor alone shall leave the shelter to see the
misfire.
 Drilling near the hole that has misfired shall not be permitted until one of the two following
operations have been carried out by the Supervisor:
I) The Supervisor should very carefully (when the tamping is of damp clay) extract the
tamping with a wooden scraper of jet of water or compressed air (using a pipe of soft
material) and withdraw the fuse with the primer and detonator attached. A fresh
primer and detonator with fuse shall then be placed in this hole and fired.
II) The Supervisor shall get one foot of the tamping cleaned off and indicate the
direction by placing a stick in the hole. Another hole may then be drilled at least 9"
away and parallel to it, this hole should then be charged and fired. The balance of
the cartridges and detonators found in the muck shall be removed.
 The Supervisor shall at once report to the office all cases of misfire, the cause of the misfire
and the steps taken in connection therewith.
 If a misfire has been found to be due to defective detonator, or explosive, the whole quantity
from the box from which the defective articles were taken must be returned to the
manufacturer for inspection to ascertain whether the whole box contains defective materials.
 Re-drilling the holes that have misfired either wholly or partly shall not be permitted.
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13.0 DISPOSAL OF DETERIORATED EXPLOSIVES
All deteriorated explosives shall be disposed off in an approved manner. The Contractor
shall prepare said disposal plan, which shall be approved by Company / Local Authorities /
Controller of explosives. The quantity of the deteriorated explosives to be disposed off shall
be intimated to Company prior to its disposal. All the records of such disposal shall be
maintained by Contractor.
335 of 911
MECON LIMITED STANDARD TECHNICAL SPECIFICATION OF GASKETS,
DELHI BOLTS & NUTS
REV 0, EDITION - 1
FOR
GASKETS, BOLTS & NUTS
MECON LIMITED
DELHI 110 092

336 of 911
DELHI BOLTS & NUTS
REV 0, EDITION - 1
CONTENTS
SL.NO. DESCRIPTION
1.0 GASKETS
2.0 NUTS AND BOLTS
337 of 911
DELHI BOLTS & NUTS
REV 0, EDITION - 1
AMENDMENT STATUS

338 of 911
DELHI BOLTS & NUTS

TECHNICAL NOTES FOR GASKETS
1.0 All gaskets shall conform to the codes/standards and specifications given in the requisition.
Vendor shall strictly comply with MR / PR stipulations and no deviations shall be permitted.
2.0 Process of manufacture, dimensions and tolerances not specified in requisition shall be in
accordance with the requirements of the manufacturer's standards.
3.0 Test reports shall be supplied for all mandatory tests for gaskets as per the standards specified
in the requisition.
4.0 Chemical composition and hardness of RTJ gaskets shall also be furnished in the form of test
reports on samples.
5.0 For Spiral wound material following shall be furnished:
a. Manufacturer's test certificate for filler material and spiral material as per the relevant
material specifications.
b. Manufacturer's test certificate for raw materials and tests for compressibility / seal-
ability & recovery as per the relevant material specifications.
6.0 Full face gaskets shall have bolt holes punched out.
7.0 Filler material for spiral wound gaskets shall not have any colour or dye.
8.0 All spiral wound gaskets shall be supplied with Outer ring. Material of the outer ring shall be
CS unless otherwise specified in the MR.
9.0 For spiral wound gaskets, material of Inner Compression ring shall be same as Spiral Strip
material. In addition to the requirements as per code and as specified in the MR, inner rings
shall be provided for the following:
a. Sizes 26" and above.
b. Class 900 and above.
10.0 Hardness of metallic RTJ gaskets shall not exceed the values specified below unless otherwise
specified in MR :
Ring Gasket Material Maximum Hardness (BHN)
Soft Iron 90
Carbon steel 120
5 Cr. ½ Mo 130
Type 304, 316, 321, 347 140
Type 304L, 316L 120
11.0 Face finish of metallic RTJ gaskets shall be 32 to 63 AARH.
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12.0 Gaskets of different types and sizes shall be placed in separate shipping containers and each
container clearly marked with the size, rating, material specification and item code.
13.0 All items shall be inspected and approved by MECON Inspector or any other agency authorized
by MECON.
14.0 Any additional requirements specified in the requisition, shall be fully complied with.
15.0 Non-metallic ring gaskets as per ASME B16.21 shall match flanges to ASME B16.5 upto 24"
(except 22" size) and to ASME B16.47B above 24" unless specified otherwise. For 22" size, the
matching flange standard shall be MSS-SP44 unless specified otherwise.
16.0 Spiral wound gasket as per ASME B16.20 shall match flanges to ASME B16.5 upto 24" (except
22" size) and to ASME B16.47B above 24" unless specifically mentioned otherwise. For 22"
size, the matching flange standard shall be MSS-SP44 unless specified otherwise.
17.0 The following abbreviations have been used in the Material Requisition for Spiral Wound
Gaskets :
(I) : Inner Ring

(O) : Outer Ring
CAF : Compressed Asbestos Fibre
GRAFIL : Grafoil Filler
340 of 911
DELHI BOLTS & NUTS

TECHNICAL NOTES FOR BOLTS & NUTS
1.0 The process of manufacture, heat treatment, chemical & mechanical requirements and
marking for all stud bolts, m/c bolts, jack screws & nuts shall be in accordance with the codes
/ standards and specification given in the requisition. The applicable identification symbol in
accordance with the material specification shall be stamped on each bolt and nut. Vendor shall
strictly comply with MR / PR stipulations and no deviations shall be permitted.
2.0 Test reports shall be supplied for all mandatory tests as per the relevant material
specifications.
3.0 Material test certificate shall also be furnished. (Heat Analysis, Product Analysis and
Mechanical Requirement)
4.0 Stress Rupture Test as detailed in ASTM A453 shall be carried out for all ASTM A453 bolting
material irrespective of the temperature.
5.0 All bolting shall be as per ANSI B 18.2.1 for studs. M/c bolts and jackscrews and ANSI BI8.2.2
for nuts.
6.0 Threads shall be unified (UNC for 1" dia and BUN for> 1" dia) as per ANSI B.1.1 with class 2A
fit for studs, M/c bolts and jackscrews and class 2B fit for nuts.
7.0 Stud bolts shall be threaded full length with two heavy hexagonal nuts. Length tolerance shall
be in accordance with the requirement as per ANSI B 16.5.
8.0 The nuts shall be double chamfered, semi-finished, heavy hexagonal type and shall be made
by the hot forged process and stamped as per respective material specification.
9.0 Heads of jackscrews and m/c bolts shall be heavy hexagonal type. Jackscrew end shall be
rounded.
10.0 Each size of studs & m/c bolts with nuts and jackscrews shall be supplied in separate
containers marked with size and material specifications. 'CRYO' shall be marked additionally in
case 'CRYO' is specified in the requisition.
11.0 All items shall be inspected and approved (stage wise) by MECON inspector or any other
agency authorized by MECON.
12.0 The heat treatment for stud bolts & nuts shall be as per code unless mentioned otherwise.
13.0 All austenitic stainless steel bolts, nuts, screws shall be supplied in solution annealed condition
unless specified otherwise in the material specification.
14.0 Any additional requirements specified in the requisition shall be fully complied with.
Stud bolts, nuts & jackscrews shall be impact tested wherever specified in the material specification
and also where the material specification is indicated as "CRYO". For" S.S. nuts and bolts minimum
341 of 911
DELHI BOLTS & NUTS

impact energy absorption shall be 27 Joules and test temperature shall be -196°C unless mentioned
otherwise. For other materials impact energy and test shall be as per respective code.
15.0 Bolts / nuts of material of construction B7M / 2HM shall be 100% Hardness tested as per
supplementary requirement S3 of ASTM A 193.
16.0 When specified as galvanized, the studs, m/c bolts and nuts shall be 'hot dip zinc coated' in
accordance with requirements of 'class C' of 'ASTM A 153'. As an alternative, electro-
galvanizing as per IS 1573, 'Service Grade Number 2' is also acceptable.
17.0 All Stud Bolts of Bolt diameter size 1" and above shall be provided with three nuts irrespective
of whatever has been specified elsewhere in the MR.
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DELHI INFORMATION MANAGEMENT SYSTEM (PIMS)
REV 0, EDITION - 1
FOR
PIPELINE INFORMATION
MANAGEMENT SYSTEM (PIMS)
MECON LIMITED
DELHI 110 092

343 of 911
REV 0, EDITION - 1
CONTENTS
SL. NO. DESCRIPTION
1.0 Purpose
2.0 Scope
3.0 Technical Requirements
4.0 Responsibilities
5.0 Project Deliverables
6.0 SLA Compliance
7.0 PIMS Documents required
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345 of 911
BASED PIPELINE INFORMATION MANAGEMENT SYSTEM- Web Based
1.0 Purpose :
The objective of implementing Web Based Pipeline Information Management System is to

provide a web based software solution, for getting online, validated pipeline construction
data, which gets updated through a process, on a daily basis. The software solution
(PIMS) is required to track the field progress of various activities on daily basis and shall
make available validated data with relevant records on project website through predefined
process logics.
Qualification Criteria
• The PIMS vendor should have executed at least 3 projects (completed or in

progress), 1 nos of which should have been completed. The completed projects
pipeline length shall be minimum 100 kms. The cumulative implementation
experience ( all inclusive ) shall not be less than 250 kms.
• GIS implementation experience shall be at least in 2 projects (completed or in

progress ), but not less than cumulative 200 kms. of implementation experience.
• Credentials in the form of Work Orders & respective Completion Certificates as on

day of bidding shall be submitted along with bid submission. The completion
certificates of those projects which have been implemented as per PIMS tender
specification in the pipe laying tender shall be accepted.
• The owner reserves the right to enquire & verify the authenticity of the completion
certificates submitted with the respective Pipeline Project Owners before or any time
during the entire project duration period.
• The PIMS provider shall be independent third party vendor.
• The organization should be certified to international quality management system
• (QMS) certifications like ISO 9001:2000 and the certificate scope shall clearly
mention relevance to PIMS.
• The PIMS vendor should have proper auditable PIMS & IT security system in place.
The relevant work procedures shall be submitted along with bid submission
• The pipeline contractor shall submit proof of tie-up (Comfort Letter / Commitment
Letter) with PIMS vendor
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2.0 Scope :
This document specifies the technical scope of the Web based Pipeline Information
Management System that shall be implemented by the contractor for the Pipeline Project.
3.0 Technical Requirements:
The software solution shall have features to handle, manage and query data for all major
pipeline activities, but not limited to, following field activities:
1. Right of Way
2. Stringing
3. Bending
4. Trenching
5. Welding
6. Tie-In Welding
7. Welding Repair
8. Non Destructive Testing – Radiography
9. Non Destructive Testing – Ultrasonic Testing
10. Non Destructive –Magnetic Particle Testing
11. Non Destructive – Liquid Penetration Testing
12. Radiography
13. Joint Coating
14. Lowering
15. Back-filling
16. Restoration
17. Hydro-testing
18. Sectionalizing Valve stations / Tap Off Point – Mechanical
19. Terminal stations
Progress of each construction activity requires shall be tracked separately through individual
reporting data & GIS modules for each activity, with appropriate hyperlinks to relevant field
inspection reports, activity history & work procedures. The project website shall have
integrated Electronic Document Management System (EDMS).
The access to entire project data shall be through GIS and PIMS data module and there
shall be seamless integration & navigation between them. The PIMS vendor shall use
licensed software versions for development & deployment of PIMS & GIS.
347 of 911
The PIMS vendor shall demonstrate the entire process of data enabling, on project website
to the client for its proper evaluation, including proof & use of licensed software as a part of
IT compliance. The PIMS vendor shall have adequate IT security systems in place to
evince client confidence in the network security.
The software vendor shall submit its detailed work procedures for its evaluation along with
the bid. PIMS vendor shall demonstrate IT security systems as a part of compliance to data
security through detailed work procedures, traceability of IT events & incidents, records
maintenance and use of network devices & components.
The vendor shall also mention the reports generated - manually through data input,
dynamically online through user defined queries. The system should be able to generate
"Daily Progress Report" based only on verified data inputs.
The PIMS should be customizable to the needs of the project, for which a separate system
study shall be carried out by the vendor. The software should conform to the internationally
acceptable standards like PODS & APDM.
The PIMS vendor should adhere to the Service Level Agreement. The PIMS vendor to
clearly mention all the reports that the system can dynamically generate for use as a MIS &
input for project review meetings.
The PIMS vendor shall have following qualified skilled personnel as a minimum for an
effective implementation of PIMS software solution.
o Implementation Specialists - 9 nos.

o Quality Assurance - 2 nos.
o Team Leader - 2 nos.
o Software Support - 4 nos.
o GIS Developers - 2 nos.
o Project Manager - 1 no.
The PIMS vendor to demonstrate the working of its software solution with live data, as a part
of evaluation, during or after bidding process.
4.0 Responsibilities:
The responsibilities of the PIMS vendor should include:
• Collection of daily reports from the contractor

• Maintaining Traceability of Field reports received & its related registering process.
• Ensure completeness of data that is published on to web server
• Provide requisite software & hardware to meet the requirements specified for PIMS.
348 of 911
• Provide access to 25 Users and track their usage

• Provide necessary "Fulfillment Team" to meet the agreed Service Level Agreement
(SLA), with a competent Team Leader
• To generate activity progress reports as required for project review meetings
• To participate in all project review meetings
• Provide system generated Pipebook, lowering & hydro-testing clearances "on
demand" for the selected chainages in a standard approved Pipebook template
• Provide material reconciliation reports "on demand"
• Provide system generate pipeline work completion certificate for contractor's billing
purpose
• Web based Project Management system including documentation which is
compatible with Primavera software.
The responsibility of Pipeline Contractor includes:
• To provide necessary office space & furniture for PIMS implementation team
• To provide timely submission of field inspection reports on a daily basis
• To provide printer for printing documents as required
• To provide internet connection (minimum bandwidth 256 kps) for computers used in
PIMS implementation
• To provide lodging, boarding & conveyance for carrying out the PIMS work by the
PIMS vendor
• To provide digital photographs of project site with complete description of all
important locations defined by the client
• To provide all valid data in soft & hard copies for the Pipe Mill supplied material
5.0 Project Deliverables
• PIMS vendor to mention his deliverables with complete details.

• A web enabled version of Project Data which can be accessed throughout the
organization's LAN/WAN network and any alternate solution to access data post
construction.
• PIMS vendor to submit details of his web enabled version features as a part of bid
evaluation.
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6.0 SLA Compliance
• The construction field data as submitted by the Pipeline contractor on the previous
day shall be published on to the PIMS web server by 11:30 hrs of following day.
• The PIMS shall be able to generate Pipebook online on demand.
• The generated Pipebook should have validated data only.
• The availability of the PIMS web server shall be 99.9%
7.0 PIMS Documents required: (within a week of award of work contract)
• PIMS Process Work Flow Schematic

• Implementation Work Procedures
• QA Process
• IT Security Work Procedures
• Incident Management
• Business Continuity Planning
• CV's of implementation team
• Project Plan
• Auditable events & procedures
• PIMS Reporting formats
• Daily reports
• Weekly reports
• Monthly reports
• Graphical Reports
• Manually generated reports
• Compiled from various reports
• Dynamically generated from system.
350 of 911
MECON LIMITED STANDARD TECHNICAL SPECIFICATION FOR
DELHI WARNING MATS
REV 0, EDITION - 1
FOR
WARNING MATS
MECON LIMITED
DELHI 110 092

351 of 911
DELHI WARNING MATS
REV 0, EDITION - 1
AMENDMENT STATUS
Sl. Clause / Paragraph / Page Status of Revision and Date

Rev-1 Rev-2 Rev-3 Rev-4
Drawing Amended
352 of 911
DELHI WARNING MATS
SPECIFICATION FOR THE WARNING MATS
Purpose : For using as a warning sign for Under Ground

Gas, Liquids, Slurries and HDPE Duct/ OFC
Width : D+300 mm, D- Dia of Line Pipe
Thickness : 1.00mm thk. for Underground Pipelines.
Material of the mat : The material shall be of high density

Polyethylene of virgin quality and non
Biodegradable type. It shall have Non-
hazardous, Non-toxic and Anti-Rodent
properties.
Colour of the mat : Golden yellow with letters printed in RED of

non-deletable type with high abrasion resistant.
Art Work : A sample piece of 30mm wide and 200mm long

of every batch shall be checked by immersing in
20% solution of Ammonium Sulphide for period
of 2 weeks at a temperature of 15°C for colour
intactness of the strip. Copy of art work is
enclosed at Page 4.
The art work shall be printed in English and
local language alternatively at every 1 mtr.
Distance.
Mechanical Properties of HDPE

Tensile Strength : Minimum 200 kg/cm2
Elongation at Break : Minimum 175%
Bundle Length : 1.0mm thick warning mat shall be supplied as

100 mtrs. Length in each bundle packed in PE
Woven sack material.
Tests : Minimum Following Test has to be done with

each batch of warning mat
 Tensile Strength test
 Elongation test
 Impact Strength Test
 Color Fastness Test
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DELHI WARNING MATS
Heat Stability Test


Print Stability Test

Oxidation Induction test

ESCR Test

Melt Flow Rate Test

Anti- Rodent Test

UV Stabilizer test

DSC Scan Test of Raw Materials & Finish

goods
Vendor has to submit the all test certificates to
purchaser.
Inspection : The manufacturer has to submit the QAP before

commencement of production. Inspection of the
material will be done at vendor’s works by
Client/ MECON Representative. Vendor has to
submit all test reports before inspection call.
Any test failed during inspection for the offered
lot, the total lot will be rejected.
Documentation : Vendor shall submit all test reports including

Document regarding Toxicology data &
ROHS compliance , documentary evidence regarding Non-biocide product, value of Lethal Dosage
(LD), value of % dermal toxicity, details of active ingredient in the product and final inspection
reports along with the supply of materials.
354 of 911
DELHI WARNING MATS
HIGH PRESSURE WATER PIPELINE

BELOW
COMPANY NAME
COMPANY
NAME
IN EMERGENCY PLEASE CONTACT

PHONE NOS. …………………………….
355 of 911
DELHI WARNING MATS
HIGH PRESSURE SLURRY PIPELINE

BELOW
COMPANY NAME
COMPANY
NAME
IN EMERGENCY PLEASE CONTACT

PHONE NOS. …………………………….
356 of 911
MECON LIMITED STANDARD TECHNICAL SPECIFICATION OF HEALTH,
DELHI SAFETY AND ENVIRONMENT (HSE) MANAGEMENT
REV 0, EDITION - 1

HEALTH, SAFETY
AND
ENVIRONMENT (HSE)
MANAGEMENT
MECON LIMITED
DELHI 110 092

357 of 911
REV 0, EDITION - 1
CONTENTS
SL. NO. DESCRIPTION
1.0 SCOPE
2.0 REFERENCES
3.0 REQUIREMENT OF HEALTH, SAFETY & ENVIRONMENT (HSE) MANAGEMENT SYSTEM TO

BE COMPLETED BY BIDDERS.
4.0 DETAILS OF HSE MANAGEMENT SYSTEM BY CONTRACTOR
5.0 RECORDS
ANNEXURE-A
ANNEXURE-B
ANNEXURE-C
ANNEXURE-D
ANNEXURE-E
HSE CHECKLIST CUM COMPLIANCE REPORT FORMAT NO.: HSE-1
ACCIDENT / INCIDENT REPORT FORMAT NO.: HSE-2
SUPPLEMENTARY ACCIDENT / INCIDENT INVESTIGATION REPORT FORMAT NO.: HSE-3
NEAR MISS INCIDENT – SUGGESTED PROFORMA FORMAT NO.: HSE-4
MONTHLY HEALTH, SAFETY & ENVIRONMENT (HSE) REPORT FORMAT NO.: HSE-5
PERMIT FOR WORKING AT HEIGHT (ABOVE 2 METER) FORMAT NO.: HSE-6

CONFINED SPACE ENTRY PERMIT FORMAT NO.: HSE-7
FORMAT FOR RADIATION WORK PERMIT FORMAT NO.: HSE-8
FORMAT FOR DEMOLISHING / DISMANTLING FORMAT NO.: HSE-9
358 of 911
REV 0, EDITION - 1
AMENDMENT STATUS

359 of 911

1.0 SCOPE
This specification establishes the Healthy, Safety and Environment (HSE)

management requirement to be compiled with by the Contractors during
construction.
This specification is not intended to replace the necessary professional judgement

needed to design & implement an effective HSE system for construction activities
and the contractor is expected to exceed requirements given in this specification.
Requirement stipulated in this specification shall supplement the requirement of HSE

management given in relevant Act (S)/ legislations. General Condition of Contract
(GCC) Special Condition of Contract (SCC) and Job Specifications. Where different
documents stipulate different requirements, the most stringent shall be adopted.
2.0 REFERENCES
This document should be read in conjunction with following:
- General Conditions of Contract (GCC)

- Special Conditions of Contract (SCC)
- Building and other construction workers (regulation of employment and
condition of service) Act, 1996
- Job Specifications
- Relevant IS Codes (refer Annexure-A)
- Reporting Formats (refer Annexure-B)
- Statutory requirements
3.0 REQUIREMENT OF HEALTH, SAFETY & ENVIRONMENT (HSE) MANAGEMENT

SYSTEM TO BE COMPLETED BY BIDDERS.
3.1 Management Responsibility
3.1.1 The Contract should have a document HSE policy to cover commitment of the
organization to ensure health, safety and environment aspects in their line of
operations
3.1.2 The HSE management system of the Contractor shall cover HSE requirement
including but not limited to what specified under clause 1.0 & 2.0 mentioned above
3.1.3 Contractor shall be fully responsible for planning and implementing HSE requirement
to the satisfaction of the company. Contractor as a minimum requirement shall
designate/deploy the following to co-ordinate the above:
No. Of workers deployed

Up to 250 - Designate one safety supervisor who will guide
the workers from time to time, as well as impart
training basic guidelines at least weekly once.
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Above 250 & upto 500 - Deploy one qualified and experienced safety
Engineer/ Officer who will guide the workers
from time to time as well as impart basic
guideline & training at least weekly once. He /
She shall possess a recognized Degree in any
branch of engineering or technology or
architecture and had a post qualification
construction experience of minimum two years
or possess a recognized Diploma in any branch
of engineering or technology or Graduate in
Science stream and had a post qualification
construction experience of minimum five years.
Above 500 - One additional safety engineer/Officer

(for every 500 or less) whose function will be as mentioned
above
Contractor shall indemnify and hold harmless OWNER/ MECON & their
representative’s from any and all liabilities arising out of non fulfillment of HSE
requirements.
Above is the minimum requirement and the Contractor shall ensure physical
presence of a safety personnel at each place where Hot work permit is required. No
work shall be started at site until above safety personnel are physically present at
site. The contractor shall submit a safety organogram clearly indicating the lines of
responsibility and reporting system. He shall furnish Bio-Data/Resume/Curriculum
Vitae of the safety personnel he intends to mobilize, at least 1 month before the
intended mobilization, for MECON/Owner's approval.
3.1.4 The Contractor shall ensure that the Health, Safety and Environment (HSE)
requirements are clearly understood & faithfully implemented at all levels, at each
and every site/ work place.
3.1.5 The Contractor shall promote and develop consciousness for Health, Safety and
Environment among all personnel working for the Contractor. Regular awareness
programs and fabrication shop/work site meeting shall be arranged on HSE activities
to cover hazards involved in various operations during construction.
3.1.6 Arrange suitable first aid measures such as First Aid Box, trained personnel to give
First Aid, Stand by Ambulance or Vehicle and install fire protection measures such
as: adequate number of steel buckets with sand and water and adequate fire
extinguishers to the satisfaction of OWNER/ MECON. In case the number of workers
exceeds 500, the Contractor shall position an ambulance /vehicle on full time basis
very close to the worksite.
3.1.7 The Contractor shall evolve a comprehensive planned and documented system for
implementation and monitoring of the HSE requirements. This shall submitted to
OWNER & MECON for approval well in advance, prior to start of work. The
monitoring for implementation shall be done by regular inspection and compliance to
361 of 911

the observations thereof. The Contractor shall get similar HSE requirements
implemented at his sub-contractor (s) work site/ Office. However, compliance of HSE
requirement shall be the sole responsibility of the Contractor. Any review/ approval
by OWNER/ MECON shall not absolve the Contractor of his responsibility/ liability in
relation to all HSE requirements.
3.1.8 Non-Conformance on HSE by the Contractor (including his Sub-contractors) as

brought out during review/ audit by MECON/ OWNER representative shall be
resolved forthwith by Contractor. Compliance report shall be possibility submitted to
MECON/ OWNER at the earliest.
3.1.9 The Contractor shall ensure participation of his Resident Engineer/Site-in-Charge in

the Safety Committee/HSE Committee meetings arranged by OWNER/ MECON.
The compliance of any observation shall be arranged urgently. Contractor shall
assist OWNER/MECON to achieve the targets set by them on HSE during the
project implementation.
The contractor shall ensure that his staff members & workers (permanent as well
casual) shall not be in a state of intoxication during working hours and shall abide by
any law relating to consumption & possession of intoxicating drinks or drugs in force.
Awareness about local laws on this issue shall form part of the Induction Training.
The contractor shall ensure that all personnel working for him comply with No-
smoking requirements of the owner as notified from time to time. Cigarettes, lighters,
auto ignition tools or appliances shall not be allowed inside the plant complex.
Smoking shall be permitted only inside smoking booths expressly designated &
authorized by the Owner/MECON.
3.1.10 The Contractor shall adhere consistently to all provisions of HSE requirements. In
case of non-compliance or continuous failure in implementation of any of HSE
provisions; OWNER/ MECON may impose stoppage of work without any Cost &
Time implication to Owner and/or impose a suitable penalty for non-compliance with
a notice of suitable period, upto a cumulative limit of 1.0% (one percent) of Contract
value with a ceiling of Rs. 10 lakhs.
0.2% (Zero decimal two percent) of the contract value for LSTK, EPC, EPCC or
Package contracts with an overall ceiling of Rs. 1,00,00,000/- (Rupees one crore).
S. Violation or HSE norms Penalty Amount

No.
1. For not using personal protective Rs. 250/- per day / item /
equipment (Helmet, Shoes, Goggles, person
Gloves, Full body harness, Face shield,
Boiler suit, etc.)
2. Working without Work Permit / Rs.5,000/- per occasion
Clearance
3. Unsafe electrical practices (not installing Rs.3,000/- per item per day.
ELCB, using poor joints of cables, using
naked wire without top plug into socket,
362 of 911


No.
laying wire / cables
on the roads, electrical jobs by
incompetent person, etc.)
4. Working at height without full body Rs.1,000/ per case per day.
harness, using non-standard / rejected
scaffolding and not arranging fall
protection arrangement as
required like Safety Nets.
5. Unsafe handling of compressed gas Rs. 100/- per item per day
cylinders (No trolley, jubilee clips double
gauge regulator, improper storage /
handling).
6. Use of domestic LPG for cutting Rs.1,000/- per occasion

purpose.
7. No fencing / barricading of excavated Rs.1,000/- per occasion
areas.
8. Not providing shoring / strutting / proper Rs.5,000/- per occasion
slope and not keeping the excavated
earth at least 1.5 M away from
excavated area.
9. Non display of caution boards, list of Rs.500/- per occasion
hospitals, emergency services available
at work locations.
10. Traffic rules violations like over speeding Rs.1,000/- per occasion
of vehicles, rash driving, wrong parking,
not using seat belts, vehicles not fitted
with reverse warning alarms.
11. Absence of Contractor's top most Rs.1,000/- per occasion
executive at site in the safety meetings
whenever called by MECON / Owner
12. Failure to maintain safety records by Rs.1,000/- per month.

Contractor Safety personnel.
13. Failure to conduct daily safety site Rs.1,000/- per occasion
inspection, HSE meeting and HSE audit
at predefined frequencies.
14. Failure to submit the monthly HSE report Rs. 1,000/- per occasion and
th
by 5 of subsequent month to Engineer- Rs. 100/- per day for further
in-Charge. delay.
15. Poor House Keeping Rs.1,000/- per occasion
16. Failure to report & follow up accident Rs. 10,000/- per occasion
(including Near Miss) reporting system.
17. Degradation of environment (not Rs.1,000/- per occasion
confining toxic spills oil / lubricants onto
ground)
18. Not medically examining the workers Rs.1,000/- per occasion
363 of 911


No.
before allowing them to work at height,
not providing ear muffs while allowing
them to work in noise polluted areas,
made them to work in air polluted areas
without respiratory protective devices,
etc.
19. Violation of any other safety condition as Rs.1,000/- per occasion
per job HSE plan, work permit and HSE
conditions of contract (using crowbar on
cable trenches, improper welding booth,
not keeping fire extinguisher ready at
hot work site, unsafe rigging practices,
non-availability of First-Aid box, etc.)
20. Any violation not covered above. To be decided by MECON /
Owner
This penalty shall be in addition to all other penalties specified else where in the
contract. The decision of imposing stoppage of work, its extent & monitory penalty
shall rest with MECON/OWNER & binding on the Contractor.
3.1.11 All fatal accidents and other personnel accidents shall be investigated by a team of
Contractor’s senior personnel for root cause and recommend corrective and
preventive actions. Findings shall documented and suitable actions taken to avoid
recurrences shall be communicated to OWNER / MECON. OWNER / MECON shall
have the liberty to independently investigate such occurrences and Contractor shall
extend all necessary help and co-operation in this regard. MECON / Owner shall
have to right to share the content of this report with the outside world.
3.2 House Keeping
3.2.1 Contractor shall ensure that a high degree of house keeping is maintained and shall
ensure the followings:
a. All surplus earth and debris are removed/disposed off from the working site to
identified location (s).
b. Unused/Surplus Cables Steel items and steel scrap lying scattered at

different places within the working areas are removed to identified location
(s).
c. All wooden scrap, empty wooden cable drums and other combustible packing
materials shall be removed from work place to identified location(s).
d. Roads shall be kept clear and materials like pipes, steel, sand, boulders,
concrete chips and bricks, etc. shall not be allowed in the roads to obstructs
free movement of men & machineries.
364 of 911

e. Fabricated steel structurals, pipes & piping materials shall be stacked

properly for erection.
f. Water logging on rods shall not be allowed.
g. No parking of trucks/ trolleys, cranes and trailors etc. shall be allowed on of

roads, which may obstruct the traffic movements.
h. Utmost care shall be taken to ensure over all cleanliness and proper up keep
of the working areas.
i. Trucks carrying sand, earth and pulverized materials etc. shall be covered
while moving within the plant areas.
j. The contractor shall ensure that the atmosphere in plant area and on roads is
free from particulate matter like dust, sand, etc. by keeping the top surface
wet for ease in breathing.
k. At least two exits for any unit area shall be assured at all times.
3.3 Healthy, Safety and Environment
a) The Contractor shall provide safe means of access to any working place
including provision of suitable and sufficient scaffolding at various stages
during all operations of the work for the safety of his workmen, and OWNER/
MECON. Contractor shall ensure deployment of appropriate equipment and
appliances for adequate safety and healthy of the workmen and protection of
surrounding areas.
Contractor shall ensure identification of all Occupational Health, Safety &

Environmental hazards in the type of work he is going to undertake and enlist
mitigation measures. Contractor shall carry out Job Safety Analysis (JSA)
specifically for high risk jobs like working at height & in confined space, deep
excavations, radiography jobs, electrical installations, blasting operations,
demolishing / dismantling activities, welding / gas cutting jobs and submit the
findings to MECON / Owner. The necessary HSE measures devised shall be
in place prior to start of an activity by the contractor.
b) The Contractor shall ensure that all their staff workers including their sub-
Contractor (s) shall wear Safety Helmet and Safety shoes. Contractor shall
also ensure use of safety belt, protective goggles, gloves etc. by the
personnel as per jobs requirements. All these gadgets shall conform to
relevant IS specification equivalent.
The Contractor shall ensure that all their staff, workers and visitors including
their sub-contractor(s) have been issued (records to be kept) & wear
appropriate PPEs like nape strap type safety helmets preferably with head
& sweat band with ¾" cotton chin strap (made of industrial HDPE), safety
shoes with steel toe cap and antiskid sole, full body harness (C∈ marked and
365 of 911

conforming to EN361), protective goggles, gloves, ear muffs, respiratory

protective devices, etc. All these gadgets shall conform to applicable IS
Specifications / C∈ or other applicable international standards.
Owner may issue a comprehensive color scheme for helmets to be used by

various agencies. The Contractor shall follow the scheme issued by the
owner. All Safety / Fire personnel shall preferably wear red colour helmet so
that workmen can approach them for guidance during emergencies.
For shot blasting, the usage of protective face shield and helmets, gauntlet
and protective clothing is mandatory.
For offshore jobs/contracts, contractor shall provide PPEs (new) to MECON &
Owner's personnel, at his (contractor's) cost. All personnel shall wear life
jacket at all time.
An indicative list of HSE standards/codes is given under Appendix-A.
The contractor shall issue height permit for working at height after verifying
and certifying the checkpoints as specified in the attached permit (Format No.
HSE-6). He shall also undertake to ensure compliance to the conditions of
the permit during the currency of the permit including adherence to personal
protective equipments.
The permit shall be issued initially for one week or expected duration of an
activity and extended further for the balance duration. This permit shall be
applicable in areas where specific clearance from Owner's operation Deptt. /
Safety Deptt. is not required. MECON field Engineers / Safety Officers / Area
Coordinators may verify and counter sign this permit (as an evidence of
verification) during the execution of the job.
In case work is undertaken without taking sufficient precautions as given in

the permit, MECON Engineers may cancel the permit and stop the work till
satisfactory compliance is arranged. Contractors are expected to maintain a
register for issuance of permit and extensions thereof including preserving
the used permits for verification during audits etc.
Contractor shall arrange (at his cost) and ensure use of Fall Arrester Systems
by his workers. Fall arresters are to be used while climbing / descending tall
structures. These arresters should lock automatically against the anchorage
line, restricting free fall of the user. The device is to be provided with a double
security opening system to ensure safe attachment or release of the user at
any point of rope. In order to avoid shock, the system should be capable of
keeping the person in vertical position in case of a fall.
Contractor shall ensure that Full body harnesses conforming EN361 and
having authorized CC marking is used by all personnel while working at
height. The lanyards and life lines should have enough tensile strength to
take the load of the worker in case of a fall. One end of the lanyard shall be
366 of 911

firmly tied with the harnesses and the other end with life line. The harness
should be capable of keeping the workman vertical in case of a fall, enabling
him to rescue himself.
Contractor shall provide Roof Top Walk Ladders for carrying out activities on
sloping roofs in order to reduce the chances of slippages and falls.
c) Contractor shall ensure that a proper Safety Net System shall be used at
appropriate locations. The safety net shall be located not more than 30 feet
(9.0 metres) below the working surface at site to arrest or to reduce the
consequences of possible fall of persons working at different heights.
d) Contractor shall ensure that flash back arrestors conforming to BS:6158 or

equivalent are installed on all gas cylinders as well as at the torch end of the
gas hose, while in use. All cylinders shall be mounted on trolleys and
provided with a closing key. The burner and the hose placed downstream of
pressure reducer shall be equipped with Flash Back Arrester / Non Return
Valve device. The hoses for acetylene and oxygen cylinders must be of
different colours. Their connections to cylinders and burners shall be made
with a safety collar. At end of work, the cylinders in use shall be closed and
hoses depressurized. All welding machines shall have effective earthing. In
order to help maintain good housekeeping, and to reduce fire hazard, live
electrode bits shall be contained safely and shall not be thrown directly on the
ground.
e) The Contractor shall assign to his workmen, tasks commensurate with their
qualification, experience and state of health for driving of vehicles, handling
and erections of materials and equipment’s. All lifting equipments shall be
tested certified for its capacity before use. Adequate and suitable lighting at
every work place and approach there to shall be provided by the contractor
before starting the actual work/ operation at night.
Contractor shall ensure installation of Safe Load Indicator (SLI) on all cranes
(while in use) to minimize overloading risk. SLI shall have capability to
continuously monitor and display the load on the hook, and automatically
compare it with the rated crane capacity at the operating condition of the
crane. The system shall also provide visual and audible warnings at set
capacity levels to alert the operator in case of violations.
The contractor shall be responsible for safe operations of different

equipments mobilized and used by him at the workplace like transport
vehicles, engines, cranes, mobile ladders, scaffoldings, work tools, etc.
f) Hazardous and/or toxic material such as solvent coating or thinners shall be

stored in appropriate containers.
g) All hazardous materials shall be labeled with the name of the materials, the
hazards associated with its use and necessary precautions to be taken.
367 of 911

The work place shall be checked prior to start of activities to identify the
location, type and condition of any asbestos materials which could be
disturbed during the work. In case asbestos material is detected, usage of
appropriate PPEs by all personnel shall be ensured and the matter shall be
reported immediately to MECON / Owner.
h) Contractor shall ensure that during the performance of the work all hazards to
the health of personnel have been identified assessed and eliminated.
i) Chemical spills shall be contained & cleaned up immediately to prevent

further contamination.
j) All personnel exposed to physical agents such as ionizing or non-ionizing

radiation ultraviolet rays or similar other physical agents shall be provided
with adequate shielding or protection commensurate with type of exposure
involved. For ionizing radiation, requirements of Bhabha Atomic Research
Centre (BARC)/ Atomic Energy Regulatory Board (AERB) shall be followed.
k) Where contract or exposure of hazardous materials could exceed limits or

could otherwise have harmful affects, appropriate personal protective
equipment’s such as gloves, goggles, aprons, chemical resistant clothing and
respirator shall be used.
l) Contractor shall ensure the following facilities at work sites:
I) A Crèche where 10 or more female workers are having children below

the age of 6 years.
II) Reasonable Canteen facilities are made available at appropriate location depending
upon site conditions.
m) Suitable facilities for toilet, drinking water, proper lighting shall be provided at
site and labor camps, commensurate with applicable Laws/Legislation.
n) Contractor shall ensure storage and utilization methodology of material that

are not detrimental to the environment. Wherever required Contractor shall
ensure that only the environment friendly material are selected.
Emphasize on recycling of waste materials such as metals, plastics, glass,

paper, oil & solvents. The waste that can not be minimized, reused or
recovered shall be stored and disposed of safely. In no way, toxic spills shall
be allowed to percolate into the ground. The contractor shall not use the
empty areas for dumping the wastes.
o) All person deployed at site shall be knowledgeable of and comply with the
environmental laws, rules & regulation relating to the hazardous materials
substance and wastes. Contractor shall not dump, release or otherwise
discharge or dispose off any such materials without the authorization of
OWNER/ MECON.
368 of 911

Suitable scaffoldings shall be provided to workmen for all works that cannot
be safely done from the ground or from solid construction except such short
period work that can be safely done using ladders. When a ladder is used, an
extra workman shall be engaged for holding the ladder.
The contractor shall ensure that the scaffolds used during construction
activities shall be strong enough to take the designed load. Owner / MECON
reserves the right to ask the contractor to submit certification and or design
calculations from his Engineering regarding load carrying capacity of the
scaffoldings.
All scaffolds shall be inspected by a Scaffolding Inspector of the contractor.

He shall paste a GREEN tag on each scaffold found safe and a RED tag on
each scaffold found unsafe. Scaffolds with GREEN tag only shall be
permitted to be used and RED ones shall immediately be removed from the
site.
All electrical installations / connections shall be carried out as per the

provisions of latest revision of following codes/standards, in addition to the
requirements of Statutory Authorities and IE / applicable international rules &
regulations:
- OISO SID 173 : Fire prevention & protection system for

electrical installations
- SP 30 (BIS) : National Electric Code
All electrical installations shall be approved by the concerned statutory

authorities.
• The contractor shall meet the following requirements:
i) Ensure that electrical systems and equipment including tools &

tackles used during construction phase are properly selected,
installed, used and maintained as per provisions of the latest revision
of the Indian Electrical / applicable international regulations.
ii) Shall deploy qualified & licensed electricians for proper & safe
installation and for regular inspection of construction power
distribution system / points including their earthing. A copy of the
license shall be submitted to MECON / Owner for records. Availability
of at least one competent licensed electrician shall be ensured at site
round the clock to attend to the normal / emergency jobs.
iii) All switchboards / welding machines shall be kept in well-ventilated &

covered shed. The shed shall be elevated to avoid water logging. No
flammable materials shall be used for constructing the shed. Also
flammable materials shall not be stored in and around electrical
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equipment / switchboard. Adequate clearances and operational space

shall be provided around the equipment.
iv) Fire extinguishers and insulating mats shall be provided in all power
distribution centers.
v) Temporary electrical equipment shall not be employed in hazardous

area without obtaining safety permit.
vi) Proper house keeping shall be done around the electrical installations.
vii) All temporary installations shall be tested before energising, to ensure

proper earthing, bonding, suitability of protection system,
adequacy of feeders/cables etc.
viii) All welders shall use hand gloves irrespective of holder voltage.
ix) Multilingual (Hindi, English and local language) caution boards, shock
treatment charts and instruction plate containing location of isolation
point for incoming supply, name & telephone No. of contact person in
emergency shall be provided in substations and near all distribution
boards / local panels.
x) Operation of earth leakage device shall be checked regularly by

temporarily connecting series test lamp (2 bulbs of equal rating
connected in series) between phase and earth.
xi) Regular inspection of all installations (at least once in a month)
• The following features shall also be ensured for all electrical installations
during construction phase by the contractor:
i) Each installation shall have a main switch with a protective device,

installed in an enclosure adjacent to the metering point. The operating
height of the main switch shall not exceed 1.5 M. The main switch
shall be connected to the point of supply by means of armoured cable.
ii) The outgoing feeders shall be double or triple pole switches with fuses
/ MCBs. Loads in a three phase circuit shall be balanced as far as
possible and load on neutral should not exceed 20% of load in the
phase.
iii) The installation shall be adequately protected against overload, short

circuit and earth leakage by the use of suitable protective devices.
Fuses wherever used shall be HRC type. Use of rewirable fuses shall
be strictly prohibited. The earth leakage device shall have an
operating current not exceeding 30 mA.
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iv) All connections to the hand tools / welding receptacles shall be taken
through proper switches, sockets and plugs.
v) All single phase sockets shall be minimum 3 pin type only. All unused
sockets shall be provided with socket caps.
vi) Only 3 core (P+N+E) overall sheathed flexible cables with minimum
2
conductor size of 1.5 mm copper shall be used for all single phase
hand tools.
vii) Only metallic distribution boxes with double earthing shall be used at
site. No wooden boxes shall be used.
viii) All power cables shall be terminated with compression type cable
glands. Tinned copper lugs shall be used for multistrand wires /
cables.
ix) Cables shall be free from any insulation damage.
x) Minimum depth of cable trench shall be 750 mm for MV & control

cables and 900 mm for HV cables. These cables shall be laid over a
sand layer and covered with sand, brick & soil for ensuring
mechanical protection. Cables shall not be laid in waterlogged area as
far as practicable. Cable route markers shall be provided at every 25
M of buried trench route. When laid above ground, cables shall be
properly cleated or supported on rigid poles of atleast 2 M high.
Minimum head clearance of 6 meters shall be provided at road
crossings.
xi) Under ground road crossings for cables shall be avoided to the extent
feasible. In any case no under ground power cable shall be allowed to
cross the roads without pipe sleeve.
xii) All cable joints shall be done with proper jointing kit. No taped /
temporary joints shall be used.
xiii) An independent earthing facility should preferably be established

within the temporary installation premises. All appliances and
equipment shall be adequately earthed. In case of armoured cables,
the armour shall be bonded to the earthing system.
xiv) All cables and wire rope used for earth connections shall be
terminated through tinned copper lugs.
xv) In case of local earthing, earth electrodes shall be buried near the
supply point and earth continuity wire shall be connected to local earth
plate for further distribution to various appliances. All insulated wires
for earth connection shall have insulation of green colour.
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xvi) Separate core shall be provided for neutral. Earth / Structures shall
not be used as a neutral in any case.
xvii) ON/OFF position of all switches shall be clearly designated / painted

for easy isolation in emergency.
The contractor shall identify all operations that can adversely affect the health of its
workers and issue & implement mitigation measures.
For surface cleaning operations, sand blasting shall not be permitted even if not
explicitly stated elsewhere in the contract.
To eliminate radiation hazard, Tungsten electrodes used for Gas Tungsten Arc
Welding shall not contain Thorium.
Appropriate respiratory protective devices shall be used to protect workmen from

inhalation of air borne contaminants like silica, asbestos, gases, fumes, etc.
Workmen shall be made aware of correct methods for lifting, carrying, pushing &
pulling of heavy loads. Wherever possible, manual handling shall be replaced by
mechanical lifting equipments.
For jobs like drilling / demolishing / dismantling where noise pollution exceeds the
specified limit of 85 decibels, ear muffs shall be provided to the workers.
To avoid upper limb disorders and backaches, Display Screen Equipments'

workplace stations shall be carefully designed & used with proper sitting postures.
Power driven hand-held tools shall be maintained in good working condition to
minimize their vibrating effects and personnel using these tools shall be taught how
to operate them safely & how to maintain good circulation in hands.
The contractor shall arrange health check up for all the workers at the time of
induction. Health check may have to be repeated if the nature of duty assigned to
him is changed necessitating health check or doubt arises about his wellness.
MECON / Owner reserve the right to ask the contractor to submit test reports.
Weather Protection
Contractor shall take appropriate measures to protect workers from severe storms, solar
radiations, poisonous gases, dust, etc. by ensuring proper usage of PPEs like Sun glasses,
Sun screen lotions, respirators, dust masks, etc. and rearranging / planning the construction
activities to suit the weather conditions.
Communication
All persons deployed at the work site shall have access to effective means of
communication so that any untoward incident can be reported immediately and assistance
sought by them.
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All health & safety information shall be communicated in a simple & clear language easily
understood by the local workforce.
Unsuitable Land Conditions
Contractor shall take appropriate measures and necessary work permits / clearances if work
is to be done in or around marshy areas, river crossings, mountains, monuments, etc.
Under Water Inspection
Contractor shall ensure that boats and other means used for transportation, surveying &
investigation works shall be certified seaworthy by a recognized classification society. It shall
be equipped with all life saving devices like life jackets, adequate fire protection
arrangements and shall posses communication facilities like cellular phones, wireless,
walkie-talkie. All divers used for seabed surveys, underwater inspections shall have required
authorized license, suitable life saving kit. Number of hours of work by divers shall be limited
as per regulations. MECON / Owner shall have the right to inspect the boat and scrutinize
documents in this regard.
TOOL BOX MEETING (TBM)
Contractor shall conduct daily TBM with workers prior to start of work and shall maintain
proper record of the meeting. A suggested format is given below. The TBM is to be
conducted by the immediate supervisor of the workers.
TOOLBOX MEETING RECORDING SHEET
Date & Time

Subject
Presenter
Hazards involved
Precautions to be taken
Worker’s Name Signature Section
Remarks, if any
The topics during TBM shall include
- Hazards related to work assigned on that day and precautions to be taken.

- Any forthcoming HSE hazards / events / instruction / orders, etc.
The above record can be kept in local language, which workers can read. These records
shall be made available to MECON / Owner whenever demanded.
TRAINING
Contractor shall ensure that all his personnel possess appropriate training to carry out the
assigned job safely. The training should be imparted in a language understood by them and
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should specifically be trained about
- Potential hazards to which they may be exposed at their workplace

- Measures available for prevention and elimination of these hazards
The topics during training shall cover, at the minimum;
- Education about hazards and precautions required

- Emergency and evacuation plan
- HSE requirements
- Fire fighting and First-Aid
- Use of PPEs
- Local laws on intoxicating drinks, drugs, smoking in force
Records of the training shall be kept and submitted to MECON / Owner whenever
demanded.
For offshore and jetty jobs, contractor shall ensure that all personnel deployed have
undergone a structured sea survival training including use of lifeboats, basket landing, use
of radio communication etc. from an agency acceptable to Owner / MECON.
INSPECTION
The contractor shall carryout daily HSE inspection and record observations at a central
location. These inspection records shall be freely accessible to Owner / MECON
representatives. The contractor shall also assist Owner / MECON representatives during the
HSE inspections conducted by them.
ADDITIONAL SAFETY REQUIREMENTS FOR WORKING INSIDE A RUNNING PLANT
As a minimum, the contractor shall ensure adherence to following safety requirements while
working in or in the close vicinity of an operating plant :
a) Contractor shall obtain permits for Hot work, Cold work, Excavation and Confined
Space from Owner in the prescribed format.
b) The contractor shall monitor, record and compile list of his workers entering the
operational plant/unit each day and ensure & record their return after completing the
job.
c) Contractor's workers and staff members shall use designated entrances and
proceed by designated routes to work areas only assigned to them. The workers
shall not be allowed to enter units' area, tanks area, pump rooms, etc. without work
authorization permit.
d) Work activities shall be planned in such a way so as to minimize the disruption of

other activities being carried out in an operational plant / unit and activities of other
contractors.
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e) The contractor shall submit a list of all chemicals / toxic substances that are intended
to be used at site and shall take prior approval of the Owner.
f) Specific training on working in a hydrocarbon plant shall be imparted to the work

force and mock drills shall be carried out for Rescue operations / First-Aid measures.
g) Proper barricading / cordoning of the operational units / plants shall be done before
starting the construction activities. No unauthorized person shall be allowed to
trespass. The height and overall design of the barricading structure shall be finalized
in consultation with the Owner and shall be got approved from the Owner.
h) Care shall be taken to prevent hitting underground facilities such as electrical cables,
hydrocarbon piping during execution of work.
i) Barricading with water curtain shall be arranged in specific/critical areas where

hydrocarbon vapors are likely to be present such as near horton spheres or tanks.
Positioning of fire tenders (from owner) shall also be ensured during execution of
critical activities.
j) Emergency evacuation plan shall be worked out and all workmen shall be apprised
about evacuation routes. Mock drill operations may also be conducted.
k) Flammable gas test shall be conducted prior to any hot work using appropriate
measuring instruments. Sewers, drains, vents or any other gas escaping points shall
be covered with flame retardant tarpaulin.
l) Respiratory devices shall be kept handy while working in confined zones where there
is a danger of inhalation of poisonous gases. Constant monitoring of presence of
Gas / Hydrocarbon shall be done.
m) Clearance shall be obtained from all parties before starting hot tapping, patchwork
on live lines and work on corroded tank roof.
n) Positive isolation of line/equipment by blinding for welding/cutting/grinding shall be

done. Closing of valve will not be considered sufficient for isolation.
o) Welding spatters shall be contained properly and in no case shall be allowed to fall
on the ground containing oil. Similar care shall be taken during cutting operations.
p) The vehicles, cranes, engines, etc. shall be fitted with spark arresters on the exhaust
pipe and got it approved from Safety Department of the Owner.
q) Plant air should not be used to clean any part of the body or clothing or use to blow
off dirt on the floor.
r) Gas detectors should be installed in gas leakage prone areas as per requirement of
Owner's plant operation personnel.
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s) An experienced full time safety personnel shall be exclusively deployed to monitor

safety aspects in running plants.
HSE PROMOTION
The contractor shall encourage his workforce to promote HSE efforts at workplace by way of
organizing workshops / seminars / training programmes, celebrating HSE awareness weeks
& National Safety Day, conducting quizzes & essay competitions, distributing pamphlets,
posters & material on HSE, providing incentives for maintaining good HSE practices and
granting bonus for completing the job without any lost time accident.
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4.0 DETAILS OF HSE MANAGEMENT SYSTEM BY CONTRACTOR
4.1 On Award of Contract
The Contractor shall prior to start of work submit his Health. Safety and Environment
Manual of procedure and HSE Plans for approval by OWNER/MECON. The
Contractor shall participate in the pre-start meeting with OWNER/MECON to finalize
HSE plans including the following.
- Job procedure to be followed by Contractor for activities covering Handling of

equipment’s, Scaffolding, Electric Installation, describing the risks involved,
actions to be taken and methodology for monitoring each.
- Organizations structure alongwith responsibility and authority records/ reports

etc. on HSE activities.
4.2 During job execution
4.2.1 Implement approved Health, Safety and Environment management procedure

including but not limited to as brought our under para 3.0. Contractor shall also
ensure to:
- Arrange workmen compensation insurance, registration under ESI Act, third

party liability insurance etc. as applicable.
- Arrange all HSE permits before start of activities (as applicable) like her work,
confined space, work at heights, storage of Chemicals/explosives materials
and its use and implement all precautions mentioned therein
- Submit timely the completed check list on HSE activities, Monthly HSE report,
accident report, investigation report, etc. as per OWNER/MECON
requirements. Compliance of instructions on HSE shall be done by Contractor
and informed urgently to OWNER/MECON.
- Ensure that resident Engineers/Site-In-Charge of the Contractor shall amend

all the Safety Committee/HSE meeting arranged by OWNER/ MECON only in
case of his absence from site, a seconds senior most person shall be
nominated by him in advance and communicated to OWNER/MECON.
- Display at site office and work locations caution boards, list of hospitals for
emergency services available.
- Provided posters, banners, for safe working to promote safety consciousness
- Carryout audits/inspection at sub Contractor work as per approved HSE

documents & submit the reports for OWNER/MECON review.
- Assist in HSE audits by OWNER/ MECON and submit compliance report.
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- Generate & submit HSE records/ reports as per HSE Plan.
- Appraise OWNER/MECON on HSE activities at site.
5.0 RECORDS
At the minimum, the contractor shall maintain/ submit HSE records in the following
reporting formats:
1. Monthly HSE Checklist cum compliance report HSE-1

2. Accident / Incident Report HSE-2
3. Supplementary Accident / Incident Investigation report HSE-3
4. Near Miss Incident Report HSE-4
5. Monthly HSE Report HSE-5
6. Permit for working at height HSE-6
7. Permit for working in confined space HSE-7
8. Permit for radiation work HSE-8
9. Permit for demolishing / dismantling HSE-9
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ANNEXURE-A
A. I.S. CODES ON HSE
SP:53 Safety code for the use, Care and protection of hand operated tools.
IS: 818 Code of practice for safety and health requirements in electric and gas
welding and cutting operations
IS: 1179 Eye and Face precautions during welding, equipment etc.
IS: 1860 Safety requirements for use, care and protection of abrasive grinding wheels.
IS: 1989(Part-I & II) Leather safety boots and shoes
IS: 2925 Industrial Safety Helmets
IS: 3016 Code of practice for fire safety precautions in welding and cutting operations.
IS: 3043 Code of practice for earthing.
IS: 3764 Code of safety for excavation work
IS: 3786 Methods for computation of frequency and severity rates for industrial injuries
and classification of industrial accidents.
IS: 3996 Safety Code of scaffolds and ladders.
IS: 4082 Recommendation on stacking and storage of construction materials and

components at site.
IS: 4770 Rubber gloves for electrical purposes
IS: 5121 Safety code for piling and other deep foundations
IS: 5216 (Part-I) Recommendations on Safety procedures and practices in electrical works
IS: 5557 Industrial and Safety rubber lined boots.
IS: 5983 Eye protectors
IS:6519 Selection, care and repair of Safety footwear
IS: 6994 (Part-I) Industrial Safety Gloves (Leather & Cotton Gloves)
IS: 7293 Safety Code for working with construction Machinery
IS: 8519 Guide for selection of industrial safety equipment for body protection
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IS: 9167 Ear protectors
IS: 11006 Flash back arrestor (Flame arrestor)
IS:11016 General and safety requirements for machine tools and their operation
IS: 11057 Specification for Industrial safety nets
IS: 11226 Leather safety footwear having direct moulded rubber sole
IS: 11972 Code of practice for safety precaution to be taken when entering a sewerage
system
IS: 13367 Code of practice-safe use of cranes
IS: 13416 Recommendations for preventive measures against hazards at working place
B. INTERNATIONAL STANDARDS ON HSE
Safety Glasses : ANSI Z 87.1, ANSI ZZ 87.1, AS 1337, BS 2092, BS 1542, BS 679,
DIN 4646 / 58211
Safety Shoes : ANSI Z 41.1, AS 2210, EN 345
Hand Gloves : BS 1651
Ear Muffs : BS 6344, ANSI S 31.9
Hard Hat : ANSI Z 89.1 / 89.2, AS 1808, BS 5240, DIN 4840
Goggles : ANSI Z 87.1
Face Shield : ANSI Z 89.1
Breathing Apparatus : BS 4667, NIOSH
Welding & Cutting : ANSI Z 49.1
Safe handling of : P-1 (Compressed Gas Association

compressed Gases 1235 Jefferson Davis Highway, Arlington VA 22202 – USA)
in cylinders
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ANNEXURE-B
DETAILS OF FIRST AID BOX
SL.
DESCRIPTION QUANTITY
NO
1. Small size Roller Bandages, 1 inch wide (Finger Dressing small) 6 Pcs.
2. Medium size Roller Bandages, 2 inch wide (Hand and Foot Dressing) 6 Pcs.
3. Large size Roller Bandages, 4 inch wide (Body Dressing Large) 6 Pcs.
4. Large size Burn Dressing (Burn Dressing Large) 4 Pkts.
5. Cotton wool (20 gms packing) 4 Pkts.
6. Antiseptic Solution Dettol (100 ml.) or Savlon 1 Bottle
7. Mercurochrome Solution (100 ml.) 2% in water 1 Bottle
8. Ammonia Solution (20 ml.) 1 Bottle
9. A Pair of Scrissors 1 Piece
10. Adhesive Plaster (1.25 cm x 5 m) 1Spool
11. Eye pads in Separate Sealed Packet 4 Pcs.
12. Tourniqut 1 No.
13. Safety Pins 1 Dozen
14. Tinc. Iodine / Betadin (100 ml.) 1 Bottles
15. Ointment for burns (Burnol 20 gms.) 1 Bottole
16. Polythene Wash cup for washing eyes 1 No.
17. Potassium Permanganate (20 gms.) 1 Pkt.
18. Tinc. Benzoine (100 ml.) 1 Bottole
19. Triangular Bandages 2 Nos.
20. Band Aid Dressing 5 Pcs.
21. Iodex / Moov (25 gms.) 1 Bottole
22. Tongue Depressor 1 No.
23. Boric Acid Powder (20 gms.) 2 Pkt.
24. Sodium Bicarbonate (20 gms.) 1 Pkt.
25. Dressing Powder (Nebasulf) (10 gms.) 1 Bottole
26. Medicinal Glass 1 No.
27. Duster 1 No.
28. Booklet (English & Local Language) 1 No. each
29. Soap 1 No.
30. Toothache Solution 1 No.
31. Eye Ointment 1 Bottle
32. Vicks (22 gms.) 1 Bottle
33. Forceps 1 No.
34. Cotton Buds (5 nos.) 1 Pkt.
35. Note Book 1 No.
36. Splints 4 Nos.
37. Lock 1 Piece
38. Life Saving/Emergency/Over-the Counter Drugs As decided at site
Box size : 14” x 12” x 4”
Note : The medicines prescribed above are only indicative. Equivalent medicines can also be used.
A prescription, in this regard, shall be required from a qualified Physician.
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ANNEXURE – C
TYPE OF FIRES VIS-À-VIS FIRE EXTINGUISHERS
Fire Fire Extinguishers

Water Foam CO2 Dry Powder Multi Purpose
(ABC)
Originated from paper, √ √ Can control Can control √
clothes, wood minor minor
surface fires surface fires
Inflammable liquids x √ √ √ √
like alcohol, diesel,
petrol, edible oils,
bitumen
Originated from gases x x √ √ √

like LPG, CNG, H2
Electrical Fires x x √ √ √
Legend : √ Can be used

x Not to be used
Note : Fire extinguishing equipment must be checked atleast once a year and after every use by
an authorized person. The equipment must have an inspection label on which the next
inspection date is given: Type of extinguisher shall clearly be marked on it.
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ANNEXURE – D
Indicative List of Statutory Acts & Rules Relating to HSE
- The Indian Explosives Act and Rules

- The Motor Vehicle Act and Central Motor Vehicle Rules
- The Factories Act and concerned Factory Rules
- The Petroleum Act and Petroleum Rules
- The Workmen Compensation Act
- The Gas Cylinder Rules and the Static & Mobile Pressure Vessels Rules.
- The Indian Electricity Act and Rules
- The Indian Boiler Act and Regulations
- The Water (Prevention & Control & Pollution) Act
- The Water (Prevention & Control of Pollution) Cess Act
- The Mines & Minerals (Regulation & Development) Act
- The Air (Prevention & Control of Pollution) Act
- The Atomic Energy Act
- The Radiation Protection Rules
- The Indian Fisheries Act
- The Indian Forest Act
- The Wild Life (Protection) Act
- The Environment (Protection) Act and Rules
- The Hazardous Wastes (Management & Handling) Rules
- The Manufacturing, Storage & import of Hazardous Chemicals Rules
- The Public Liability Act
- The Building and Other Construction Workers (Regulation of Employment and Condition of
service) Act
- Other statutory acts Like EPF, ESIS, Minimum Wage Act.
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ANNEXURE – E
CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES
ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

(A) EXCAVATION  Falling into pit  Personal injury  Provide guard
rails/barricade with
Pit Excavation up warning signal.
to 3.0m  Provide at least two
entries/exits.
 Provide escape
ladders.
 Earth  Suffocation /  Provide suitable size
Collapse Breathlessness of shoring and
 Buried strutting, if required.
 Keep soil heaps
away from the edge
equivalent to 1.5m or
depth of pit
whichever is more.
 Don’t allow vehicles
to operate too close
to excavated areas.
Maintain at least 2m
distance from edge
of cut.
 Maintain sufficient
angle of repose.
Provide slope not
less than 1:1 and
suitable bench of
0.5m width at every
1.5m depth of
excavation in all soils
except hard rock.
 Battering/benching
the sides.
 Contact with  Electrocution  Obtain permission
buried electric  Explosion from competent
cables authorities, prior to
 Gas/ Oil excavation, if
Pipelines required.
 Locate the position
of buried utilities by
referring to plant
drawings.
 Start digging
manually to locate
the exact position of
buried utilities and
thereafter use
mechanical means.
Pit Excavation  Same as  Can cause  Prevent ingress of
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beyond 3.0m above plus drowning situation water
 Flooding due  Provide ring buoys
to excessive  Identify and provide
rain/ suitable size
underground dewatering pump or
water well point system
 Digging in the  Building/ Structure  Obtain prior approval
vicinity of may collapse of excavation
existing  Loss of health & method from local
Building/ wealth authorities
Structure  Use under-pining
method
 Construct retaining
wall side by side
 Movement of  May cause cave-  Barricade the
vehicles / in or slides excavated area with
equipments  Persons may get proper lighting
close to the buried arrangements
edge of cut.  Maintain at least 2m
distance from edge
of cut and use stop
block to prevent
over-run.
 Strengthen shoring
and strutting
Narrow deep  Same as  May cause severe  Battering/benching

excavations for above plus injuries or prove of sides
pipelines, etc.  Frequent fatal  Provide escape
cave-in or ladders
slides
 Flooding due  May arise  Same as above plus
to Hydrostatic drowning situation  Bail out accumulated
testing water
 Maintain adequate
ventilation
Rock excavation by  Improper  May prove fatal  Ensure proper
blasting handling of storage, handling &
explosives carrying of
explosives by trained
personnel.
 Comply with the
applicable explosive
acts & rules.
 Uncontrolled  May cause severe  Allow only authorized
explosion injuries or prove persons to perform
fatal blasting operations.
 Smoking and open
flames are to be
strictly prohibited.
 Scattering of  Can hurt people  Use PPE like
stone pieces goggles, face mask,
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in atmosphere helmets etc.
Rock excavating by  Entrapping of  May cause severe  Barricade the area
blasting (Contd) persons/ injuries or prove with red flags and
animals. fatal blow siren before
blasting.
 Misfire  May explode  Do not return to site

suddenly for at least 20
minutes or unless
announced safe by
designated person.
Piling Work  Failure of pile-  Can hurt people  Inspect Piling rigs
driving and pulley blocks
equipment before the beginning
of each shift.
 Noise  Can cause  Use personal
pollution deafness protective
 and psychological equipments like ear
imbalance plugs, muffs, etc.
 Extruding rods  Can hurt people  Barricade the area

/ casing an install sign boards
 Provide first-aid
 Working in the  Can cause  Keep sufficient
vicinity of electrocution / distance from Live-
‘Live- asphyxiation Electricity as per IS
Electricity’ code.
 Shut off the supply, if
possible
 Provide
artificial/rescue
breathing to he
injured.
(B) CONCRETING  Air pollution  May affect  Wear respirators or
by cement Respiratory cover mouth and
System nose with wet cloth.
 Handling of  Hand s may get  Use gloves and
ingredients injured other PPE.
 Protruding  Feet may get  Use Safety shoes.
reinforcement injured  Provide platform
rods. above reinforcement
for movement of
workers.
 Earthing of  Can cause  Ensure earthing of
electrical electrocution / equipments and
mixers, asphyxiation proper functioning of
vibrators, etc. electrical circuit
not done before
commencement of
work.
 Falling of  Persons may get  Use hard hats
materials from injured  Remove surplus
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height material immediately
from work place
 Ensure lighting
arrangements during
night hours.
 Continuous  Cause tiredness  Insist on shift pattern
pouring by of workers and  Provide adequate
same gang may lead to rest to workers
accident. between subsequent
pours.
 Revolving or  Parts of body or  Allow only mixers
concrete clothes may get with hopper
mixer/ entrapped.  Provide safety cages
vibrators around moving
motors
 Ensure proper
mechanical locking
of vibrator
Super-structure  Same as  Shuttering / props  Avoid excessive
above plus may collapse and stacking on
 Deflection in prove fatal shuttering material
props or  Check the design
shuttering and strength of
material shuttering material
before
commencement of
work
 Rectify immediately
the deflection noted
during concreting
 Passage to  Improperly tied  Ensure the stability
work place and designed and strength of
props / planks passage before
may collapse commencement of
work
 Do not overload and
under the passage.
(C)  Curtailment  Persons may get  Use PPE like gloves,
REINFORCEMENT and binding of injured shoes, helmets, etc.
rods  Avoid usage of shift
tools
 Carrying of  Workers may  Provide suitable
rods for short injure their hands pads on shoulders
distance/ at and shoulders and use safety
heights gloves.
 Tie up rods in easily
liftable bundles
 Ensure proper
staging.
 Checking of  Rods may cut or  Use measuring
clear distance/ injure the finger devices tape,
cover with measuring rods, etc.
387 of 911


hands
 Hitting  Persons may get  Use safety shoes
projected rods injured and fall and avoid standing
and standing down unnecessarily on
on cantilever cantilever rods
rods  Avoid wearing loose
clothes
 Falling of  May prove fatal  Use helmets
material from  Provide safety nets
height
 Transportation  Protruded rods  Use red flags/lights
of rods by may hit the at the ends
trucks / persons  Do not protrude the
trailers rods in front of or by
the side of driver’s
cabin.
 Do not extend the
rods 1/3rd of deck
length or 1.5 m
which is less
(D) WELDING  Welding  Radiation can  Use specified
AND GAS radiates damage eyes and shielding devices
CUTTING invisible skin. and other PPE of
ultraviolet and correct specifications
infrared says  Avoid throated
tungsten electrodes
for GTAW.
 Improper  Explosion may  Move out any leaking
placement of occur cylinder
oxygen and  Keep cylinder in
acetylene vertical position
cylinders  Use trolley for
transportation of
cylinders and chain
them
 Use flash back
arrestors
 Leakage /  May cause fire  Purge regulators
cuts in hoses immediately and
then turn off
 Never use grease or
oil on oxygen line
connections and
copper fittings on
acetylene lines
 Inspect regularly gas
carrying hoses
 Always use red hose
for acetylene & other
fuel gases and black
388 of 911


for oxygen.
 Opening-up of  Cylinder may  Always stand back
cylinder burst from the regulator
while opening the
cylinder
 Turn valve slowly to
avoid bursting
 Cover the lug
terminals to prevent
short circuiting.
 Welding of  Explosion may  Empty & purge them

tanks, occur before welding
container or  Never attach the
pipes storing ground cable to
flammable tanks, container or
liquids pipe storing
flammable liquids
 Never use LPG for
gas cutting
(E)  Ionizing  Radiations may  Ensure safety
RADIOGRAPHY Radiation react with the skin regulations as per
and can cause BARC/AERB before
cancer, skin commencement of
irritation, job.
dermatitis, etc.  Cordon off the area
and install Radiation
warning symbols
 Restrict the entry of
unauthorized
persons
 Wear appropriate
PPE and film badges
issued by
BARC/AERB
 Transportation  Same as above  Never touch or
and Storage handle radiography
of source with hands
Radiography  Store radiography
source source inside a pit in
an exclusive isolated
storage room with
lock and key
arrangement. The pit
should be approved
by BARC/AERB
 Radiography source
should never be
carried either in
passenger bus or in
a passenger
compartment of
389 of 911


trains.
 BARC/AERB have to
be informed before
source movement.
 Permission from
Director General of
Civil Aviation is
required for booking
radio isotopes with
airlines.
 Loss of Radio  Same as above  Try to locate with the
isotope help of Survey
Meter.
 Inform
BARC/AERB(*)
(*) Atomic Energy

Regulatory Board
(AERB), Bhabha
Atomic Research
Centre (BARC)
Anushaktinagar,
Mumbai – 400 094
(F) ELECTRICAL  Short  Can cause  Use rubberized hand
INSTALLATION circuiting Electrocution or gloves and other
AND USAGE Fire PPE
 Don’t lay wires under
carpets, mats or
door ways.
 Allow only licensed
electricians to
perform on electrical
facilities
 Use one socket for
one appliance
 Ensure usage of only
fully insulated wires
or cables
 Don’t place bare wire
ends in a socket
 Ensure earthing of
machineries and
equipments
 Do not use damaged
cords and avoid
temporary
connections
 Use spark-
proof/flame proof
type field distribution
boxes.
 Do not allow
390 of 911


open/bare
connections
 Provide all
connections through
ELCB
 Protect electrical
cables / equipment’s
from water and
naked flames
 Check all
connections before
energizing.
 Overloading  Bursting of  Display voltage and
of Electrical system can occur current ratings
System which leads to fire prominently with
‘Danger’ signs.
 Ensure approved
cable size, voltage
grade and type.
 Switch off the
electrical utilities
when not in use.
 Do not allow
unauthorized
connections.
 Ensure proper grid
wise distribution of
Power.
 Improper  Can cause  Do not lay
laying of electrocution and unarmored cable
overhead and prove fatal directly on ground,
underground wall, roof of trees
transmission  Maintain at least 3m
lines / cables distance from HT
cables
 All temporary cables
should be laid at
least 750 mm below
ground on 100 mm
fine sand overlying
by brick soling
 Provide proper
sleeves at crossings/
intersections
 Provide cable route
markers indicating
the type and depth of
cables at intervals
not exceeding 30m
and at the diversions
/ termination.
(G) FIRE  Small fires  Cause burn  In case a fire breaks
391 of 911


PREVENTION can become injuries and may out, press fire alarm
AND big ones and prove fatal. system and shout
PROTECTION may spread to “Fire, Fire”
the  Keep buckets full of
surrounding sand & water/fire
areas extinguishing
equipment near
hazardous locations
 Confine smoking to
‘Smoking Zones’
only
 Train people for
using specific type of
fire equipments
under different
classes of fire
 Keep fire doors/
shutters, passages
and exit doors
unobstructed
 Maintain good house
keeping and first-aid
boxes (for detail
refer Annex-2)
 Don’t obstruct
assess to Fire
extinguishers
 Do not use elevators
for evacuation during
fire
 Maintain lightening
arrestors for
elevated structures
 Stop all electrical
motors with internal
combustion.
 Move the vehicles
from dangerous
locations.
 Remove the load
hanging from the
crane booms.
 Remain out of the
danger areas.
 Improper  It may not  Ensure usage of
selection of extinguish the fire correct fire
Fire extinguisher meant
Extinguisher for the specified fire
(for details refer
Appendix-C)
 Do not attempt to
extinguish Oil and
392 of 911


electric fires with
water. Use foam
cylinders/CO2/sand
or earth.
 Improper  Same as above  Maintain safe

storage of distance of
highly flammable
inflammable substances from
substances source of ignition
 Restrict the
distribution of
flammable materials
to only min.
necessary amount
 Construct specifically
designed fuel
storage facilities
 Keep chemicals in
cool and dry place
away from hat.
Ensure adequate
ventilation
 Before welding
operation, remove or
shield the flammable
material properly
 Store flammable
materials in stable
racks, correctly
labeled preferably
with catchments
trays.
 Wipe off the spills
immediately
 Short  Same as above  Don’t lay wires under

circuiting of  Can cause carpets, mats or
electrical Electrocution door ways
system  Use one socket for
one appliance
 Use only fully
insulated wires or
cables
 Do not allow
open/bare
connections
 Provide all
connections through
ELCB
 Ensure earthing of
machineries and
393 of 911


equipments
(H) VEHICULAR  Crossing the  Personal injury  Obey speed limits

MOVEMENT Speed Limits and traffic rules
(Rash driving) strictly
 Always expect the
unexpected and be a
defensive drive
 Use sat
belts/helmets
 Blow horn at
intersections and
during overtaking
operations.
 Maintain the vehicle
in good condition
 Do not overtake on
curves, bridges and
slopes
 Adverse  Same as above  Read the road ahead

weather and ride to the left
condition  Keep the wind
screen and lights
clean
 Do not turn at speed
 Recognize the
hazard, understand
the defense and act
correctly in time.
 Consuming  Same as above  Alcohol and driving

alcohol before do not mix well.
and during he Either choose
driving alcohol or driving.
operation  If you have a choice
between hitting a
fixed object or an
oncoming vehicle, hit
the fixed object
 Quit the steering at
once and become a
passenger.
Otherwise take
sufficient rest and
then drive.
 Do not force the
driver to drive fast
and round the clock
 Do not day dram
while driving
 Falling objects  May prove fatal  Ensure effective
394 of 911


/ Mechanical braking system,
failure adequate visibility for
the drives, reverse
warning alarm.
 Proper maintenance
of the vehicle as per
manufacturer
instructions
(I) PROOF  Bursting of  May cause injury  Prepare test

TESTING piping and prove fatal procedure & obtain
(HYDROSTATIC/  Collapse of CONSULTANT/
PNEUMATIC tanks Owner’s approval
TESTING  Tanks flying  Provide separate
off gauge for
pressurizing pump
and
piping/equipment
 Check the calibration
status of all pressure
gauges, dead weight
testers and
temperature
recorders
 Take dial readings at
suitable defined
intervals and ensure
most of them fall
between 40-60% of
the gauge scale
range
 Provide safety relief
valve (set at
pressure slightly
higher than test
pressure) while
testing with
air/nitrogen
 Ensure necessary
precautions,
stepwise increase in
pressure, tightening
of bolts/ nuts,
grouting, etc. before
and during testing
 Keep the vents open
before opening any
valve while draining
out of water used for
hydro testing of
tanks
 Pneumatic testing
395 of 911


involves the hazard
of released energy
shored in
compressed gas.
Specific care must
therefore be taken to
minimize the chance
of brittle failure
during a pneumatic
leak test. Test
temperature is
important in this
regard and must be
considered when the
designer chooses
the material of
construction
 A pressure relief
device shall be
provided, having a
set pressure not
higher than the test
pressure plus the
lesser of 345 KPa
(50 psi) or 10% of he
test pressure. The
gas used as test
fluid, if not air, shall
be nonflammable
and nontoxic.
(J) WORKING AT  Person can  May sustain  Provide guard
HEIGHTS fall down severe injuries or rails/barricade at the
prove fatal work place
 Use PPE like safety
belts, full body
harness, life line,
helmets, safety
shoes, etc.
 Obtain a permit
before starting the
work at height above
3 meters
 Fall arrest systems
like safety nets, etc.
must be installed
 Provide adequate
working space (min.
0.6 m)
 Tie/weld working
platform with fixed
support
 Use roof top walk
396 of 911


ladder while working
on a slopping roofs
 Avoid movement on
beams
 May hit the scrap /  Keep the work place
material stacked neat and clean
at the ground or in  Remove the scrap
between immediately
 Material can  May hit the  Same as above plus

fall down workers working  Do not throw or drop
at lower levels material or
and prove fatal. equipment from
height
 All tools to be carried
in a toolkit bags or
on working uniform
 Remove scrap from
the planks
 Ensure wearing of
helmet by the
workers at low level
(K) CONFINED  Suffocation /  Unconsciousness,  Use respiratory
SPACES drowning death devices, if required
 Avoid over crowding
inside a confined
space
 Provide Exhaust
Fans for ventilation
 Do not wear loose
clothes, neck ties,
etc.
 Fulfill conditions of
the permit.
 Check for presence
of hydrocarbons, O2
level
 Obtain work permit
before entering a
confined space
 Ensure that the
connected piping of
the equipment which
is to be opened is
pressure free, fluid
has been drained,
vents are open and
piping is positively
isolated by a blind
flange
 Presence of  Inhalation can  Same as above plus
foul smell and pose threat to life.  Check for
397 of 911


toxic hydrocarbon and
substances Aromatic
compounds before
entering a confined
space
 Depute one person
outside the confined
space for continuous
monitoring and for
extending help in
case of an
emergency
 Ignition /  Person may  Keep fire

flame can sustain burn extinguishers at a
cause fire injuries or hand distance
explosion may  Remove surplus
occur material and scrap
immediately
 Do not smoke inside
a confined space
 Do not allow gas
cylinders inside a
confined space
 Use low voltage
(24V) lamps for
lighting
 Use tools with air
motors or electric
tools with max.
voltage of 24V
 Remove all
equipments at the
end of the day
(L) HANDLING  Failure of load  Can cause  Avoid standing under
AND LIFTING lifting and accident and the lifted load and
EQUPMENTS moving prove fatal within the operating
equipments radius of cranes
 Check periodically
oil, brakes, gears,
horns and tyre
pressure of all
moving machinery
 Check quality, size
and condition of all
chain pulley blocks,
slings, U-clamps, D-
shackles, wire ropes,
etc.
 Allow crane to move
only on hard, firm
and leveled ground
398 of 911


 Allow lifting slings as
short as possible
and check gunny
packings at the
friction points
 Do not allow crane to
tilt its boom while
moving
 Install Safe Load
Indicator
 Ensure certification
by applicable
authority.
 Overloading  Can cause  Safe lifting capacity

of lifting electrocution and of derricks and
equipments fire winches written on
them shall be got
verified.
 The max safe
working load shall be
marked on all lifting
equipments
 Check the weight of
columns and other
heavy items painted
on them and
accordingly decide
about the crane
capacity, boom and
angle of erection
 Allow only trained
operators and
riggers during crane
operation
 Overhead  Can cause  Do not allow boom

electrical electrocution and or other parts of
wires fire crane to come within
3 m reach of
overhead HT cables
 Hook and load being
lifted shall preferably
remain in full visibility
of crane operator.
(M)  Person can  Person may  Provide guard rails

SCAFFOLDING, fall down sustain severe for working at height
FORMWORK AND injuries and prove  Face ladder while
LADDERS fatal climbing and use
both hands
 Ladders shall extend
399 of 911


about 1m above
landing for easy
access and tying up
purpose
 Do not place ladders
against movable
objects and maintain
base at ¼ unit of the
working length of the
ladder
 Suspended scaffolds
shall not be less than
500 mm wide and
tied properly with
ropes
 No loose planks
shall be allowed
 Use PPE, like
helmets, safety
shoes, etc.
 Failure of  Same as above  Inspect visually all

scaffolding scaffolding materials
material for stability and
anchoring with
permanent
structures.
 Design scaffolding
for max. load
carrying capacity
 Scaffolding planks
shall not be less than
50x250 mm full
thickness lumber or
equivalent. These
shall be cleared or
secured and must
extend over the end
supports by at least
150mm and not
more that 300 mm
 Don’t overload the
scaffolds
 Do not splice short
ladders to make a
longer one. Vertical
ladders shall not
exceed 6m.
 Material can  Persons working  Remove excess

fall down at lower level gets material and scrap
injured. immediately
400 of 911


 Carry the tools in a
tool-kit bag only
 Provide safety nets
(N) STRUCTURAL  Personal  Can cause injury  Do not take rest

WORKS negligence or casualty inside rooms built for
and danger of welding machines or
fall electrical distribution
system
 Avoid walking on
beams at height
 Wear helmet with
chin strap and safety
belts when working
at height
 Use hand gloves and
goggles during
grinding operations
 Cover or mark the
sharp and projected
edges
 Do not stand within
the operating radius
of cranes
 Lifting /  Same as above  Do not stand under

slipping of the lifted load
material  Stack properly all the
materials. Avoid
slippage during
handling
 Control longer
pieces lifted up by
cranes from both
ends
 Remove loose
materials from height
 Ensure tightening of
all nuts and bolts
(O) PIPELINE  Erection /  Can cause injury  Do not stand under
WORKS lowering the lifted Load
failure  Do not allow any
person to come
within the radii of the
side boom handling
pipes
 Check the load
carrying capacity of
the lifting tools and
tackles
 Use safe Load
Indicators
401 of 911


 Use appropriate
PPEs
 Other  Same as above  Wear gum boots in

marshy areas
 Allow only one
person to perform
signaling operations
while lowering of
pipes
 Provide night caps
on pipes
 Provide end covers
on pipes for
stoppage of pigs
while
testing/cleaning
operations.
402 of 911

FORMAT NO. : HSE-1, REV. 0
HSE CHECKLIST CUM COMPLIANCE REPORT (1/6)
Project: _________________________ Contractor :_______________________

Date: _________________________ Owner :________________________
Inspection By:___________________ Report No. :________________________
Frequency : Fortnightly Job No :_______________________
Note: write ‘NA’ wherever the item is not applicable
SL. ITEM YES NO REMARKS ACTION

NO.
1 HOUSEKEEPING
a) Waste containers provided and used
b) Sanitary facilities adequate and clean
c) Passageways and Walkways clear
d) General neatness of working areas
e) Others
2 PERSONNEL PROTECTIVE EQUIPMENT
a) Goggles; Shields
b) Face protection
c) Hearing protection
d) Safety shoes
e) Hand protection
f) Respiratory Masks etc.
g) Safety Belts
h) Safety Helmet/Hard Hat
I) Others
3 EXCAVATIONS/OPENINGS
a) Openings properly covered or barricaded
b) Excavations shored
c) Excavations barricaded
d) Overnight lighting provided
e) Others
4 WELDING & GAS CUTTING
a) Gas cylinders chained upright
b) Cables and hoses not obstructing
c) Screens or shields used
d) Flammable materials protected
e) Fire extinguisher(s) accessible
f) Others
5 SCAFFOLDING
a) Fully decked platforms
b) Guard and intermediate rails in place
c) Toe boards in place
d) Adequate shoring
403 of 911


NO.
e) Adequate access
f) Others
6 LADDERS
a) Extension side rails 1m above
b) Top of landing
c) Properly secured
d) Angle + 70 from horizontal
e) Others
7 HOISTS, CRANES AND DERRICKS
a) Condition of cables and sheaves OK
b) Condition of slings, chains, hooks and eyes OK
c) Inspection and maintenance logs maintained
d) Outriggers used
e) Signs/barricades provided
f) Signals observed and understood
g) Qualified operators
h) Others
8 MACHINERY, TOOLS AND EQUIPMENT
a) Proper instruction
b) Safety devices
c) Proper cords
d) Inspection and maintenance
e) Others
9 VEHICLE AND TRAFFIC
a) Rules and regulations observed
b) Inspection and maintenance
c) Licensed drivers
d) Others
10 TEMPORARY FACILITIES
a) Emergency instructions posted
b) Fire extinguishers provided
c) Fire-aid equipment available
d) Secured against storm damage
e) General neatness
f) In accordance with electrical requirements
g) Others
11 FIRE PREVENTION
a) Personnel instructed
b) Fire extinguishers checked
c) No smoking in Prohibited Areas
d) Hydrants Clear
e) Others
12 ELECTRICAL
a) Use of 3-core armoured cables
404 of 911


NO.
b) Usage of 'All insulated' or 'double insulated' electrical
tools
c) All electrical connection are routed through ELCB
d) Natural Earthing at the source of power (main DB)
e) Continuity and tightness of earth conductor
f) Covering of junction boxes, panels and other
energized wiring places
g) Ground fault circuit interrupters provided
h) Prevention of tripping hazards
i) Others
13 HANDLING AND STORAGE OF MATERIALS
a) Properly stored or stacked
b) Passageways clear
c) Others
14 FLAMMABLE GASES AND LIQUIDS
a) Containers clearly identified
b) Proper storage
c) Fire extinguishers nearby
d) Others
15 WORKING AT HEIGHT
a) Erection plan and work permit obtained
b) Safety nets
c) Full body harness and lanyards; chute lines
d) Health Check record available for workers going up?
e) Others
16 CONFINED SPACE
a) Work permit obtained
b) Test for toxic gas and sufficient availability of oxygen
conducted
c) At least one person outside the confined space for
monitoring deputed
d) Availability of sufficient means of entry, exit and
ventilation
e) Fire extinguishers and first-aid facility ensured
f) Lighting provision made by using 24V lamps
g) Proper usage of PPEs ensured
17 RADIOGRAPHY
a) Proper storage and handling of source as per BARC /
AREB guidelines
b) Working permit obtained
c) Cordoning of the area done
d) Use of appropriate PPE's ensured
e) Proper training to workers/supervisors imparted
f) Minimum occupancy of workplace ensured
18 HEALTH CHECKS
405 of 911


NO.
a) Workers medically examined and found to fit for
working :
i) At heights
ii) In confined space.
b) Availability of First-aid facilities
c) Proper sanitation at site, office and labour camps
d) Arrangement of medical facilities
e) Measures for dealing with illness
f) Availability of Portable drinking water for workmen &
staff
g) Provision of crèches for children
h) Stand by vehicle available for evacuation of injured.
19 ENVIRONMENT
a) Chemical and other effluents properly disposed
b) Cleaning liquid of pipes disposed off properly
c) Seawater used for hydro-testing disposed off as per
agreed procedure
d) Lubricant Waste/Engine oils properly disposed
e) Waste from Canteen, offices, sanitation etc. disposed
properly
f) Disposal of surplus earth, stripping materials, oily
rags and combustible materials done properly
g) Green belt protection
___________________
Signature of Resident
Engineer with Seal
406 of 911

ACCIDENT / INCIDENT REPORT

(To be submitted by Contractor after every Accident / Incident within 24 hours)
Report No:___________________
Date: _______________________
Name of Site:-_______________________
CONTRACTOR______________________
Type of Accident / Incident : Fatal Other Lost Time Non Loss Time First-Aid case
NAME OF THE INJURED………………………………………………………………………………

AGE ……………………………………………………………………………………………………….
FATHER’S NAME………………………………………………………………………………………..
SUB-CONTRACTOR M/S………………………………………………………………………………..
DATE & TIME OF ACCIDENT………………………………………………………………………….
LOCATION ………………………………………………………………………………………………
BRIEF DESCRIPTION OF ACCIDENT
CAUSE OF ACCIDENT
NATURE OF INJURY/DAMAGE
MEDICAL AID PROVIDED/ACTIONS TAKEN
INTIMATION TO LOCAL AUTHORITIES (IF APPLICABLE)
DATE: SIGNATURE OF CONTRACTOR

WITH SEAL
To : OWNER………………………….. 1 COPY
: RCM/SITE-IN-CHARGE, MECON 3 COPIES
Divisional Head (Constn.) through RCM

Project Manager MECON, through RCM
407 of 911

SUPPLEMENTARY ACCIDENT / INCIDENT INVESTIGATION REPORT
Supplementary to Report No: _________(Copy enclosed)
Project:_____________________ Site:________________________
Name of Work :____________________ Date:_______________________
Contractor:______________________ Work Order / LOI No. :______________
NAME OF THE INJURED …………………………………………………………………………….

AGE : …………………………………………………………………………………...
SUB-CONTRACTOR M/S……………………………………………………………………………...
DATE & TIME OF ACCIDENT / INCIDENT ……………………………………………………………
LOCATION……………………………………………………………………………………………
BRIEF DESCRIPTION & CAUSE OF A ACCIDENT/ INCIDENT
NATURAL OF INJURY/DAMAGE
COMMENTS FROM MEDICAL PRACTITIONER WHO ATTENDED THE VICTIM/INJURED
SUGGESTED IMPROVEMENT IN THE WORKING CONDITION IF ANY
LOSS OF MANHOURS AND IMPACT ON SITE WORKS
ANY OTHER COMMENT BY SAFETY OFFICER.

WITH SEAL
To : OWNER………………………….. 1 COPY

408 of 911

NEAR MISS INCIDENT – SUGGESTED PROFORMA
Report No: ___________________

Name of Site :_____________________ Date :________________________
Name of Work :____________________ Contractor :_______________________
INCIDENT REPORTED BY :
DATE & TIME OF INCIDENT :
LOCATION :
BRIEF DESCRIPTION OF INCIDENT
PROBABLE CAUSE OF INCIDENT
SUGGESTED CORRECTIVE ACTION
STEPS TAKEN TO AVOID RECURRENCE YES NO

WITH SEAL
To : OWNER………………………….. 1 COPY

409 of 911


MONTHLY HEALTH, SAFETY & ENVIRONMENT (HSE) REPORT
(To be submitted by each Contractor)
Actual work start Date:________________ For the Month of:__________________

Project:_____________________________ Report No:_______________________
Name of the Contractor:________________ Status as on:_____________________
Name of Work:_______________________ Name of Safety officer:______________
ITEM UPTO THIS CUMU-

PREVIOUS MONTH LATIVE
MONTH
a) Average number of Staff & Workmen (average
daily headcount, not man days)
b) Manhours Worked
c) Number of HSE meeting organized at site
d) Number of HSE awareness programmes
conducted at site
e) Number of Lost Time Accidents Fatal
(LTA) Other LTA
f) Number of Loss time Injuries Fatalities
(LTI) Other LTI
g) Number of Loss Time Accidents
h) Number of First Aid Cases
i) Number of Near Miss Incidents
j) Man-days lost due to accidents
k) LTA Free Manhours i.e. Number of LTA free
manhours from the Lst LTA
l) Compensation cases raised with Insurance
m) Compensation case resolved and paid to
workmen
n) Whether workmen compensation policy taken Y/N
o) Whether workmen compensation policy valid Y/N
p) Whether workmen registered under ESI Act Y/N
Remark
DATE: Safety Officer /Resident Engineer

(Signature and Name)
To : OWNER
: RCM/, MECON (2 COPIES)
410 of 911

PERMIT FOR WORKING AT HEIGHT (ABOVE 2 METER)
Project Site : ……………………………………… Sr. No.: ………………………

Name of the work: ………………………………. Date: …………………………
Name of Contractor : …………………………….. Nature of Work : ……………
Total No.of Workers: …………………………….. Exact location of work : ……
Duration of work: from ..………. to …………
The following items have been checked and compliance shall be ensured during the
currency of the permit:
------------------------------------------------------------------------------------------------------------------------------
Sl. ITEM DONE NOT REQD.
------------------------------------------------------------------------------------------------------------------------------
1. Equipment/Work Area inspected
2. Considered hazard from other routine/non-routine

operations and concerned person alerted
3. ELCB provided
4. Proper lighting provided
5. Area cordoned off.
6. Precautions against public traffic taken
7. Sound Scaffolding provided
8. Adequate protected Platform provided
9. Acces and Exit to the area

(Ladder properly fixed)
10. Floor Openings covered
11. Safety Net provided
12. Heath check of personnel
-------------------------------------------------------------------------------------------------------
A. Following personal protective equipment are provided ( mark) and used as relevant
Safety helmet/Gloves/Goggles/Shoes/Face Shield/Life Line/Safety Belt/Safety Harness.
B. This permit shall be available at the work site at all times.
C. Permit shall be issued for maximum one week only (Monday to Sunday).
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D. This permit shall be applicable in non-operational areas.
E. After completion of the work, used permits shall be preserved for record purposes.
F. Additional precautions, if any ………………………………………………………….
Permission is granted to work (See overleaf) = Yes/No
Name of Contractor’s Supervisor Name of Contractor’s Safety Officer

(Initiator) (Issuing Authority)
GRANT OF PERMIT AND EXTENSIONS
Issuing
Validity Verification
Work time Initiator Authority
Sl. Period by
From …..Hrs. (Supervisor of (Safety
No. From ……… CONSULTANT
To ……….Hrs. Contractor) Officer)
To ……… with date
of Contractor
Additional safety instructions, if any.
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CONFINED SPACE ENTRY PERMIT
Project Site : ……………………………………… Sr. No.: ………………………

Name of the work: ………………………………. Date: …………………………
Name of Contractor : …………………………….. Nature of Work : ……………
Exact location of work : ………………………….
Safety Requirements : POSITIVE ISOLATION OF THE VESSEL IS MANDATORY
(A) Has the equipment been ?

Y NR Y NR Y NR
isolated from water flushed &/or radiation sources
power / steam / air steamed removed
isolated from liquid Manways open & Proper lighting
or gases ventilated provided
depressurized &/or cont. inset gas flow
drained arranged
blanked / blinded / adequately cooled
disconnected
(B) Expected Residual Hazards

Y NR Y NR Y NR
lack of O2 combustible gas / H2S / toxic gases
liquid
corrosive pyrophoric iron / electricity / static
chemicals scales
Heat / stream / high humidity ionizing radiation
frost
(C) Protective Measures

Y NR Y NR Y NR
gloves ear plug / muff goggles / face
shield
protective clothing dust / gas / air line personal gas alarm
mask
Grounded air attendant with rescue equipment /
educater / blower / SCBA / air mask team
AC
Fire fighting safety harness & communication
arrangements lifeline equipment
Authorization / Renewal (It is safe to enter the confirmed space)
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Date No. of Name of Signature Time Signatur

Persons Persons e
Allowed allowed Contractor’s Contractor’s From To Workman
Supervisor Safety
Officer
Permit Closure :
(A) Entry was closed stopped will continue on
(B) Site left in a safe condition

Housekeeping done
(C) Multi lock removed key transferred

Ensured all men have come out Manways barricaded
Remarks, if any :
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RADIATION WORK PERMIT
Project : Sr. No.:

Name of the work : Date:
Name of Contractor : Job No. :
Location of work :
Source Strength :
Cordoned distance (m) :
Name of Radiographing agency : Approved by Owner / MECON
The following items have been checked & compliance shall be ensured during currency of the
permit :
S. Item Description Done

No.
1. Safety regulations as per BARC/AERB ensured while source in use/ in transit &
during storage.
2. Area cordoned off.
3. Lighting arrangements for working during nights ensured.
4. Warning signs / flash lights installed.
5. Cold work permit taken (if applicable)
6. PPEs like film badges, dosimeters used.
Additional precautions, if any ______________________________________________________
(Radiography Agency’s BARC / AREB authorized Supervisor) (Contractor’s Safety Officer)
Permission is granted.
Permit is valid from _________ AM/PM ____________ Date to ________ AM/PM ____________
Date
(Signature of permit issuing authority)
Name : Designation : Date :
Permit renewal :
415 of 911

Permit extended upto Additional precautions Sign of issuing authority

Date Time required, if any. with date
Work completed / stopped / area cleared at ____________ Hrs. of Date _______________
(Sign of permit issuing authority)

Name :
416 of 911

PERMIT FOR DEMOLISHING / DISMANTLING
Project : Sr. No.:

Name of the work : Date:
Name of Contractor : Job No. :
Name of Contractor :
Line No. / Equipment No. /Structure to be dismantled :
Location details of dismantling / demolition with sketch : (Clearly indicate the area)
The following items have been checked & compliance shall be ensured during currency of the
permit :
S. Item Description Done Not

No. Applicable
1. Services like power, gas supply, water, etc. disconnected.
2. Dismantling / Demolishing method reviewed & approved.
3. Usage of appropriate PPEs ensured.
4. Precautions taken for neighboring structures
5. First-Aid arrangements made
6. Fire fighting arrangements ensured
7. Precautions taken for blasting
(Contractor’s Supervisor) (Contractor’s Safety Officer)
Permission is granted.
(Permit issuing authority)

Name :
Date :
Completion Report :
417 of 911

Dismantling / Demolishing is completed on __________ Date at __________ Hrs.
Materials / debris transported to identified location
Tagging completed (as applicable)
Services like power, gas supply, water, etc. restored
(Permit issuing authority)

Name :
418 of 911
MECON LIMITED STANDARD TECHNICAL SPECIFICATION OF QUALITY
DELHI ASSURANCE SYSTEMS REQUIREMENTS
REV 0, EDITION - 1
FOR
QUALITY ASSURANCE SYSTEMS
REQUIREMENTS

MEC/S/05/28/66
MECON LIMITED
DELHI 110 092

419 of 911
REV 0, EDITION - 1
CONTENTS
Sl.No. Description
1.0 INTRODUCTION
2.0 DEFINITIONS
3.0 CONTRACTORS SCOPE OF WORK
4.0 QUALITY ASSURANCE REQUIREMENTS
FORMAT FOR QUALITY PLAN FORMAT 00001
FORMAT FOR OBSERVATION ON FORMAT 00002
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REV 0, EDITION - 1
AMENDMENT STATUS

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1.0 INTRODUCTION
This specification establishes the Quality Assurance Requirements to be met by the sub-
contractors (including turnkey Contractors) and their sub-vendors.
In case of any conflict between this specification and other provisions of the contract/
purchase order, the same shall be brought to the notice of MECON, at the stage of bidding
and shall be resolved with MECON, prior to the placement of order.
2.0 DEFINITION
Bidder
For the purpose of this specification, the word “Bidder” means the person(s), firm, company
or organisation who is under the process of being contracted by MECON/ Owner for delivery
of some products (including service). The word is considered synonymous to supplier,
contractor or vendor.
Correction
Action taken to eliminate the detected non-conformity.
Refers to repair, rework or adjustment and relates to the disposition of an existing non-
conformity.
Corrective Action
Action taken to eliminate the causes of an existing non-conformity, defect or other

undesirable situation in order to prevent recurrence.
Preventive Action
Action taken to eliminate the causes of a potential non-conformity, defect or other

undesirable situation in order to prevent its recurrence.
Process
Set of inter-related resources and activities which transform inputs into outputs.
Special Process
Processes requiring pre-qualification of their process capability.
422 of 911

3.0 CONTRACTORS SCOPE OF WORK
3.1 Prior to award of contract
The bidder shall understand scope of work, drawings, specifications and standards etc.,
attached to the tender/ enquiry document, before he makes an offer.
The bidder shall submit milestone chart showing the time required for each milestone
activity and linkages between different milestone activities alongwith overall time period
required to complete the entire scope of work.
The bidder shall develop and submit manpower and resource deployment chart.
The bidder shall submit, alongwith the bid, a manual or equivalent document describing/
indicating/ addressing various control/ check points for the purpose of quality assurance and
the responsibilities of various functions responsible for quality assurance.
3.2 After the award of contract
The bidder shall submit the schedule for submission of following documents in the kick-off
meeting or within two weeks of the placement of order, whichever is earlier.
• Detailed Bar Chart

• Quality plan for all activities, required to be done by the bidder, to accomplish offered
scope of work.
• Inspection and test plans, covering various control aspects.
• Job procedures as required by MECON/ Owner.
• Procurement schedule for items to be supplied by contractor covering inspection of
the same.
Various documents submitted by the bidder shall be finalised in consultation with MECON.
Here it shall be presumed that ones a bidder has made an offer, he has understood the
requirements given in this specification and agrees to comply with them in totality unless
otherwise categorically so indicated during pre-award stage through agreed deviation/
exception request. All Quality Assurance Plan (QAP) documents shall be reviewed by
concerned functional groups of MECON and the bidder shall be required to incorporate all
comments within the framework of this specification at this stage of the contract. It is also
obligatory on the part of the bidder that obtains approval on every Quality Assurance Plan
(QAP) documents, before he starts using a particular document for delivery of contracted
scope of work. Participation of MECON/ Owner in review/ approval of quality plan/ QAP
documents does not absolve the contractor of his contractual obligations towards specified
and intended use of the product (or service) provided/ to be provided by him under the
contract.
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3.3 During job execution
During job execution, the bidder shall fully comply with all quality document submitted and
finalised/ agreed against the requirements of this specification. Approval of MECON on all
these documents shall be sought before start of work.
Bidder shall produce sufficient quality records on controlled/ agreed forms such that
requirements given in this specification are objectively/ demonstrable.
Bidder shall facilitate MECON/ Owner during quality/ technical audits at his works/ sites.
Bidder shall discharge all responsibilities towards enforcement of this specification on all his
sub-contractors for any part of the scope which is sub-contracted.
4.0 QUALITY ASSURANCE SYSTEM REQUIREMENTS
4.1 The bidder shall nominate an overall incharge of the contract titled as “Project Manager” for
the scope of work of agreed contract. The name of this person shall be duly intimated to
MECON including all subsequent changes, if any. MECON shall correspond only with the
project manager of the bidder on all matters of the project. The project manager of the
bidder shall be responsible for co-ordination and management of activities with bidder’s
organisation and all sub-vendors appointed by the bidder.
After award of work, the bidder may review augmentation of manpower and resources
deployment chart (submitted earlier), detail it out, if so consented by MECON/ Owner and
resubmit the same as “issued for effective implementation of the project”.
4.2 The bidder shall plan the contract scope of work on quality plan format such that no major
variation is expected during delivery of contract scope of work. These quality plan shall be
made on enclosed format complete in all respect. The quality plan shall be assumed to be
detailing bidder’s understanding and planning for the contract/ offered scope of work. The
bidder shall plan the type of resources including various work methodology which he agrees
to utilize for delivery of contract scope of work.
4.3 The bidder is required to review the contract at all appropriate stages to evaluate his
capabilities with respect to timely and quality completion of all activities pertaining to
contracted scope of work and shall report for constraints, if any to MECON/ Owner.
4.4 The design activities, if any, performed during delivery of contract scope of work shall be so
controlled that the outputs is reliable enough. It is expected that during development of
design, the bidder shall take recourse to detailed checking, inter departmental reviews and
documented verification methods.
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4.5 For all documents which the bidder is likely to utilise for delivery of contract scope of work, a
system must exist which assures that latest/ required version(s) of the document(s) is
available at all location/ point of use.
4.6 In case the bidder decides to sub-contract any part/ full of the contract scope of work
(without prejudice to main Contractual condition), the bidder shall :
• Evaluate the technical and financial capabilities and past performance of the sub-
contractor(s) and their products and/ or services before awarding them with the sub-
contracted scope of work. Selection of a sub-contractor should meet MECON
approval in documented form.
• Requirement of this specification shall be enforced on sub-contracted agency also.

The bidder shall choose sub-contractor based on their capability to meet
requirements of this specification also.
Note: It may so happen that, in a given situation, a sub-contractor may not have a
system meeting the requirements of this specification. In all such
eventualities, bidder may lend his system to sub-contractor for the contract
such that sub-contractor effectively meets the requirements of this
specification. In all such cases MECON shall be duly informed.
4.7 Bidder shall establish adequate methodology such that the materials supplied by the Owner/
MECON shall be adequately preserved, handled and made use of for the purpose for which
they are provided.
4.8 All output delivered against contract scope of work shall be suitably identified in such a
manner that either through identification or some other means, sufficient traceability is
maintained which permits effective resolution of any problem reported in the outputs.
4.9 Critical activities shall be identified and the bidder is required to have documented
methodologies which he is going to utilize for carrying out such activities under the contract
scope of work. Wherever it is difficult to fully inspect or verify the output (special process),
bidder shall pre-qualify, the performers and methodologies.
4.10 All inspections carried out by the bidder’s surveillance/ inspection staff shall be conformity to
quality plans and/ or inspection and test plans. All inspection results shall be duly
documented on controlled/ agreed forms such that results can be co-related to specific
product, that was inspected/ tested.
4.11 All inspection, measuring & test equipments (IMTEs) shall be duly calibrated as per
National/ International standards/ codes and only calibrated and certified IMTEs shall be
utilized for delivery of contract scope of work.
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4.12 All outputs/ products delivered against contract scope of work shall be duly marked such
that their inspection status is clearly evident during all stages/ period of the contract.
4.13 All non-conformities (NCs) found by the contractor’s inspection/ surveillance staff shall be
duly recorded, including their disposal action. The deficiencies observed during stage of the
product, shall be recorded and resolved suitably. Effective corrective and preventive action
shall be implemented by the bidder for all repetitive NCs, including deficiencies.
4.14 All deficiencies noticed by MECON/ Owner representative(s) shall be recorded on a

controlled form (Format No. 00002). Such deficiencies shall be analysed by the bidder and
effective and appropriate correction, corrective and preventive actions shall be implemented.
Bidder shall intimate MECON/ Owner of all such corrective and preventive action
implemented by him.
4.15 Bidder shall establish appropriate methodologies for safe and effective handling, storage,
preservation of various materials/ inputs encountered during delivery of contract scope of
work.
4.16 Bidder shall prepare sufficient records for various processes carried out by him for delivery
of contract scope of work such that requirements of this specification are objectively
demonstrable. In case MECON/ Owner finds that enough objective evidence/ recording is
not available for any particular process, bidder shall be obliged to make additional records
so as to provide sufficient objective evidence. The decision of MECON/ Owner shall be final
and binding on such issues.
4.17 The bidder shall arrange internal quality audits at quarterly intervals, to independently
assess the conformance by various performers to the requirements of this specification.
The findings of such assessment shall be duly recorded and a copy shall be sent to
MECON/ Owner for review.
4.18 For all special processes, bidder shall deploy only qualified performers. Wherever MECON/
Owner observes any deficiency, the bidder shall arrange the adequate training to the
performer(s) before any further delivery of work.
426 of 911

FORMAT – 00001
Bidder’s Quality Plan Project Name : PO/ Contract Ref:
General Performing Functions Inspection Functions Audit Function
Activity Description Procedure Code of Performer Checker Reviewer/ Sampling Testing and Type of Audit Scope Owner’s/ MECON
Number Conformance Approver Plan Inspection (Approval) Review/ Audit
Code Surveillance Requirement
Note: 1) The bidder ensures that the filled up format conforms to minimum requirements on Quality Plan/ Quality Assurance, specified by MECON on drawings/ standards/ specifications/ write-
up.
2) The bidder confirms that document is issued for information/ approval of Owner/ MECON for the project implementation
427 of 911

OBSERVATION OF QUALITY ASPECTS

FORMAT – 00002
Job No. and Description No. :

Issued to : M/s Date :
Location of Work :
Item of Work :
Details of Observation(Deficiency) Recommended Course of Action
Time Allowed for Correction :
Issued by : _____________________________________
Name of Signature of RCM, MECON Site
Corrective Action taken report by Contractor/ Vendor :
Date :
Name and Signature
Distribution (before resolution) :

Project Manager Chief Business MECON Inspection Resident Construction
Owner Executive New Delhi Manager, MECON Site
MECON
Verification of Resolution by MECON :
Date :
Name of Signature
Distribution (before resolution) :

Project Manager Chief Business MECON Inspection Resident Construction
Owner Executive New Delhi Manager, MECON Site
MECON
428 of 911
DELHI DOCUMENTATION FOR PIPELINE CONSTRUCTION
REV 0, EDITION - 1
FOR
DOCUMENTATION FOR PIPELINE
CONSTRUCTION
MECON LIMITED
DELHI 110 092

429 of 911
REV 0, EDITION - 1
CONTENTS
SL.NO. DESCRIPTION
1.0 SCOPE
2.0 RECORDS
3.0 AS-BUILT DRAWINGS AND PIPE BOOK
430 of 911
REV 0, EDITION - 1
AMENDMENT STATUS

431 of 911

1.0 SCOPE
1.1 This specification covers the minimum requirements of various records, reports and
drawings for all aspects of pipeline construction to be prepared by Contractor and
submitted to the Company at intervals as described in this specification and as
directed by Company.
1.2 All document required to prepared and submitted by Contractor as per this
specification shall be in addition to the various reports, records, methodology
statement, calculation, drawings etc. to be submitted by the Contractor for
Company’s record, review or approval as per the requirements of all other
specification included in the Contract between the Company and Contractor.
and document included in the Contract between Company and Contractor.
2.0 RECORDS
Contractor shall submit daily, weekly, monthly and after completion to the Company,
various records and reports for Company’s documentation purpose during and
immediately after the construction. This shall as minimum include, but not limited to
the following:
2.1 Daily
• Separate progress reports of all crews

• Daily welding results and repairs
• Actual weather conditions
• Application for deviations, if any
• Accidents
• Damages
• Activities required from Company
• Materials Receipts
• Urgently required materials
2.2 Weekly
• Up-to-date list of confirmed site instruction issued by Company

• Materials `taken over’
• Material defects and repairs
• Outstanding activities of Company
432 of 911

• List of installed markers, chainage

• Required approval from Company
• Progress planned
• Reports of manning of all crews, equipment and plant
• Report of equipment and plant
• Report of accidents
• Report of damages
• Report of acquired release, permits
• Priced variations
• Required materials for next month
2.3 Monthly
• Progress report for payment, safety report, report of accidents, security

report, health and environment report, material balance, approved deviations.
2.4 Further, Contractor shall supply (for approval if required) to the Company with
document such as but not limited :
• Organogram for construction work.

• Bio-data of key personnel (including foremen).
• (Revised) list of address of personnel in particular of medical staff, safety and
security offers.
• (Revised) list of approved coaters.
• (Revised) list of approved sub-contractors.
• Time schedule.
• Acquired permits and/ or approvals from Authorities, if any.
• Minutes of meeting with Company with comments, if any.
• Material certificates, material receipt.
• Guarantee from vendors and sub-contractor.
• Calculations, temporary works, bouyance, blasting.
• Drawings issued by Contractor.
• Vendors drawings.
• As-built of route maps, alignment sheets, details drawings and isometric
drawings.
• Procedures such as surveying, stacking, fencing.
• Welding procedure qualification records, radiographic procedure qualification,
welder qualification.
• Coating procedure.
• Installation of crossings.
• Hydrostatic testing.
• Blasting.
433 of 911

• Radiographic report alongwith original radiographs

• Pipe and welding book.
• Reports
- Material tests (coating, welding, painting)

- Computerised Potential Logging Test
- Water Samples
- Cleaning, Pigging Report before Hydrostatic Test
- Hydrostatic Test
- Calibration Test
- Blasting Trials
- Equipment certificate (dead weight tester, instruments, vessels,
equipment)
- Manuals
- Major water crossings
- Waste disposal
- Disposal of water after hydrostatic test.
2.5 Contractor shall submit to company colour photographs of various construction

activities/ operations at regular intervals. Size, number and frequency of the
photographs shall be mutually agreed upon at a later stage. Also Contractor shall
make video recordings of all operations right from the start of construction till the
completion of the work, covering to the extent as instructed by Company and submit
to Company. Upon completion of the work, Contractor and submit edited master
tape plus six copies of video recording in VHS formats or any format ordered by the
Company. The duration of video recording shall be of ½ hour and shall cover all
aspects of the job.
3.0 AS-BUILT DRAWINGS AND PIPE BOOK
3.1 General
Contractor shall prepare “as-built” drawings of all by or on behalf of Company issued

drawings and of all Contractor work drawings including vendor drawing, such as but
not limited to :
For Pipeline Section :
- Route Maps
- Alignment Sheets
- Detail Drawings (road, railway, minor water crossings, major water crossings,
valley crossings)
434 of 911

- Isometric drawings of installations

- Special installation
Further Contractor shall prepare a pipe Weld Book.
If required by the Company, Contractor shall update the diskettes for drawings
issued for construction of the job.
3.2 “As-Built” Drawings
Contractor shall prepare a complete set of “as-built” drawings. From the start of
construction, Contractor shall on daily basis process any changes in two sets of
drawings. Deleted parts shall be indicated in red, new parts in blue, remarks in
green and unchanged parts in yellow. Said drawings shall be kept at site and be
available to Company at all times. Contractor shall prepare “as-built” drawings
based on these data. On completion of the work, one revised film transparency of all
drawing made “as-built” by Contractor containing the “as-built” information shall be
handed over to Company as well as one complete set of CD ROM/ floppy diskettes
as specified by Company.
Contractor shall prepare and submit a specimen of the layout of the drawings for
Company’s approval.
The required measurement for “as-built” drawing shall be executed by Contractor by

experienced, qualified surveyors.
The surveyors shall daily take care of all measurement required such as but not
limited to:
- Horizontal location of pipeline with regard to deviations and Permanent Grid

Pillars.
- Vertical Level with regard to Mean Sea Level of pipeline and grade.
- Location and type of bends, fittings etc. and grades, points of intersection.
- Change of wall thickness, materials.
- Location and details of valves, insulating flanges, fencing.
- Location and details of crossing pipes, vents.
- Location and type of coating.
- Location and type of weighting, anchoring.
- Location and type of markers.
- Location of further appurtenance (Pig-Signallers)
- Location of ROU and of pipeline with respect to ROU.
- Type of soil.
435 of 911

- Type of rock.
- Type of blasting and ripping.
- Sand padding.
- Type of road pavement.
- Details of bank protection, number of insulators, seals.
Contractor shall also prepare isometric drawings of all installation (facilitates) etc. for
which the data as mentioned in or required for the Pipe and Welding Book can be
identified and these drawings can also be used for material accounting.
3.3 Nameplates of Equipment
All permanent equipment supplied and installed by Contractor shall be provided with
plates by Contractor. All texts shall be submitted to Company for approval before
plates may be manufactured.
3.4 Pipe Book
Every page of the pipe and Welding Book shall mention:
- Data relevant to the project and section there of.

- Sequential number.
- Length brought forward (for pipes and other materials).
- Length to bring forward (for pipes and other materials).
Alignment sheet number and atleast the location thereon of two welds on every page
of the pipe Book.
Further,
- Diameter of pipeline
- Length of each pipe
- Wall thickness
- Pipe number
- Heat number, certificate number
- Cut and re-numbered pipe ends
- Coating type
- Date of stringing
- Date of welding
- Weld number
- Welder number
- Direction of working
436 of 911

- Type of welding, electrodes, diameter of electrode etc.

- Heat treatment
- Equipment used for radiography
- Limits of water crossings
- Test pressure and date of test.
In order to achieve this, Contractor shall identify all pipe elements. Sample format of
Pipe Book shall be submitted for Company approval.
3.5 As-Built Documents
Contractor shall prepare all documents in the prescribed format as indicated below.
In addition to the hard copies, softcopies of final documents shall also be submitted
in electronic media i.e. CD / DVD format.
Software used for the preparation of these documents shall be as follows:
Type document Software

a) Reports/ Documents MS Office
b) Drawings Auto CAD
For the purpose of preparation of as-built drawings, Contractor shall update the
“Issued for construction” drawings issued by the Company. It shall be the
Contractor’s responsibility to covert the drawings furnished by the Company in hard
copy into CAD drawings including scanning, digitising and converting the drawings
into a suitable format compatible with the AutoCAD and above. As-built drawings
shall be prepared only on AutoCAD drawings.
437 of 911
DELHI
CALLIPER PIGGING
SPECIFICATION NO : MEC/S/05/28/70 A
REV 0, EDITION - 1
OIL & GAS SERVICE – GAS/LIQUID/SLURRY

SECTION
FOR
CALLIPER PIGGING
TECHNICAL SPECIFICATION NO.: MEC/S/05/28/70 A
MECON LIMITED
DELHI 110 092

438 of 911
DELHI
CALLIPER PIGGING
REV 0, EDITION - 1
CONTENTS
Sl. No. Description
1.0 INTENT
2.0 OBJECTIVE
3.0 SCOPE OF WORK
4.0 VELOCITY OF DIFFERENT PIGS
5.0 FOAM PIG RUN
6.0 GAUGE PIG RUN
7.0 CLEANING PIG RUN
8.0 CALIPER PIG RUN
9.0 PIG TRACKING
10.0 MARKER DEVICES
11.0 DEFECT VERIFICATION
12.0 ABNORMAL SITUATIONS
13.0 WORK REPORT
14.0 INFORMATION TO BE FURNISHED BY BIDDER
439 of 911
DELHI
CALLIPER PIGGING
REV 0, EDITION - 1
AMENDMENT STATUS
Sl. Clause / Paragraph / Page Status of Revision and Date

Rev-1 Rev-2 Rev-3 Rev-4
Drawing Amended
440 of 911
DELHI
CALLIPER PIGGING

SPECIFICATION FOR CALIPER PIGGING
1.0 INTENT
The intent of this specification is to setforth the requirements of the caliper

pigging. The specification is not intended to be all-inclusive and the use of
this specification will not absolve the contractor of his responsibility of
generating valid, interpretable and physically verifiable data.
2.0 OBJECTIVE
The objective of the present pigging programme to access the internal

geometry of the following pipelines and detect significant geometry defects if
any, which may affect safe operation of the pipeline.
The relevant technical specifications of the pipeline including launcher and

receiver details in the Annexure.
3.0 SCOPE OF WORK
To achieve the above objective, contractors SCOPE OF WORK includes

running of adequate numbers of foam pigs, cleaning pigs (magnet, brush,
commination of brush and magnet, scraper, pin wheel etc.), gauge pig and
caliper pig.
Further the scope of work comprises supply of skilled personnel, all

equipment e.g. foam pigs cleaning pigs, gauging pig, caliper pigs, pig locating
and pig tracking devices, spares consumables, communication and
transportation including their mobilisation and demobilisation. It is expressly
understood that this do not limit the scope of work of the CONTRACTOR in
any way. The quantities to be mobilized for different equipment (different
types of pigs pig tracking device, marker device) accessories, spare and
consumables need to be carefully evaluate by the CONTRACTOR taking in to
the consideration that caliper pigging of various pipelines in the scope of work
should be carried out without any constraint and turn around time.
The contractor shall submit the details of each type of pig including foam,
gauge cleaning and caliper for approval of MECON/ NMDC, which he proposes
to use. Pigs shall be launched in the pipeline only after their design and size
has been approved by MECON/ NMDC. Due care shall be taken not to damage
internal coating by the contractor, while proposing the pigs for internally
coated pipeline.
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The detailed scope of work shall be, but not limited to under
- Supply of all equipment, personnel and consumables.

- Running of foam, Gauge, Cleaning and Caliper pigs and Tracking to
generate valid data.
- Placement of marker devices along the Row over the pipeline.
- Identification of defects in the field as found
- Preparation of work reports.
4.0 VELOCITY OF DIFFERENT PIGS
Contractor shall be required to maintain velocities of propelling medium in

such a way that the objective of each pig run shall be achieved.
5.0 FOAM PIG RUN
Contractor to carry out adequate number of foam pigs runs in each pipeline
covered under Scope of Work prior to running of cleaning pigs to make a final
assessment of the line piggability to the satisfaction of the Contractor and
provide detailed daily site report for each run in the approved format before
commencing the subsequent run. Contractor to select size of the foam pigs
in such a way that the objective shall be achieved.
6.0 GAUGE PIG RUN
Contractor to carry out adequate number of gauging pig runs in each pipeline
covered under Scope of work including pig tracking for pipeline to assess any
internal restriction in the pipeline that may restrict the passage of cleaning
and caliper pig. Contractor to provide detailed daily site report for each run in
the approved format before commencing the subsequent run Gauge pig shall
be equipped with a gauge plate made of Aluminium having its diameters 95%
of minimum pipeline Internal Diameter (I.D.). The gauge pig should be able
to pass over or negotiate lateral tees or bends on the pipeline.
7.0 CLEANING PIG RUN
7.1 Pipelines with Internal Coating
Contractor to carry out adequate number of cleaning pig runs by running

suitable cleaning pigs in the pipelines including pig tracking till such time
contractor is satisified with himself about the degree of cleanliness of pipeline
and provide detailed daily site report for each run in the approved format
before commencing the subsequent run. Choice of the type of cleaning pig
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has been left to the contractor. The contractor shall assure that the pigs,
which are proposed to be used, are adequately soft and they do not damage
internal coating under any circumstances. The brushes and scrappers used
shall be of nonmetallic/ plastic material. However, the details of these pigs
including their construction details of brushes, scrappers etc. (if applicable)
shall be submitted to MECON/ NMDC for approval before their usage.
7.2 Pipelines Without Internal Coating
CONTRACTOR to carry out adequate numbers of cleaning pig runs by running

suitable cleaning pigs in pipeline covered under SCOPE OF WORK including
pig tracking till such time CONTRACTOR is satisfied with himself about the
degree of cleanliness of pipeline and provide detailed daily site report for each
run in the approved format before commencing the subsequent run. Choice of
the type of cleaning pig has been left to the contractor. Contractor may
deploy brush cleaning pig, magnetic cleaning pig, combination of brush and
magnet, scrapper pig etc. the cleaning pigs should be able to pass over
negotiate lateral tees or bends on the pipeline
8.0 CALIPER PIG RUN
CONTRACTOR to carry out adequate number of electronic geometry (caliper)

pig runs each pipeline covered under SCOPE OF WORK including pig tracking
for each pipeline decided after findings of gauging pig run to generate valid
and interpretable geometry data of the pipeline and analysis of data of the
caliper survey to detect the nature, extent and location of geometry defect.
Contractor to provide detailed daily site report for each run in the approved
format before commencing the subsequent run. The caliper should be capable
of inspecting entire length of the pipeline i.e. from launcher to receiver in
single run. Battery life should be adequate to commensurate with the run
time required to travel the pipeline length. The electronic recorder system
should have requisite data storage capacity. The drive cups should have
requisite resistance to wear and tear to maintain effective seal throughout the
entire run time.
The measurement shall cover the entire 360° of internal pipe wall
circumference using properly oriented and suffcient quantity of sensors. For
internally coated pipelines adequate care shall be taken by using soft cups so
that no damage takes place to the internal coating of pipe. The tool shall be
capable to identify and locate the following features as minimum.
- Individual Girth weld
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- Dent, ovality, buckles, or any other out of roundness, change in

pipeline I.D. and difference of thickness.
- Bend with bend radius and degree of bend.
- Valves or any partially closed valves.
- Tees/ off-takes.
The caliper pig should have minimum capability to identify and detect the
defects of following threshold.
Dent : 3% of outer diameter (O. D.)

Ovality : 5% of outer Diameter (O. D.)
Location accuracy : Axial ± 3.0m
Circumferential : ± 12°
(For dents, ovalities and pipeline feature as detailed above).
9.0 PIG TRACKING
The movement of any type of pig (Except, foam pig) put into the line during
caliper pigging shall be required to be monitored along the pipeline length
from launcher to receiver trap. The BIDDER 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 at least 5

to and 10 km - interval on each pipeline at preselected locations. The exact
KM chainage of these locations shall be decided at site in consultation with
the Contractor and CONSULTANT/ COMPANY.
10.0 MARKER DEVICES
The contractor shall submit the details of marker devices, which he proposes
to place for relocating the defect accurately in the field, when the same has
been identified as a result of Caliper survey.
The contractor shall be responsible for placing these devices (Marker Magnets
or Locator coils or any other device) at suitable interval so that the defect can
be easily located in the field with minimum above ground measurement. It
may be noted that placement of marker devices, their retrieval and locating
the identified defect in the field shall be the responsibility of the contractor.
The liquidation of defects, if any, is however, not included in the scope of
work of the contract.
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11.0 DEFECT VERIFICATION
At the discretion of the COMPANY/ CONSULTANT identify at least two

verification dig sites for each pipeline jointly with MECON and NMDC from the
recorded data and provide MECON/ NMDC with their distance from the
nearest pipeline feature or reference marker to facilitate location of defect in
the field.
The contractor shall depute his representative to observe the verification at

verification sites for proving that filed log detected anomalies conform to
sizing including linear and circumferential positions.
12.0 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.
The following abnormal condition have been foreseen by the Comapny.

However, if the BIDDER foresees any other abnormal condition, he is free to
make a mention of the same in his technical BID offer:
12.1 Tool Failure
CONTRACTOR is required to get valid interpretable and verifiable data for

pipeline. In case CONTRACTOR’S equipment fails to perform electronic
geometry inspection to generate valid data for any of the pipeline,
CONTRACTOR will make extra runs of pigs to get valid and physically
verifiable data.
12.2 Stuck-Up Tool
The BIDDER shall details out a contingency plan in his BID as proposed by
him in case any of the pigs get 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 do not move from stuck up location, by any measure, then the pipeline
section shall have to be cut for retrieval of Pig. Necessary erection, fabrication
and modification of pipe with new pipe piece after retrieval of pig shall be
done by Contractor. The cost for this works shall be borne by Contractor on
actuals. After fabrication & erection, pigging contractor shall run Gauge pig to
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CALLIPER PIGGING

check internal restriction, if any. Locating the stuck up pig and its retrieval
shall be the responsibility of the CONTRACTOR.
13.0 WORK REPORT
The work report shall be prepared and submitted in hard copy (4 sets) and
Electronics media (2 sets)
The work report shall consist of following as a minimum.
- All field activities.

- Equipment description
- List of installations
- List of significance with feature information and installation reference
- Survey log and enlargement areas of special interest to suitable scale.
14.0 INFORMATION TO BE FURNISHED BY BIDDER IN HIS OFFER FOR

EVALUATION.
- List of similar projects executed in the past.

- Specification of foam pigs, cleaning pigs, gauge pig and caliper pig for
pipelines with and without internal coating respectively.
- Details of caliper pig in following respect.
Max.% of Nominal pipeline ID tool can pass (% of ID)
Minimum deformation level reported (as % of ID)
Accuracy of measurement (% of ID)
Bend radius tool able to negotiate
- details of pig tracking equipment and pig tracking procedure.
- Pig contingency plan.
- Proposed methodology for execution of pipeline pigging.
- Sample reporting format.
- Minimum velocity of various pigs acceptable to bidder for generation of valid
data.
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ANNEXURE
PIPELINE DETAILS
NOMINAL DIAMETER mm (inch.) : 300 (12)

DESIGN PRESSURE Kg/ cm2 : 92
DESIGN TEMPERATURE, °C : 65
WALL THICKNESS, mm : 6.4 & 11.1
PIG LAUNCHER DETAILS:
BODY SIZE NB, mm (inch) : 400 (16)
PIG RECEIVER DETAILS:
BODY SIZE NB, mm (inch) : 450 (18)
NUMBER OF SECTIONALIZING
VALVE STATIONS
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DELHI COATINGS OF PIPELINE FOR HDD CROSSING
REV 0, EDITION - 1
FOR
FIELD JOINT COATINGS OF PIPELINE
FOR HDD CROSSING

MEC/S/05/28/74
MECON LIMITED
DELHI 110 092

448 of 911
REV 0, EDITION - 1
CONTENTS
1.0 SCOPE
3.0 SPECIFICATION FOR FIELD JOINT COATING MATERIAL
5.0 INSPECTION
6.0 TESTING
7.0 REPAIR OF FIELD JOINT COATING
8.0 REPAIR OF PIPE COATING DEFECTS
9.0 DOCUMENT
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REV 0, EDITION - 1
AMENDMENT STATUS

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1.0 SCOPE
1.1 General
This specification covers the minimum requirement for application of anti-corrosion

field joints coating on welded pipe section and field tie-in joints referred to here in
after as Joint(s). The contractor shall perform all work in accordance with this
specification, latest pipeline coating practices and to the full satisfaction of the
Owner. The anti-corrosion pipe joint coating shall be compatible with yard applied,
Ultra Violet (UV) radiation protected, 3 layer side extruded polyethylene coating
conforming to DIN-30670. The sleeve width shall be suitable for cut back of 120 ±
20 mm to be left at both the ends of coated pipes. The job includes supply of all
materials equipment, consumables, labour, supervision, quality control, inspection
repairs.
1.2 Manpower, Material & Equipment
1.2.1 The Contractor shall supply wrap around heat shrinkable sleeves which is composed
of two parts such as adhesive coated wrap around and a curable modified epoxy
primer alongwith applicator pads.
1.2.2 The supply of wrap around heat shrinkable sleeve shall be under Contractor’s scope.
1.2.3 The Contractor shall provide all skilled/ unskilled personnel required for execution of
this work.
1.2.4 The joint coating operation starting from cleaning and surface preparation till
application of joint coating and wrapping of the pipe joints shall be performed under
the supervision of skilled personnel who are well versed in the work.
1.2.5 Contractor shall at his own cost provide a fully equipped laboratory and test facilities
with adequate inventory to carry out tests required for procedure qualification and
during regular production, for testing of joint coating system.
2.1 Provision of the following documents/ codes shall generally be followed for standard
of specification and workmanship.
a) DIN – 30672 : Corrosion protection tapes and Heat Shrinkable Sleeves.
b) SIS – 055900 : Pictorial surface preparation standard for painting steel

surfaces.
c) SSPC – SP1 : Steel structure painting council – Solvent Cleaning.
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2.2 In case of conflict between the requirements of this specification and that of above
referred documents/ codes, the requirements of this specifications shall govern.
3.0 SPECIFICATION FOR FIELD JOINT COATING MATERIAL
3.1 General
This scope covers the minimum requirement of materials, equipment required for
installation of field joint coating by wraparound fibre-reinforcement heat-shrinkable
sleeve used for corrosion protection and sealing of field joints in pipelines that are
forced through the soil by Horizontal Directional Drilling technique. The sleeves shall
be suitable for 3LPE/FBE coated pipes operating up to 60°C continuously.
3.1.1 Each Joint Coating System shall consist of :
a) For HDD Joint Coating fiber glass reinforced heat shrinkable sleeve certified
to Stress class C60 type CANUSA-TBK or COVALENCE / DlRAX shall be
used. Directional drilling kit, multilayer sleeve system or equivalent to be
approved by Owner / Engineer.
b) Only coating material C-60 Class as per EN 12068 and DVGW certified
(wrapping tape and heat shrinkable material) will be accepted for all material
to be coated.
c) A solvent-free, two component liquid epoxy primer
d) A specifically designed wear cone
e) A clamping belt
3.1.2 Sleeve Backing
The heat shrinkable sleeves shall be manufactured from minimum 1.0 mm thick
radiation cross linked, thermally stabilized, UV -resistant heat-shrinkable fabric,
composed of a fibre glass reinforcement and polyolefin fibres, embedded in a
polyolefin matrix.
3.1.3 Sleeve Adhesive
The inner surface of the sleeves shall be coated with a controlled thickness of
minimum 1mm of adhesive which in combination with the modified epoxy primer, will
bond to and seal to the steel pipe and common yard applied medium temperature
yard coatings.
3.1.4 Epoxy Primer
The Epoxy primer shall be a solvent free, modified two components liquid epoxy type
primer, which is applied to cleaned and dry steel surface. When the sleeve coatings,
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comes in contact with the liquid primer during installation, a strong bond is formed
upon full curing of the system.
3.2 Properties of Field Joint Coating Material
The pipe sleeves furnished under this specification shall be tested and shall meet the
requirements specified in the table below:-
3.2.1 Heat-Shrinkable Sleeve Material
Property Test Condition Requirement

Method
Cold Crack ISO 4675 Below 40°C
Chemical ISO 175 168 hrs. immersion on either
resistance 0.1 N
NaCl @ 23°C, 0.1N H2 SO4

@
23°C, 0.1 N NaOH @ 23°C,
Fuel oil @ 23°C. Petroleum
jelly @ 70°C
Followed by test ISO 3303 23°C 1100 N Min.
for bursting
strength
Thermal ageing ISO 188 150°C 168 hrs. 1700 N Min.
Followed by test ISO 3303 23°C

for bursting
strength
3.2.2 Adhesive material

Method
Softening point ASTM 85°C minimum
E28
Peel Strength DIN 23°C. CHS* 200 N/cm minimum
30672 100 mm/ min.
60°C 60 N/ cm
Peel Strength DIN 23°C. CHS* 200 N/cm minimum
After immersion for 4 30672 100 mm/ min.
weeks
at 23°C~NaOH pH12
H2SO4
pH2 ground water
solution:-
1.2% H3PO4
1.6% KOH
1.2NaCl
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Method
1.0% Fe2O3
Peel Strength after DIN 23°C. CHS* 60 N/cm minimum

conditioning for 30 30672 100 mm/ min.
cycles from -30°C to 60°C
Shear strength ISO 4587 23°C. CHS* 200 N/cm2
50 mm/ min. minimum
Corrosive effect ASTM D 120°C. No corrosion

2671 16 hrs.
3.2.3 Primer Material
Property Test Method Condition Requirement

0
Density ASTM 23 +/- 0.5 C Part A: 60+/- 30 Pas
D1084 Part A: 2 rpm, spindle Part B: 1.55+/-0.55
#6 Pas
Part B: 20rpm, spindle
#3
Mixing ratio By weight 23°C 100:40
By volume 100:60
Shear ISO 4587 23°C. CHS* 1000 N/cm2 minimum
strength 50 mm/ min.
* CHS = Cross Head Speed
3.2.4 Functional Properties
Sl. Property Test Method Condition Requirement

No.
a) Impact DIN 30672 23°C. No holidays when
resistance Class C tested at 20 KV
b) Penetration DIN 30672 60°C. Minimum 70% of
resistance Class C original resistance
thickness left; no
holidays when tested at
20 KV
8
c) Specific DIN 30672 23°C. 10 Ohm sq. m
coating minimum; no oxidation
resistance on pipe surface
d) Cathodic ASTM G42 60°C. 15 mm increase in
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Sl. Property Test Method Condition Requirement

No.
disbondment 30 days radius of disbondment
resistance max.
e) Resistance to TEST No cut propagation
split METHOD-1*
propagation
f) Resistance to TEST 50 KN minimum
circumferentia METHOD-2*
l edge loading
g) Resistance to TEST 6 KN minimum
*
local edge METHOD-3
loading
(chisel test)
*Test Methods
3.3 Test Methods
3.3.1 Resistance to split propagation (Test Method -1)
A rectangular piece of 50mm width by 150 mm length shall be cut from the material
as delivered. A 5mm long, clean cut shall be made mid-way in the piece along once
of the long edges perpendicular to this edge. The sample shall be mounted on a
clamp that holds it securely and avoids any shrinking during testing.
0
The assembly shall be placed in an air-circulating oven present at 170 C.
After 15 minutes, the sample shall be removed from the oven, allowed to cool down
to room temperature and examined for cut propagation.
This test simulates the unlikely event when the sleeve gets cut during the installation
phase. Sleeves based upon extruded polyelfin show a distinct tendency to propagate
the cut along the total width of the sleeve. Sleeves suitable for HDD works shall not
exhibit this behaviour.
3.3.2 Resistance to circumferential edge loading (Test method -2)
The sleeve shall be installed on a DN 200 three -layer PE coated steel pipe piece. A
thick wall steel ring that fits a DN 200 three-layer PE coated steel pipe with a
tolerance of 0.2+-0.2 mm shall be positioned against the front edge of the wear cone
sleeve and then pushed towards the sleeve system at a constant speed of 5 mm/
min over a distance of 50 mm. The forces necessary shall continuously be
registered. The minimum required force shall be less than 50 KN.
During the pushing or pulling operation, any obstacle protruding from the smooth
pipe surface is loaded by the surrounding soil that passes by. This test simulates the
shear forces that are exerted on to the sleeve by rigid soil type.
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3.3.3 Resistance to local edge loading (Chisel test: Test Method -3)
The sleeve shall be installed on a DN 200 three-layer-PE coated steel pipe piece.
A chisel as depicted in Figure -1 shall be positioned against the front edge of the
wear cone sleeve and, pushed parallel to the pipe surface towards the sleeve
system at a constant speed of 5mm/ min over a distance of 50 mm. The forces
necessary shall continuously be registered. The minimum required force should not
be less than 6 KN.
During the pushing or pulling operation, the pipe may traverse soil area containing
solid particles, such as stones, pebbles or crushed rock. These particles tend to rip
away the pipe coating locally. Any obstacle protruding from the smooth pipe surface
is lifted, leading to soil undercutting. This test determines the resistance of sleeve
against this type of abuse.
35mm I5mm
View AA
Figure- 1 Chisel
456 of 911
3.4 Qualification for Contractor’s supplied Materials and their Manufacturer
3.4.1 Prior to procurement of coating materials, Contractor shall furnish the following
information for qualification of the Manufacturer and material:
a. Complete descriptive technical catalogs describing the materials offered

along with samples of corrosion coating materials, its properties and
application instruction as applicable specifically to the project.
b. Reference list of previous supplies, in last 5 years, of the similar material or

manufacturer shall be notified to Company, whose approval in writing of all
charges shall be obtained before the materials are manufactured.
3.4.2 Contractor shall ensure that the coating materials supplied by him are properly
packed and clearly marked with the following :-
- Manufacturer’s name
- Material Qualification Certificate Number
- Batch Number
- Date of Manufacturing and date of expiry
3.4.3 Prior to shipment of materials from the Manufacturer’s Works. Contractor shall
furnish the following documents:
a. Test certificate/results as per Manufacturer’s Quality Control Procedure for

each batch of materials complying with the requirements of relevant sub-
clauses of clause no. 3.2 of the this specification.
b. Specific application instructions with pictorial illustrations.
c. Specific storage and handling instructions.
3.4.4 All documents shall be in English language only.
3.5 Storage of Materials
Material shall be stored in sheltered storage by the Contractor in the manufacturer’s

original packing and away from direct sunlight and in accordance with
manufacturer’s instructions.
4.1 General
a) The application procedure shall be in accordance with manufacturer’s

instruction and the minimum requirements required below whichever are the
most stringent and shall be demonstrated to and approved by the Owner.
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b) Contractor shall provide and maintain mobile facilities which contains all
necessary tools, propane torches, epoxy primer pumps, silicon rollers, testing
instruments, equipment, and spares for cleaning, coating, repairs, inspection
and testing.
c) Contractor shall furnish sufficient number of the following equipment and the
required spares as a minimum for inspection and testing purpose for each
crew :
- Fully automatic full circle adjustable holiday detector with audio and
visual output signal for inspection of coating.
- Portable Tensile Strength Tester
- Digital Thermometer
- Solid state digital thickness gauge for measuring thickness of joint
coating.
4.2 Pipe Surface Preparation
a) The Contractor shall thoroughly clean and dry the joint surface by power tool
cleaning in accordance with SSPC-SP1. The complete procedure and details
of equipment used shall be prepared by the Contractor for Owner’s approval
prior to commencement of joint coating work.
b) Prior to cleaning operation, Contractor shall visually examine the joint surface
area and shall ensure that all defects, flats and other damages have been
repaired or removed.
c) Where oil, grease or other materials detrimental to the finished coating is

present, it shall be removed with a continuous removal solvents cleaning
system to remove completely all such materials in accordance with SSPC-
SP1.
d) The standard of finish for cleaned pipe surface shall conform to SA 2½ of

Swedish Standard SIS-055900 latest edition. The degree of preparation
required to obtain an end product that fulfil the requirements of this
specification may not be sufficiently covered and is not limited by SIS-
055900. Surface of pipe after shot blasting shall be have an anchor pattern of
50 to 70 microns. This shall be measured by a suitable instrument such as
Elecometer.
e) Piper temperature immediately prior to blasting shall be minimum 20°C. At

no time shall be blast cleaning be performed when the relative humidity
exceeds 85%. Surface temperature must be at least 3°C above the dew
point temperature.
f) The abrasive blast material shall be free of impurities and inclusions, water
and oil. All abrasives shall be removed after blast by brush or vacuum type
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cleaner prior to applying joint coating. The abrasive shall be stored in a dry
condition and maintained dry during use.
g) The compressed air for blasting shall be free of water and oil. Contractor to
verify air cleanliness at the start of the work and every four hours thereafter.
Separators and the traps shall be provided at the compressor and blasting
station. Separators and traps shall be checked daily for effective moisture
and oil removal during coating operations.
h) The ends of existing line pipe protective coating shall be inspected and
chamfered. Unbonded portions of the coating shall be removed and then
suitably trimmed. Portions where parent coating is removed shall be
thoroughly cleaned as specified.
i) Pipe shall be visually inspected by Contractor immediately after blast cleaning

for surface defects such as slivers, laminations, leafing, scores, indentation
slugs or any other defects considered injurious to the coating integrity. Such
defects shall be reported to Owner and on permission from Owner, such
defects shall be removed by filling or grinding in such a way as not to “blue”
the steel.
4.3 Procedure
a) The application procedure shall be in accordance with manufacturers

instruction and the minimum requirements specified below whichever are the
most stringent and shall be demonstrated to and approved by the owner.
b) Applicators for coating application shall be given necessary instructions and

training before start of work by the CONTRACTOR. To verify and qualify the
application procedures, all coating applied during the qualification test, shall
be removed for destructive testing until the requirements stated in sections
‘Inspection’ and ‘testing’ of this specification are met.
c) Prior to surface cleaning, the surface shall be completely dry. An effective

heating equipment which shall not give rise to deposits shall be used. Care
shall be taken to avoid damage to existing coating.
d) All pipe joint surfaces shall be thoroughly examined before the application of
the coating in order to ensure that the surfaces are free of oil, grease, rust,
mud, earth or any other foreign matter.
e) Liquid epoxy primer shall be applied on the joints immediately after the
completion of heating operation.
f) The heat shrink sleeve is then wraparound the joint while the primer is still
wet and shall overlap the existing pipe coating by minimum 100 mm on each
side.
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g) The wraparound sleeve is shrunk on pipe joint with a propane torch moved
back and forth over the surface when heated above 125°C, the sleeve shall
shrink tightly around the substrate on to the wet-primer. At the time of
application of the primer, th pipe surface temperature shall be at least 60°C at
every point. To check this, approved temperature indicators shall be used .
temperature indicating crayons shall not be used.
h) The wraparound sleeve shall be entirely wrapped around the pipe positioning
the closure patch off to one side of the pipe in 10m or 2 O’clock position, with
edge of the undergoing layer facing upward and an overlap of min. 100 mm.
i) Heat shrinking shall be procedure shall be applied to shrink the sleeve in

such a manner that all entrapped air is removed using gloved hands and
hand rollers. The complete shrinking of entire sleeves shall be obtained
without undue heating of existing pipe coating and providing due bonding
between pipe, sleeve and pipe coating. A thermochrome paint shall be
applied a an closure patch to indicate that sufficient heat/ temperature has
been obtained. The joint coating shall have wear cone applied over the
leading edge of the sleeve and the clamping belt tightened over it.
j) Application of Wear Cone - The leading edge will be given an extra wear
0
cone. Start by heating the leading edge area of the main sleeve to 70 C.
Wrap the leading edge sleeve over the transition Mill coating. Ensure that the
closure is placed away from the main sleeve closure Shrink the leading edge
sleeve.
k) Application of Metal Belt - The metal belt shall be applied over the wear cone
sleeve. The metal belt will be tightened using the strapper tool supplied by
the manufacturer.
l) Sufficient manpower working on opposite sides of each pipe joint are

required for installation of the sleeve.
m) The installed sleeve shall not be disturbed until the adhesive has solidified.
5.0 INSPECTION
5.1 For wraparound coating, a visual inspection shall be carried out for the following :
- Mastic extrusion on either ends of the sleeves shall be examined

- There shall be no sign of punctures or pinholes or bond failure. The external
appearance of the sleeves shall be smooth, free of dimples, air entrapment or
void formation.
- Weld bead profile shall be visible over the sleeves.
- The entire closure patch shall have changed colour uniformly.
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5.2 Holiday Inspection
5.2.1 The Holiday Detector used shall be checked and calibrated daily with an accurate
D.C. voltmeter. The detector electrode shall be in direct contact with the surface of
coating to be inspected.
5.2.2 The entire surface of the joint section shall be inspected by means of a full circle
Holiday Detector approved by OWNER set to DC Voltage of at least 25 kV for
wraparound sleeves. Inspection of the heat shrink sleeve coating shall be conducted
only after the joint has cooled below + 50°C.
5.2.3 All the coated joints shall be subjected to Holiday Detection test.
5.2.4 An installed sleeve with more than two holiday shall be stripped and a new one be
installed.
6.0 TESTING
a) OWNER reserves the right to test one out of every 30 joint coating subject to
a minimum of 2 joints. CONTRACTOR shall provide all assistance in
removing and testing of field joint coatings. From each test sleeve, one or
more strips of size 25 mm x 200 mm shall be cut one perpendicular to the
pipe axis and slowly peeled off. This test shall be conducted between either
sleeve and metal or sleeve and mill coating as per direction of Owner/
Engineer-in-charge.
b) The required peel strength shall be 60 N/cm (min.) at 23°C. The system shall
fail only in the adhesive layer. No failure either in adhesion to steel or
adhesion to backing shall be permitted. The adhesive layer that remains on
the pipe surface shall be free of voids resulting from air or gas inclusion.
c) If the sleeve taken away for test does not meet the requirement of clause 6.0
(b), the adjacent two sleeves do not meet the requirements of clause 6.0 (b)
the field joint coating shall be stopped until OWNER is satisfied with
application methods.
d) For the test tensile strength, two parallel incisions spaced 1 CM. Apart are
made right down to the surface of the steel. A further incision shall then be at
right angles to the first angles to the first two incisions. With the aid of a 1 cm.
Wide knife the coating is lifted over a length of about 2 cm. And clamped into
the tensile tester, where upon a uniform pull is exerted at an angle of 90
degree. The tensile strength shall be more than a 2500psi.
e) Coating thickness shall be checked by non destructive method for each field
joint.
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7.0 REPAIR OF FIELD JOINT COATING
7.1 If a field joint is detected to be unacceptable after inspection and testing as per
clause no. 6.0 of this specification. The CONTRACTOR shall , at his own cost :
- determine the cause of the faulty results of the coatings.
- mobilise the services of expert of manufactures, if required.
- test to the complete satisfaction of the OWNER, already completed field joint
coatings.
- stop joint coating until remedial measures are taken against the causes of
such failures, to the complete satisfaction of the OWNER.
7.2 CONTRACTOR shall replace all the joints coating found or expected to be
unacceptable as per clause no. 6.0 of this specification.
7.3 CONTRACTOR shall, at his own cost repair all areas where the coating has been
removed for testing by the OWNER or by the CONTRACTOR to the complete
satisfaction of the OWNER.
7.4 The upright edges of the damaged areas shall be chamfered, in addition to the steel
shall be free from rust, dirt, oil and grease. The coating around the damaged area
shall be roughened. After thorough mixing (in accordance with the recommendations
of the manufacturer) the filler shall be applied, to sufficient Thickness with the aid of
stooping knife, whilst observing ample overlap hardening. The material will require
the approval of OWNER.
7.5 After the coating work on welded joints and repairs to the coating have been
completed, The coating area as a whole shall be tested with spark-tester before pull
back/ lowering/jacking the pipeline.
7.6 Company shall be entitled to check the coating on buried pipelines or parts of
pipelines with equipment such as the “Pearson meter” and the resistance meter. If
the coating defects are established, the Contractor shall be responsible for
excavation at such points, repairing the coating, spark testing and backfilling the
excavations without extra charge.
8.0 REPAIR OF PIPE COATING DEFECTS
8.1 Any defect or damage in pipe coating observed till incorporation on permanent works
shall be rectified by the Contractor at his risk and cost. However, for repair of
damaged coating observed during taking over of Owner supplied pipe, if any, shall
be paid extra in accordance with the relevant items of Schedule of Rates.
8.2 Field repair of coated pipes shall be carried out by using same type of wraparound
sleeves used for joint coating.
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8.3 The repair procedure shall be same as specified herein above for application of anti-
corrosion field joint coating on welded pipe.
9.0 DOCUMENTATION
9.1 Prior to start the coating works at site Contractor shall furnish following Owner/
Consultant’s approved documents in addition to that mentioned in clause no. 3.4 of
this specification.
- Procedure for field joint coating & their repair

- Procedure for repair of pipe line coating defects
- Procedure qualification record
- Inspection test plan
- Inspection format
9.2 Final submission of all documents after finish the work shall be as per relevant
specification & SCC enclosed with the tender or as per direction of Engineer-in-
charge.
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DELHI CROSSINGS USING HORIZONTAL DIRECTIONAL
DRILLING METHOD
REV 0, EDITION - 1
FOR
PIPELINE CROSSINGS USING HORIZONTAL
DIRECTIONAL DRILLING METHOD
MECON LIMITED
DELHI 110 092

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DRILLING METHOD
REV 0, EDITION - 1
CONTENTS
SL.NO. DESCRIPTION
1.0 SCOPE
3.0 DESIGN AND ENGINEERING
4.0 CONSTRUCTION
5.0 DOCUMENTATION
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SERVICE – GAS/LIQUID/SLURRY
AMENDMENT STATUS

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1.0 SCOPE
1.1 This specification covers the minimum requirements for various activities to be
carried out by the Contractor for the engineering and construction of pipeline
crossing using directional drilling method.
1.2 This specification shall be read in conjunction with the requirements of specification
and other documents included in the CONTRACT between owner and Contractor.
1.3 Contractor shall, execute the work in compliance with laws, by laws, ordinance and
regulations. Contractor shall provide all services, labour, inclusive of supervision
thereof, supply of all materials (excluding “Owner supplied Material), equipment ,
appliances etc..
1.4 Contractor shall take full responsibility for the stability and safety of all operation and
methods involved in the work.
1.5 Contractor shall be deemed to have inspected and examined the work area and its
surroundings and to have satisfied himself as far as practicable with the surface
conditions, hydrological and climatic conditions, the extent and nature of the work
and materials necessary for the completion of the work, and the means of access to
the work area.
1.6 Contractor shall be deemed to have obtained all necessary information with regard
to risks, contingencies and all other circumstances, which may influence the work.
1.7 Contractor shall, in connection with the work, provide and maintain at his own costs
all lights, guards, fencing, as necessary or directed by Owner or their representative.
1.8 For the purpose of this specification, the following definitions shall hold.
- The words `Shall’ and `Must’ are mandatory.
- The words `Should, May and Will’ are non mandatory, advisory, or
recommendatory.
1.9 Contractor shall provide free of charge reasonable facilities to Owner’s personnel to
witness all stages of construction.
Reference has been made in this specification to the latest edition (edition enforce at
the time of issue of enquiry) of the following codes, standards and specifications :
a. ASME B 31.4 : Pipeline Transportation Systems for Liquids and Slurries
b. ASME B 31.8 : Gas Transmission and Distribution Piping Systems.
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c. OISD 226 : Natural Gas Transmission Pipeline and City Gas

Distribution Network.
d. MECON’s Standards : Navigable Waterway Pipeline Crossing Warning Sign

MEC/S/05/21/10
e. MECON’s Standards : Standard Specification for Pipeline Construction

MEC/S/05/21/01
In case of conflict between the requirements of this specification and the above
referred documents, the requirements of this specification shall govern.
3.0 DESIGN AND ENGINEERING
3.1 The limits of each crossing shall be determined by the Contractor on the basis of
crossing profile based on survey drawings, design, equipment, installation technique
and site condition. Contractor shall furnish all engineering design calculation and
crossing drawings etc. to owner for their approval prior to execution of the work.
3.2 Within the entire limits of crossing, the minimum cover to top of coated pipe shall be
as specified in the Special Conditions of Contract (SCC).
However, wherever the drilled length for a crossing includes the crossings of
obstacles such as roads, railroads, cannals, streams, etc. The following minimum
requirements of cover to the pipe shall be satisfied unless specified otherwise in the
scope of work in SCC.
For Road Crossing : 1.4 m from top of road to top of pipe.
For railroad crossing : 1.7 m from base of Rail to top of pipe.
For canal crossing : 1.5 m from lowest bed level to top of pipe.
In case the pipeline crosses other utilities, viz., other pipelines, sewers, drain pipes,
water mains, telephone conduits and other underground structures, the pipeline shall
be installed with at least 500 mm free clearance from the obstacle or as specified in
the drawing or such greater minimum distance as may be required by authorities
having jurisdiction. Also in all cases, the minimum covers specified above shall be
maintained within the entire limits of crossing.
3.3 The entry and exit points of the pipeline at ground level shall not come within the
limits of crossing as defined in the crossing drawings.
3.4 Contractor shall carry out calculations for determining the maximum permissible
overburden on pipe, to check that the empty pipeline is safe from collapse at any
point along the drilled crossing section. Contractor shall submit these calculations to
Owner for approval.
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3.5 Pipeline Axis
The plane containing the pipeline route axis shall be perpendicular to the horizontal
plane. There shall be no bending of the pipeline route axis at depths shall lower
than 2 meters below ground level.
3.6 Back-reamed hole and Pipeline Interface
3.6.1 Contractor shall derive combination of:
- Back-reamed hole diameter

- Bentonite density
- Pipeline submerged weight in bentonite (and means to achieve that weight)
to optimise the crossing design in terms of pipeline stresses and power requirement
3.6.2 Contractor shall indicated what maximum shear stress in the pipeline coating will
result from his choice of above parameters and other characteristics described in this
section.
3.6.3 Contractor shall furnish all calculations for Owner’s approval. If shear stress in pipe
coating is, in the opinion of Owner, beyond the permissible limits, Contractor shall
revise his choice of parameters to reduce shear stress on pipe coating to permissible
value.
3.7 Contractor shall determine in the minimum allowable elastic bend radius for pipe
from the following consideration:
3.7.1 Maximum Longitudinal Stress During Installation
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, in order to check this requirement, evaluate the maximum tensile
forces to which the pipeline is subjected to at any phase of its installation during the
pulling operation.
3.7.2. Maximum Equivalent Stress During Final Hydrostatic Test
After installation, the pipeline shall be hydrostatically tested to a minimum test

pressure equal to 1.4 times the design pressure or at a pressure stipulated in the
Special Conditions of Contract whichever is higher. However, during hydrostatic
testing, the combined equivalent stress in the pipeline due to bending and test
pressure shall not exceed 90% of the SMYS of pipe material.
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3.7.3 Maximum Equivalent Stress During Service
Permissible values of maximum equivalent stress during services shall be governed

by the requirements of ANSI B 31.8/B 31.4 as applicable. The details of pipeline
operating parameters are provided in the Special Conditions of Contract.
3.7.4 The minimum allowable radius of curvature for the pipeline shall be the highest value
of the minimum pipeline elastic radius as computed from the considerations outlined
in clause 2.7.1 to 2.7.3 above after correction for drilling inaccuracies or
multiplication by the factor 1.85. whichever results in the highest permissible value
of minimum elastic bend radius.
3.7.5 Contractor shall submit all calculations for Company’s approval alongwith procedure.
3.8 Pipeline Configuration along the Support String Before Entry Point
3.8.1 Contractor shall determine the required pipeline configuration in order to allow
smooth pull in the crossing entry point and admissible stress in the supported
pipeline string. Pipeline combined stress shall not exceed 95% of the specified
minimum yield strength for line pipe material.
3.8.2 Contractor shall furnish all calculation and specify the number of required supports,
description of the supports, their co-ordinates and capacity in metric tons.
3.8.3 Contractor shall also furnish a drawing of the launching ramp indicating the pipeline
configuration.
3.8.4 The distance between each roller shall also be specified and justified.
3.9 Contractor shall, based on result of design and engineering carried out by him,
prepare construction drawings for the crossing and shall submit the same for
Owner’s approval. Construction drawings shall indicate the pipeline profile with levels
furnished at sufficient intervals for proper control during construction. Other relevant
details viz., entry and exit angles, radius of bends, etc. shall also be indicated.
Contractor shall also calculated the total length of pipeline required as well as the
maximum tension required on the pull head of the rig.
3.10 All construction works shall be carried out in accordance with the construction
drawings approved by Owner.
3.11 Before commencement of any field work, Contractor shall furnish for Owner’s
approval all design calculations and construction drawings as stipulated in the above
clauses.
4.0 CONSTRUCTION
Contractor shall comply with all the conditions and requirements issued by
Authorities having jurisdiction in the area where the work is to be performed.
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If no public road exists, Contractor shall arrange on his own for access to his work
area at no extra cost to owner.
4.1.0 Installation Procedure
4.1.1 Contractor shall, before commencing any work at site, submit for Owner’s approval a
detailed installation procedure.
4.1.2 The installation procedure as a minimum shall include the following:
a) Project Organisation Chart:
This shall indicate Contractor’s organisational set-up at site and manpower

deployment.
b) Details of fabrication yard and launching areas.
c) Details of Equipment :
Contractor shall furnish the complete list of all equipment to be deployed for
preparation of pipe string and installation of crossing. Technical
characteristics and capacity of each equipment including instrumentation,
monitoring and control equipment shall be furnished in details.
d) Pipeline string preparation details (hauling, stringing, welding etc.)
e) Hydrostatic test procedure (pre and post installation)
f) Disposal methodology of bentonite slurry.
g) Method of installation covering all steps of construction, viz. Rig up, Pilot
hole, Back-Reaming, Pulling Down, Backfilling etc.
h) Calculation for maximum pulling force on the rig and recommended

maximum pulling velocity.
i) Time schedule for construction.
4.1.3 The time schedule shall be in accordance with overall time schedule for the project.
4.1.4 Approval by Owner of the methods used by Contractor shall in no way relieve
Contractor from the sole responsibility for safe and satisfactory installation, working
and operational use of the pipeline crossing.
4.2 Pipe String Preparation
Complete pipe string shall be prepared as a single string for pulling. Welding,
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radiographic inspection of joints and joint coating of the string shall be performed in
accordance with the respective applicable specifications included in the Contract
document.
4.3 Pre-testing
4.3.1 Contractor shall hydrostatically pre-test the complete pipe string of each crossing
before installation as per approved procedure for a minimum period of 24 hours.
4.3.2 After pre-testing, joint coating of the welds shall be done as per specification for
specific field joint coating of pipeline for HDD crossing included in the contract
document
4.3.3 The section of the pipeline corresponding to the crossing shall, before installation, be
subjected to hydrostatic test pressure as stipulated in the Special Conditions of
Contract. During the test, Contractor shall check all welds for leakage. Failure, if any,
during the test shall be rectified by the Contractor.
4.4 Gauging
4.4.1 Before pre and post installation hydrostatic testing, Contractor shall prove the
diameter of the pipeline by passing a gauging pig through the pipeline. The gauging
pig shall have a diameter equal to 95% of the nominal internal diameter of the pipe.
Contractor shall supply and install all temporary scraper launchers/ receivers and
other equipment, piping and materials and consumables required for the purpose.
4.5 Installation
4.7.1 Installation shall be done in accordance with approval installation procedure.
4.7.2 The lateral offset of the actual exit point of the pilot hole from the calculated and
theoretical exit point shall not exceed half per cent (0.5%) of the length of the
crossing.
4.7.3 The length tolerance shall not exceed one per cent of the crossing length, subject to
the condition that the actual exit point shall not be within the limits of crossing as
defined in the approved drawings.
4.7.4 Back reaming shall be done separately from the pipeline pulling operation. The size
of the back-reamed hole shall be adequate (approximately 1.5 times the pipeline
diameter) to allow enough clearance for a smooth pull-back of the pipeline.
4.7.5 Contractor shall be responsible for maintaining the drilled hole till such time the
pipeline is pulled in.
4.7.6 During pulling operation, the buoyancy of the pipeline shall be controlled by suitable
approved methods so as to maintain the buoyancy as close as possible to zero
during pull-back in order to reduce friction forces of the pipeline in the hole.
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4.7.7 Bentonite slurry of specified viscosity shall be pumped into the hole, preventing the
wall from collapsing and protecting the pipeline coating.
4.6 Contractor shall be responsible for the integrity of the corrosion coating.
4.6.1 Before pull-back operation, megger test shall be done for the entire pipeline
(externally corrosion coated) string made for crossing by HDD method.
4.6.2 After pull-back operation to ensure the integrity of pipeline coating, again megger
test shall be done for the bored string before tied-in to the mainline pipe. The
megger value before & after pulling operation of the pipeline string shall be nearly
same and acceptable to Owner.
4.6.3 However, if, in Owner’s opinion, the integrity of external corrosion coating of bored
pipeline string is not established by above (Clause No. 3.6.1 & 3.6.2), then further in
order to ensure the integrity of coating of the bored pipeline string, megger test of
the coating shall be carried out in accordance with the following steps:
a) The test must be carried out before the bored pipe is tied-in to the mainline
pipe
b) Measure the natural potential of the bored pipe at both ends.
c) Set up the temporary impressed current system with a digital multimeter

connected to measure the output current. Position the test electrode anode
as far from the bored pipe as interconnecting cable will allow and no closer
than 10 meters.
d) Place the reference electrode at the remote end (opposite to impressed

current system) to monitor the bored pipe potential
e) Impress a current into the bored pipe start at Zero amp. and increase slowly
until the bored pipe potential is depressed to 1.5 V with respect to the
reference electrode.
f) Note the current from the digital multimeter and calculate the current
density.
g) The desirable value of calculated current density should be less than 70 micro
ampere per square meter of drilled pipe surface in contact with the soil.
4.6.4 If Contractor again fails to establish the integrity of coating of the bored pipeline
string and the same is not acceptable to Owner, the above works shall not be
continued further until the cause analysed and rectified by the Contractor to the
entire satisfaction of Owner.
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4.7 Final Hydrostatic Test
4.7.1 The complete crossing section shall be tested after installation. The test pressure
shall be as stipulated in the Special Conditions of Contract. After temperature
stabilisation, pressure shall be retained in the pipeline for a period of 6 hours and
recorded by manothermograph. The hydrostatic testing shall be carried out in
accordance with approved procedures and specification detailed elsewhere in the
document.
4.7.2 Test Procedure
Contractor shall prepare for Company's approval a hydrostatic test procedure manual
for pre-testing and post-installation testing of pipeline. The test procedure manual
shall include, but shall not be limited to, the following items:
a. For the pipe section to be tested, a diagram indicating all fittings, vents,
valves, temporary connections, relevant elevations and ratings. The diagram
shall also indicate injection locations and intake and discharge lines.
b. Estimated amount of test water, water source, including required

concentration of corrosion inhibitors and additives, procedure for inhibitor
injection and control of concentration.
c. Filling and flushing procedures, including a complete description of all

proposed equipment and instruments (including spares), their location and
set-up.
d. The type and sequence of pigs and the pig tracking system for cleaning and
removal of air pockets, pig inspection procedures, including procedure to be
followed in case the gauging pig indicates damage.
e. Procedures for levelling and stabilization after filling and for pressurization
and to allow for temperature stabilization.
f. Pressure testing procedure including a complete description of all proposed

equipment and instruments (including spares), their location and set-up, and
proposed system for observation and recording of data during the pressure
test.
g. All calculations including air-volume calculations and pressure change due to

temperature change calculations.
h. Procedure for detection and location of leaks.
i. Procedure for safe 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.
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j. Forms for recording the testing data.
4.7.3 Contractor shall furnish all necessary equipment & instrumentation for performing
the work including all temporary piping, hydro test header and scraper launcher /
receiver etc.
4.7.4 The test medium shall be fresh water to be arranged by the Contractor. The water to
be used shall be filtered, shall not be contaminated, and free from sand of silt.
Contractor shall submit laboratory test reports of water used for testing. Contractor
shall provide Company approved corrosion inhibitors, oxygen scavengers and
bactericides to be added to the test water. Contractor shall furnish and install all
temporary piping, which may be necessary to connect from source of water to its
pumps and manifolds / tankage.
4.7.5 Before filling operation, Contractor shall clean the pipeline by air driven pigs provided
with spring loaded brushes and cups to remove all mill scale, rust / sand from the
internal of pipe sections.
4.7.6 The hydrostatic test shall be considered as positive if pressure has kept a constant
value throughout the test duration, except for changes due to temperature effects,
and there is no abrupt pressure drop throughout the test duration.
If test section fails to maintain the specified test pressure after isolation, Contractor
shall determine by search the location of leakage or failure. All leaks and failures
within the pipe wall or longitudinal seam shall be repaired by replacement of entire
joint or joints in which leakage or failure occurs. In those cases where leaks occur in
circumferential welds the method of repair shall be determined by Company.
Contractor shall comply with instructions of the Company whether to replace a
section of the line pipe that includes the line leak or whether to repair the
circumferential weld. This repair should, however, meet the requirements of welding
specification contained herein. 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 the approved procedures.
All work of reinstating line pipe, to replace failures, shall be done in accordance with
the specifications contained herein.
Contractor shall haul and stockpile all damaged and defective pipes to storage
locations designated by the Company. All cracks and splits resulting nom failures
shall be coated with an application of grease to preserve the characteristics of
failures nom corrosion. Joints of failed pipes shall be marked with paint, with a tag
indicating failure details, date and location of failure and pressure at which failure
occurred.
4.7.7 After completion of successful hydrotest of the above portion, the pipeline shall be
capped and buried. Pipeline end position on the banks shall be marked on the
ground by installing location markers on both banks approved by Company.
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4.8 Permanent Pipeline Markers
On both banks of each river crossing, Contractor shall install a Navigable Waterway
Pipeline Crossing Warning Sign in accordance with Std. No. MEC/S/05/21/05.
Contractor shall supply all materials and fabricate and install the markers as per
reference drawing. Wherever feasible, the pipeline markers shall be installed on the
embankments, however, exact location shall be decided based on site conditions and
as directed by Company.
4.9 Fencing
Wherever specified, Contractor shall supply all materials and install G.I. Wire Chain
link security fencing of size 10 m x 10 m x 25 m high with lockable steel gate around
the pipe ends and test stations for temporary C.P. on both sides of each river
crossing.
4.10 Idle Time Preservation of Pipeline
When so stated in the Contract, Contractor shall supply all materials and consumable
including water and inhibitor and shall install all piping connections, valves,
instrumentation, etc., and perform all works for preservation of pipeline by
pressurization with inhibited water. Contractor shall use approved inhibitors and shall
determine the required dosages of inhibitors and pressure for idle time preservation
of the pipeline for a period of maximum six months nom the date of completion of
construction. Corrosion inhibitors and dosages shall be subject to Company's
approval prior to use.
4.11 Final Clean up
4.11.1 After completion of construction, Contractor shall clear the site of all balance material
and debris and bentonite slurry. All balance pipe lengths shall be returned to Owner’s
designated stock yard(s). Site/ ROW shall be cleared to the complete satisfaction of
the land owner’s and authorities having jurisdiction. All such works shall be done at
no extra cost to Owner. The Owner shall be indemnified against any/ all claims
arising as a result thereof.
4.11.2 Contractor shall arrange for safe disposal of all surplus soil and bentonite slurry &
corrosion inhibited test water so as to avoid any harm to the environment /
occupants at locations duly approved by authorities and pollution control boards
having jurisdiction and/or as instructed by Company without any extra cost.
5.0 DOCUMENTATION
5.1 In additional to the documents specified elsewhere in this specification. Contractor

shall submit to the Owner the following documents/ records.
• Copies of the permits obtained from authorities having jurisdiction.
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• Records of pre and post installation hydrostatic testing.

• Record of non-destructive testing of welds.
• Detailed drilling log and downhole data, including, but not limited to, the
following :
i) Torque and pulling/pushing force
ii) Data on drilling fluid.
- Density
- Type of mud and additive employed.
- Mixing, pumping and cleaning.
• Wash and drill pipe data, viz.,

i) Dimension and material properties.
ii) Data on API classification.
iii) Age of and type of inspection previously carried out on these pipes.
• Permits obtained from authorities having jurisdiction for the various works.
• Plan & profile of the drilled hole along with the water level variations.
• Records of hydrostatic pre-testing and final testing.
• Record of Non Destructive Testing of welds.
• Clearance certificates form the landowners and Authorities having jurisdiction
regarding satisfactory clean-up and restoration of pipeline RoU and work areas.
• Clearance certificate from the land owners and authorities having jurisdiction
regarding satisfactory clean-up and restoration of the pipeline ROW and work
sites.
5.2 After completion of construction, Contractor shall prepare and furnish six sets of
copies and two sets of reproducible of `As-built’ for the crossings. As built drawings
shall , as a minimum include the following information
• True profile of the crossing along the pipeline.

• True profile of the pipeline as installed and the depth of cover to top of pipe at
regular intervals.
• Location of entry and exit point and angles of entry and exit alongwith lateral
offset of exit point from the original pipeline alignment.
• Location and angle of field bends
• Location of pipeline markers.
• All As-Built drawings shall be prepared using software AutoCAD Release 2000 or
above. Manually drafted drawings are not acceptable to Company. In addition,
to the hard copies, as-built drawings shall also be submitted in electronic media
i.e. CD / DVD.
5.3 All documents shall be in English language.
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SLURRY PIPE LINE, IRON ORE BENEFICIATION PLANT,
PELLET PLANT AND WATER PIPELINE PROJECT
SUPPLY, LAYING & CONSTRUTION OF SLURRY AND WATER

NMDC LTD. PIPELINE ALONG WITH ASSOCIATED FACILITIES MECON LTD.
PIPING MATERIAL SPECIFICATION

(SLURRY PIPE LINE)
DOCUMENT NO.: 101176-S-M-014

(SUBMITTED BY AUSENCO)
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101176-S-M-014
Revision Number D
MECON Limited
Bacheli to Nagarnar Iron
Concentrate Slurry Pipeline
Station Piping Material
Specification
November 2015
04-Nov-15
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Disclaimer
This document and its contents are for the private information and benefit only of MECON Limited (MECON),
for whom it was prepared, and for the particular purpose which MECON previously described to Ausenco PSI
(Ausenco). The contents of this document are not to be reused in whole or in part, by or for the benefit of
others without prior adaptation by, and the prior specific written permission of, Ausenco.
Particular financial and other projections, analysis and conclusions set out in this document, to the extent
they are based on assumptions or concern future events and circumstances over which Ausenco has no
control, are by their nature uncertain and are to be treated accordingly. Ausenco makes no warranty
regarding any of these projections, analysis and conclusions. Ausenco, its affiliates and subsidiaries and their
respective officers, directors, employees and agents assume no responsibility for reliance on this document
or on any of its contents by any party other than MECON.
The contents of this document are copyrighted by Ausenco, © 2015. All rights are reserved.
101176-S-M-014 3
Rev: D
Date: 04-Nov-15 481 of 911
Table of Contents
1 Scope 1
1.1 Application 1
1.2 Definitions 1
1.3 Requirements 1
1.4 Requirements not covered 1
2 Applicable Codes, Standards and References 1
3 Piping Class Specification 3
4 Pipe and Fittings 4
5 Flanges and Gaskets 5
6 Vents and Drains 5
7 Valves 6
8 Branch Connections 6
9 Unspecified Components 6
Appendix 1 – Abbreviations
Appendix 2 – Pipe Material Class
Appendix 3 – Branch Connection Tables
101176-S-M-014
Rev: D
Date: 04-Nov-15 482 of 911
1 Scope
1.1 Application
This Specification covers minimum requirements for piping, valve and fitting materials for the station
piping associated with the NMDC Bacheli-Nagarnar Iron Concentrate Slurry Pipeline.
1.2 Definitions
In this document:
“Vendor” refers to the party responsible for the supply of the complete package identified herein
“Owner” refers to NMDC Limited
“Buyer” refers to MECON or other entity who will be the procurement agent
“Engineer” refers to MECON or Ausenco, who is the “Owner’s” appointed technical

representative
1.3 Requirements
Piping components shall be designed and furnished in strict accordance with this Specification,
Buyer’s drawings and the Contract/purchase order requirements. In the event of conflict between
the aforementioned documents, this Specification shall govern. The requirements herein shall not
take precedence over code requirements except where more stringent than the code.
1.4 Requirements not covered
The following work is covered by other specifications and may be referenced in this Specification:
 Fabrication and installation of piping components and valves

 Specification for and installation of control valves and instrumentation
 Specification for and installation of external coating
 Hydro testing of piping systems
 Pipe support installation for piping systems
 Specification for and installation of mainline pipe
2 Applicable Codes, Standards and References

Design, materials, fabrication and inspection shall conform to the latest editions of the following:
101176-S-M-014 1
Rev: D
Date: 04-Nov-15 483 of 911
ASME B1.20.1 Pipe Threads, General Purpose (Inch)
ASME B16.5 Pipe Flanges and Flanged Fittings
ASME B16.9 Factory-Made Wrought Steel Butt-welding Fittings
ASME B16.10 Face-to-Face and End-to-End Dimensions of Valves
ASME B16.11 Forged Fittings, Socket-Welding and Threaded
ASME B16.20 Metallic Gaskets for Pipe Flanges-Ring-Joint, Spiral-Wound and Jacketed
ASME B16.21 Nonmetallic Flat Gaskets for Pipe Flanges
ASME B16.25 Butt-welding Ends
ASME B16.28 Wrought Steel Butt-welding Short Radius Elbows and Returns
ASME B16.34 Valves- Flanged, Threaded and Welding End
ASME B16.47 Larger Diameter Steel Flanges
ASME B31.3 Process Piping
ASME B31.4 Pipeline Transportation Systems for Liquids and Slurries
ASME B36.16 M Welded and Seamless Wrought Steel Pipe
ANSI American National Standards Institute
API American Petroleum Institute
ASTM A105 Standard Specification for Carbon Steel Forgings for Piping Applications
ASTM A234 Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy
Steel for Moderate and High Temperature Service
AWWA American Water Works Association
AWS American Welding Society
MSHA Mine Safety and Health Administration, Mine Safety and Health Standards
MSS Manufacturers Standardization Society of the Valve and Fittings Industry
NFPA National Fire Protection Association
101176-S-M-014 2
Rev: D
Date: 04-Nov-15 484 of 911
OSHA Occupational Safety and Health Administration (OSHA), U.S. Department of
Labor: Occupation Safety and Health Standards and all amendments thereto
Safety and Health Regulations for Construction and all amendments thereto
(promulgated by the Bureau of Labor Standards, U.S. Department of Labor)
SSPC Steel Structures Painting Council
UL Underwriter’s Laboratories, Inc.
As an alternative, equivalent standards from other countries may be referred to Buyer for approval.
3 Piping Class Specification

The pressures and temperatures referenced in the piping class specification (part of Appendix 2)
are the maximum piping class design conditions. Particular service operating conditions shall not
exceed the stated design conditions for the relevant piping class.
Materials with higher pressure and temperature ratings or better corrosion resistant properties may
be substituted for those specified, provided that other properties are not reduced to less than the
materials specified. All substitutions are subject to the Buyer’s review and acceptance prior to use.
Manufacturers’ names and catalogue numbers for valves and piping accessories are given for
descriptive purposes only. Equal or better items from other Manufacturers may be substituted
subject to Buyer’s review and acceptance prior to use.
101176-S-M-014 3
Rev: D
Date: 04-Nov-15 485 of 911
The pipe class is a 5-part code as shown on the table below:
Pipe material class designation code

5th
1st Character 2nd Character 3rd Character 4th Character
Character
Material Type Class Rating CA or Lining Joint Type Design Code
Corrosion /Erosion
Allowance
A Aluminum and Aluminum

Alloy 0 0 0” A BW/TH/Flg 0
B Copper Alloy 1 150 1 0.0625’’ B BW/SW/Flg 1 B31.1
C Carbon Steel 2 250 2 0.125” C BW/BW/Flg 2
D Ductile Iron or Cast Iron 3 300 3 0.13”-0.14” D BW/VC/Flg 3 B31.3
E 4 4 0.15”-0.156” E BW/SW/TH/Flg 4 B31.4
F Fiberglass 5 5 0.18”-0.187” F TH/Flg 5
G Galvanized Carbon
Steel 6 600 6 0.21”-0.218” G SW/TH/Flg 6
H HDPE 7 7 0.25” H SW/Flg 7
8 800 8 0.30-0.34” 8 B31.8
J 9 900 9 9
K A 25 Lining
Lined Pipe (PE, Rubber,
L Urethane lining) B 50 E Epoxy
M C 75 H HDPE
N Carbon Steel, X52 D 100 R Rubber
P E 125 U Urethane
Q Carbon Steel, X65 F 175
R G 200
S Stainless Steel H 1000
J 1500
K 2500
4 Pipe and Fittings

Odd pipe sizes, i.e., 1¼ inches (32 mm), 3½ inches (65 mm), 5 inches (125 mm) and 7 inches (175
mm) shall not be used other than as required for equipment connections or where design velocity
requirements dictate otherwise.
ASTM-A106 is considered an acceptable substitute for ASTM-A53, Grade B pipe.
101176-S-M-014 4
Rev: D
Date: 04-Nov-15 486 of 911
Miters in steel piping generally shall not be used unless specified in the Piping Class Sheets for
sump overflows and other places where elbows or bends are not practical. Fabricated miters, where
required, shall conform to AWWA Specification C-208.
The wall thickness of reducing fittings shall match the greater wall thickness.
5 Flanges and Gaskets

The dimensions of all flanges, gaskets and bolts shall conform to the latest edition of ASME B16.5,
or MSS SP-44 as specified in the piping class sheets.
Gaskets containing asbestos shall not be used. Contractor may, at their option, submit a proposed
alternative to gaskets specified in the class sheets for Buyer’s review and acceptance prior to use.
ASME B16.5 class 150 flat-face steel flanges with full-face gaskets shall be used where required to
mate with ASME B16.1 class 125 flat-face cast iron flanges.
ASME B16.5 class 300 flat-face steel flanges with full-face gaskets shall be used where required to
mate with ASME B16.1 class 250 flat-face cast iron flanges.
Jackscrews shall be utilized in line blind assemblies.
6 Vents and Drains

Vents and drains shall be provided at all high and low points except for slurry service. Vents and
drains for slurry service shall be as shown on drawings. All vents and drains shall be provided with
a shut-off valve in accordance with the Piping Class for the stated commodity or services. All valved
vents and drains shall be plugged, capped or flanged unless connected to a header or run to a
drain or tail pipe.
Minimum vent valve sizes shall be:
 ¾ inch (20 mm) for all unlined piping and 2 inches (50 mm) for lined piping
Minimum drain valve sizes shall be:
 ¾ inch (20 mm) minimum for unlined piping ¾ inch (20 mm) through 2½ inches (65 mm)
 1½ inches (40 mm) minimum for unlined piping 3 inches (80 mm) through 6 inches (150 mm)
 2 inches (50 mm) minimum for unlined piping 8 inches (200 mm) through 12 inches (300 mm)
 3 inches (80 mm) minimum for unlined piping 14 inches (350 mm) through 16 inches (400
mm)
 4 inches (100 mm) minimum for unlined piping 18 inches (450 mm) through 24 inches (600
mm)
101176-S-M-014 5
Rev: D
Date: 04-Nov-15 487 of 911
 6 inches (150 mm) minimum for unlined piping 26 inches (650 mm) and larger
Vent or drain valve sizes that differ from the above shall be as sized on the P&IDs.
7 Valves
Valve dimensions shall conform to the latest edition of ASME B16.10, “End-to-End Dimensions
of Valves”.
Operators shall be provided as specified in the Valve List.
8 Branch Connections
Welded branch connections shall be designed and fabricated in accordance with the latest edition
of ASME B31.3 or ASME B31.4, per the design code specified in the piping class sheets.
Branch connections in the individual piping classes are for 90-degree branches only. Branch
connections other than 90 degrees shall be evaluated on an individual basis and specified on
engineering drawings.
9 Unspecified Components
Components not listed on the individual piping class sheets shall be considered out-of-specification
components and shall be identified with an applicable SP number (special piping item number) on
the piping drawings.
101176-S-M-014 6
Rev: D
Date: 04-Nov-15 488 of 911
Appendix 1 – Abbreviations
Abbreviation Term Abbreviation Term

ºC or (C) Degree Celsius DWV Drain, waste, and vent
ºF or (F) Degree Fahrenheit ECC Eccentric
A/G Aboveground EFW Electrical fusion welded
amb Ambient E Elbow
ANSI American National Standard Institute ENC Electroless nickel coated
American Society of Mechanical
ASME ERW Electrical resistance welded
Engineers
American Society for Testing and
ASTM Fed Std Federal standard
Materials
atm Atmosphere FF Flat face
BB Bolted bonnet Flg Flange
BC Bolted cap FM Factory mutual
BE Bevel end FS Forged steel
BFW Boiler feedwater Ft Foot
BLE Beveled large end Galv Galvanized
Brz Bronze GE Grooved end
BS Bell and Spigot Gm Gram
BW Butt weld GO Gear operated
C&W Coated and wrapped Gr Grade
CB Clamp Bonnet HDPE High density polyethylene
CI Cast Iron Hex Hexagonal
CO Chain operated HM Manual operated hydraulic
Conc Concentric HP High pressure
Conn Connection IBBM Iron body bronze mounted
CPVC Chlorinated polyvinyl chloride ID Inside diameter
Cr Chromium In. Inch
CS Carbon steel ISRS Inside screw rising stem
Cu Copper Kg Kilogram
CWP Cold working pressure L Liter
DI Ductile iron lb Pound
DSAW Double submerged arc welded LO Lever operated
101176-S-M-014
Rev: D 1
Date: 04-Nov-15 489 of 911
Abbreviation Term Abbreviation Term
Lt Light LP Low pressure
Lub Lubricated Scrd Screwed
M Metre SDR Standard dimension ratio
Max Maximum SE Screwed end
Mfgr Manufacturer SJ Solder joint
MI Malleable iron Smls Seamless
Min Minimum Sq Square
MJ Mechanical joint SS Stainless steel
mm Millimeter Std Standard
MH Manual handwheel actuator SW Socket weld
MP Medium pressure T&C Threaded and coupled
Mpa Megapascals TBE Threaded both ends
Neop Neoprene temp Temperature
NPS Nominal pipe size TFE Teflon
NPT National pipe taper (pipe thread) Thd Threaded
NRS Non-rising stem Thk Thick or thickness
Op Operated Tp Type
OS&Y Outside screw and yoke Tr Trim
PE Plain end TSE Threaded small end
PSI Pounds per square inch UB Union bonnet
PSIG Pounds per square inch gauge UG Underground
PTFE Polymerized tetrafluoroethylene (Teflon) UL Underwriter’s Laboratories
PVC Polyvinyl chloride VC Victaulic coupling
PVDF Polyvinylidene fluoride (Kynar) VG Victaulic groove
RF Raised face w/ With
RL Rubber lined Wfr Wafer
Sp.Gr. Specific gravity WOG Water, oil, and gas
SB Screwed bonnet wt Weight
SC Screwed cap XS Extra strong
Sch Schedule XXS Double extra strong
XH Extra Heavy WN Weld Neck
NBR Nitrile Butadiene Rubber XXH Extra Extra Heavy
101176-S-M-014
Rev: D 2
Date: 04-Nov-15 490 of 911
Appendix 2 – Pipe Material Class
Pipe Class Table
Pipe Class ASME Class Material Liner (See P&ID for thickness) Service
C11E4 150 CS None Milk of Lime
Process Water/Return Water

C14E4 150 CS None
Gland Seal Water
Slurry Vents/Slurry Drains/

C14B4 150 CS None Slurry Overflow
Slurry
Gland Seal Water

C34B4 300 CS None Process Water/Return Water
Slurry
C64B4 600 CS None Slurry
C94B4 900 CS None Slurry
CJ4B4 1500 CS None Slurry
NJ4B4 1500 CS None Slurry
QJ4B4 1500 CS None Slurry
L6RC4 600 CS Rubber Slurry
S90B3 900 SS None Hydraulic Oil
SJ0B3 1500 SS None Hydraulic Oil
101176-S-M-014
Rev: D 1
Date: 04-Nov-15 491 of 911
Piping Class Specification Ausenco Project No.: 101176
Pipe Class: C11E4
Primary Rating: ASME Class 150 Design Code: ASME B31.4
Max. Pressure: 285 psi @ 100°F Design Factor: 0.72

1965 kPa at 38°C
Corrosion / Erosion Allowance: 0.0625” (1.587 mm) Service: Milk of Lime
Hydro Test Pressure: (Note 2 & 3): 356 psi, Construction material: Carbon Steel Pipe
2455 kPa (unlined)
Pipe:
1/2” (15mm) through 2” (50mm) Carbon steel, ASTM A53, A106 or API 5L, Grade B, seamless, XS,
PE/BE
3” (80mm) through 24” (600mm) Carbon steel, ASTM A53 or API 5L, Grade B, seamless/ERW,
STD, PE/BE
_____________________________________________________________________________________
Flanges and Accessories
Flanges
Smaller than 2” (50mm) ASME Class 150, socket-weld, flat faced, forged steel, ASTM A105,
manufactured per ASME B16.5 (See Note 5).
2” (50mm) through 24” (600mm) ASME Class 150, WN or slip on, flat faced, forged steel, ASTM
A105, manufactured per ASME B16.5 (See Notes 4 and 5).
Fittings
Smaller than 2” (50 mm) 3000# socket weld/threaded, forged steel, ASTM A105. (See Note 6)
2” (50 mm) through 24” (600 mm) Butt-welded fittings to ASME B16.9, material per ASTM A234 Grade
WPB, BE, minimum wall thickness same as pipe. Elbows shall be
long radius.
Gaskets 1/8” (3.2mm) compressed non-asbestos with NBR binder, ASME

B16.21, ASME B16.5. Use full face for flat faced flanges and flat
ring for raised faced flanges.
Stud Bolts ASTM A193 Grade B7 with 2 hex nuts per ASTM A194, Grade 2H.
101176-S-M-014
Rev: D 2
Date: 04-Nov-15 492 of 911
Valves Type: Gate, Plug, Ball, Pinch
See Valve Specification and/or Valve List
______________________________________________________________________________________
Notes: 1. For branch connections, see attached Branch Connection Table 2.

Threadolet/Sockolet per ASTM A105, ASME B16.1. For header size
greater than 12” (300 mm) use Table 1.
2. No hydrostatic test required on lines open to atmosphere.
3. During hydro test valves that are not used as isolation valves shall
be partially open (50% open position) in order to pressurize stem
seals.
4. Use welding neck flanges when mating to butt-weld fittings.
5. Use raised face when mating to raised face flanges.
6. Use socket-weld unless threaded is required.
101176-S-M-014
Rev: D 3
Date: 04-Nov-15 493 of 911
Pipe Class: C14E4

1965 kPa at 38°C
Corrosion / Erosion Allowance: 0.15” (3.81 mm) Service: Process Water

Return Water
Gland Seal Water
2455 kPa (unlined)
Pipe:
1/2” (15mm) through 3/4” (20mm) Carbon steel, ASTM A53 or A106, Grade B, seamless, Sch160, PE
1” (25mm) through 2” (50mm) Carbon steel, ASTM A53 or API 5L, Grade B, seamless, XH, PE
STD, PE/BE
_____________________________________________________________________________________
Flanges
Smaller than 2” (50mm) ASME Class 150, socket-weld or threaded, flat faced, forged steel,
ASTM A105, manufactured per ASME B16.5 (See Note 5 and 6).
2” (50mm) through 24” (600mm) ASME Class 150, WN or slip on, flat faced, forged steel, ASTM
A105, manufactured per ASME B16.5 (See Notes 4 and 5).
Fittings
Smaller than 2” (50 mm) 3000# socket weld/threaded, forged steel, ASTM A105. (See Note 6)
2” (50 mm) through 24” (600 mm) Butt-welded fittings to ASME B16.9, material per ASTM A234 Grade
WPB, BE, minimum wall thickness same as pipe. Elbows shall be
long radius.
101176-S-M-014
Rev: D 4
Date: 04-Nov-15 494 of 911
Gaskets 1/8” (3.2mm) compressed non-asbestos with NBR binder, ASME
B16.21, ASME B16.5. Use full face for flat faced flanges and flat
ring for raised faced flanges.
Valves Type: Gate, Butterfly, Plug, Ball, Check

______________________________________________________________________________________

Threadolet/Sockolet per ASTM A105, ASME B16.1. For header size
greater than 12” (300 mm) use Table 1.
seals.
4. Use welding neck flanges when mating to butt-weld fittings.
5. Use raised face when mating to raised face flanges.
6. Use socket-weld for Gland Seal Water and threaded for Process and
Return Water.
101176-S-M-014
Rev: D 5
Date: 04-Nov-15 495 of 911
Pipe Class: C14B4

1965 kPa at 38°C
Corrosion / Erosion Allowance: 0.15” (3.81 mm) Service: Slurry Vents

Slurry Drains
Slurry Overflow
Slurry
2455 kPa (unlined)
Pipe:
1/2” (15mm) through 3/4” (20mm) Carbon steel, ASTM A53 or A106, Grade B, seamless, Sch160, PE
1” (25mm) through 2” (50mm) Carbon steel, ASTM A53 or API 5L, Grade B, seamless, XH, PE
STD, BE
_______________________________________________________________________________
Flanges
Smaller than 2” (50mm) ASME Class 150, socket-weld, raised faced, forged steel, ASTM
A105, manufactured per ASME B16.5 (See Note 4).
2” (50mm) through 24” (600mm) ASME Class 150, WN, raised faced, forged steel, ASTM A105. (See
Note 4)
Fittings
Smaller than 2” (50mm) 3000# socket weld, forged steel, ASTM A105.
2” (50mm) through 24” (600mm) Butt-welded fittings to ASME B16.9, material per ASTM A234 Grade
WPB, BE, minimum wall thickness same as pipe. Bends shall have
a minimum 5 diameter radius unless noted otherwise on drawings.
For vents service, bends shall be long radius.
101176-S-M-014
Rev: D 6
Date: 04-Nov-15 496 of 911
Gaskets 1/8” (3.2mm) spiral-wound gasket, 304 SS winding, flexible graphite
filler, CS outer and inner guide, ASME B16.20 to suit ASME B16.5
flanges.
Valves Type: Gate, Plug, Ball, Knife Gate

______________________________________________________________________________________
3. During hydrotest, valves that are not used as isolation valves shall be
partially open (50% open position) in order to pressurize stem seals.
4. Use flat face when mating to flat faced flanges.
101176-S-M-014
Rev: D 7
Date: 04-Nov-15 497 of 911
Pipe Class: C34B4

5100 kPa at 38°C
Corrosion / Erosion Allowance: 0.15” (3.81 mm) Service: Gland Seal Water
Process Water
Return Water
Slurry
6380 kPa (unlined)
Pipe:
1/2” (15mm) through 3/4” (20mm) Carbon steel, ASTM A53 or API 5L, Grade B, seamless, Sch160, PE
1” (25mm) through 2” (50mm) Carbon steel, ASTM A53 or API 5L, Grade B, seamless/ERW, XH
PE
3” (200mm) through 14” (350mm) Carbon steel, ASTM A53 or API 5L, Grade B, seamless/ERW, STD, BE
16” (400mm) through 20” (500mm) Carbon steel, ASTM A53 or API 5L, Grade B, seamless/ERW, XS,
BE
24” (600 mm) Carbon steel, ASTM A53 or API 5L, Grade B, seamless/ERW,
Sch30, BE
______________________________________________________________________________________
Flanges
Smaller than 2’’ (50mm) ASME Class 300, socket weld, RF, forged steel ASTM A105,
manufactured per ASME B16.5.
2” (50mm) and larger ASME Class 300, weld neck, RF, forged steel, ASTM A105,
manufactured per ASME B16.5. Bore same as pipe inside diameter
(see note 4).
Fittings
101176-S-M-014
Rev: D 8
Date: 04-Nov-15 498 of 911
Smaller than 2” (50mm) 6000# socket weld, forged steel ASTM A105.
2” (50mm) and larger Butt-welded fittings to ASME B16.9, material per ASTM A234 Grade
WPB, BE, minimum wall thickness same as pipe. For Slurry service,
bends shall have a minimum 3 diameter radius unless shown as 5
diameter radius on drawings. For water service, bends shall be long
radius.
Gaskets 1/8” (3.2mm) spiral-wound gasket 304SS winding, flexible graphite

filler and CS outer and inner guide, ASME B16.20 to suit ASME B16.5
flanges
Valves Type: Knife Gate, Ball, Check.

______________________________________________________________________________________
seals.
4. Use flat face when mating to flat face flanges.
101176-S-M-014
Rev: D 9
Date: 04-Nov-15 499 of 911
Pipe Class: C64B4

10205 kPa at 38°C
Corrosion / Erosion Allowance: 0.15’’(3.81mm) Service: Slurry
12755 kPa
Pipe:
1/2” (20mm) through 2” (50mm) Carbon steel, ASTM A53, Grade B, seamless, Sch160, PE.
3” (80mm) through 10” (250mm) Carbon steel, ASTM A53 or API 5L, Grade B, seamless/ERW, XH, BE.
12” (300mm) through 24” (600mm) Carbon steel, ASTM A53 or API 5L, Grade B, seamless/ERW, Sch
60, BE.
______________________________________________________________________________________
Flanges
Smaller than 2’’ (50mm) ASME Class 600, socket weld, RF, forged steel, ASTM A105,
(see note 4).
Fittings
diameter radius on drawings.
101176-S-M-014
Rev: D 10
Date: 04-Nov-15 500 of 911
filler and CS outer and inner guide, ASME B16.20 to suit ASME
B16.5 flanges.
Valves Type: Gate, Ball

______________________________________________________________________________________
seals.
101176-S-M-014
Rev: D 11
Date: 04-Nov-15 501 of 911
Pipe Class: C94B4

15305 kPa at 38°C
Hydro Test Pressure: (Note 2 & 3): 2775 psi, Construction material: Carbon Steel
19133 kPa
Pipe:
3/4” (20mm) through 3” (80mm) Carbon steel, ASTM A53 or API 5L, Grade B, seamless/ERW,
Sch160, PE/BE
4” (100mm) through 6” (150mm) Carbon steel, ASTM A53 or API 5L, Grade B, seamless/ERW, Sch120,
BE
BE
24” (600mm) Carbon steel, ASTM A53 or API 5L, Grade B, seamless/ERW, Sch80,
BE
______________________________________________________________________________________
Flanges
manufactured per ASME B16.5. Bore same as pipe inside diameter.
Fittings
diameter radius on drawings.
101176-S-M-014
Rev: D 12
Date: 04-Nov-15 502 of 911
flanges.

______________________________________________________________________________________
seals.
101176-S-M-014
Rev: D 13
Date: 04-Nov-15 503 of 911
Pipe Class: CJ4B4

25545 kPa at 38°C
31923 kPa
Pipe:
3/4” (20mm) through 2” (50mm) Carbon steel, ASTM A53 or API 5L, Grade B, seamless, XXS, PE
PE/BE
8” (200mm) through 24” (600mm) Carbon steel, ASTM A53 or API 5L, Grade B, seamless/ERW, Sch 140,
BE
______________________________________________________________________________________
Flanges
manufactured per ASME B16.5. Bore same as pipe inside diameter.
Fittings
diameter raduis on drawings.
101176-S-M-014
Rev: D 14
Date: 04-Nov-15 504 of 911
flanges.
Valves Type: Gate, Ball, Check.

______________________________________________________________________________________
seals.
101176-S-M-014
Rev: D 15
Date: 04-Nov-15 505 of 911
Pipe Class: NJ4B4

25545 kPa at 38°C
Pipe Material API 5L, X52
31923 kPa
Pipe:
14” (350mm) through 24” (600mm) Carbon steel, API 5L, X52 ERW, BE
14”(350mm) Wall Thickness = 0.875 inch
______________________________________________________________________________________
Flanges
14” (350mm) through 24”(600mm) ASME Class 1500, weld neck, RF, forged steel, MSS-SP-44, F52.
Bore same as pipe inside diameter.
Fittings
14” (350mm) through 24”(600mm) Butt-welded fittings per MSS-SP-75, Class WPHY-52, BE, minimum
wall thickness same as pipe. For Slurry service, bends shall have a
minimum 3 diameter radius unless shown as 5 diameter raduis on
drawings.
101176-S-M-014
Rev: D 16
Date: 04-Nov-15 506 of 911
flanges.
Valves Type: Gate, Ball,

______________________________________________________________________________________
seals.
101176-S-M-014
Rev: D 17
Date: 04-Nov-15 507 of 911
Pipe Class: QJ4B4

25545 kPa at 38°C
Pipe Material AP5 5L, X65
31923 kPa
Pipe:
Carbon Steel, API 5L, X65, seamless/ERW, BE
2” (50m) Wall Thickness = 0.25 inch
4” (100m) Wall Thickness = 0.25 inch
24”(600m) Wall Thickness = 1.125 inch
26”(650m) Wall Thickness = 1.125 inch
______________________________________________________________________________________
Flanges
2” (50mm) and larger ASME Class 1500, weld neck, RF, forged steel, MSS-SP-44,F65.
Bore same as pipe inside diameter.
Fittings
2” (50mm) and larger Butt-welded fittings per MSS-SP-44, class WPHY-65, BE, minimum wall
thickness same as pipe. For Slurry service, bends shall have a
minimum 3 diameter radius unless shown as 5 diameter raduis on
drawings.

flanges.
101176-S-M-014
Rev: D 18
Date: 04-Nov-15 508 of 911
Valves Type: Gate, Ball,

______________________________________________________________________________________
seals.
101176-S-M-014
Rev: D 19
Date: 04-Nov-15 509 of 911
Pipe Class: L6RC4

10205 kPa at 38°C
Corrosion / Erosion Allowance: 0’’ Service: Slurry
12755 kPa with rubber lining
(see note 5).
Pipe:
2” (50mm) through 12” (300mm) Carbon steel, ASTM A53 or API 5L, Grade B, seamless/ERW, STD, BE
14” (350mm) through 20” (500mm) Carbon steel, ASTM A53 or API 5L, Grade B, seamless/ERW, Sch 40,
BE
24” (600mm) Carbon steel, ASTM A53 or API 5L, Grade B, seamless/ERW, Sch 60,
BE
______________________________________________________________________________________
Flanges
2” (50mm) and larger ASME CL 600, WN, raised face, forged steel, ASTM A105,
see note 4).
Fittings
WPB, BE, wall thickness same as pipe. Bends shall have a minimum 3
diameters radius unless shown otherwise on drawings.

filler and CS inner and outer guide, ASME B16.20 to suit ASME B16.5
or B16.47 flanges.
101176-S-M-014
Rev: D 20
Date: 04-Nov-15 510 of 911

______________________________________________________________________________________
seals.
4. Modify flange face to suit lining requirement shown on drawings.
5. All fittings, bends, and pipe spools shall be rubber lined as per
rubber lining specification.
101176-S-M-014
Rev: D 21
Date: 04-Nov-15 511 of 911
Piping Class Specification Ausenco PSI Project No.: 101176
Pipe Class: S90B3
Max. Pressure: 2200 psi @ 100°F Service HO: Hydraulic Oil

15305 kPa @ 38° C
Corrosion / Erosion Allowance: 0.0” Stainless Steel

Construction material:
Pipe (Unlined)
Hydro Test Pressure: 2775 psi
(Note 1 & 2): 19130 kPa
Pipe:
½” (15 mm) through 1 ½” (40 mm) Stainless steel, ASTM A312, TP316L, Seamless, Sch. 40S, PE.
2” (50 mm) through 2 ½” (65 mm) Stainless steel, ASTM A312, TP316L, Seamless, Sch. 80S, PE.
______________________________________________________________________________________
Flanges
Smaller than 2” (50 mm) ASME CL 900, SW, raised face, SS, ASTM A182,Gr. F316L, smooth
finish manufactured per ASME B16.5 (see note 3).
2” (50 mm) through 2 ½” (65 mm) ASME CL 900, WN, raised face, SS, ASTM A182, Gr. F316L, smooth
finish manufactured per ASME B16.5. Bore same as pipe inside
diameter (see note 3).
Fittings
Smaller than 2” (50 mm) 6000# socket weld, stainless steel, ASTM A182, Grade F316L.
2” (50 mm) through 2 ½” (65 mm) Butt-welded fittings to ASME B16.9, material per ASTM A403 Grade
WP 316L, class WX, wall thickness same as pipe.
Gaskets 1/8” (3.2 mm) spiral-wound gasket, 316SS winding, flexible graphite
filler and CS outer guide, ASME 16.20 to suit ASME B16.5 flanges.
101176-S-M-014
Rev: D 22
Date: 04-Nov-15 512 of 911
Valves Type: Ball
See Valve List.
______________________________________________________________________________________
Notes: 1. No hydrostatic test required on lines open to atmosphere.
2. During hydro test valves that are not used as isolation valves shall be
3. Use flat face when mating to flat face flange.
101176-S-M-014
Rev: D 23
Date: 04-Nov-15 513 of 911
Piping Class Specification Ausenco PSI Project No.: 101176
Pipe Class: SJ0B3
Max. Pressure: 3705 psi @ 100°F Service HO: Hydraulic Oil

25,545 kPa
Corrosion / Erosion 0.0” Stainless Steel

Allowance: Construction material: Pipe (Unlined)
Hydro Test Pressure: 4630 psi

(Note 2 & 3): 31,920 kPa
Pipe:
½” (15mm) through 1-1/4” (32mm) Stainless steel, ASTM A312, TP304L, Seamless, Sch. 80S, PE
______________________________________________________________________________________
Flanges None
Fittings
1-1/4” and smaller Stainless steel, ASTM A182 F304L, 6000#, ends socket weld.
Gaskets None
Stud Bolts None
Valves Type: Ball. See Valve List.
______________________________________________________________________________________
Notes: 1. For branch connections, use tees.
2. Bushings or reducers can be used.
3. During hydro test valves that are not used as isolation valves shall be
4. Hose whips and fittings will be per hydraulic unit vendor recommendation.
101176-S-M-014
Rev: D 24
Date: 04-Nov-15 514 of 911
Appendix 3 – Branch Connection Tables
Table 1
BRANCH
SIZE :
MM (IN.)
900 (36”) T
650 (26”) RT T
600 (24”) RT RT T
500 (20”) RT RT RT T
450 (18”) RT RT RT RT T
400 (16”) RT RT RT RT RT T
350 (14") (*) RT RT RT RT RT T
300 (12") (*) RT RT RT RT RT RT T
250 (10") (*) (*) RT RT RT RT RT RT T
200 (8") (*) (*) (*) RT RT RT RT RT RT T
150 (6") (*) (*) (*) (*) (*) RT RT RT RT RT T
100 (4") (*) (*) (*) (*) (*) (*) (*) (*) RT RT RT T
80 (3") W W W W W W W W W W RT RT T
50 (2") W W W W W W W W W W W RT RT T
900 650 600 500 450 400 350 300 250 200 150 100 80 50
(36”) (26”) (24”) (20”) (18”) (16”) (14”) (12”) (10”) (8”) (6”) (4”) (3”) (2”)
HEADER SIZE
Notes: 1. Branch connection is for 90 branches only.
2. The branch connection table shall be used unless specifically noted otherwise on
piping drawings.
3. For header and branch size smaller than 2” (50mm) see Table 2.
Legend: W - Weldolet
T - Butt weld tee
RT - Butt weld reducing tee
(*) – Use of special forged or extruded reduction fittings; they shall be designed and calculated under
ASME 31.4 Code.
101176-S-M-014 1
Rev: D
Date: 04-Nov-15 515 of 911
Table 2
BRANCH SIZE :
MM (IN.)
300 (12”) T
250 (10”) RT T
200 (8”) RT RT T
150 (6") W RT RT T
100 (4") W W W RT T
80 (3") W W W W RT T
50 (2") TL/SW TL/SW TL/SW TL/SW TL/SW TL/SW TT/ST
40 (1½") TL/SW TL/SW TL/SW TL/SW TL/SW TL/SW “ TT/ST
25 (1") TL/SW TL/SW TL/SW TL/SW TL/SW TL/SW “ “ TT/ST
20 (3/4") TL/SW TL/SW TL/SW TL/SW TL/SW TL/SW “ “ “ TT/ST
15 (1/2") TL/SW TL/SW TL/SW TL/SW TL/SW TL/SW “ “ “ “ TT/ST
300 250 200 150 100 80 50 40 25 20 15

(12”) (10”) (8”) (6”) (4”) (3”) (2”) (1½”) (1”) (3/4”) (1/2”)
HEADER SIZE
Notes: 1. Branch connection is for 90 branches only.
2. The branch connection table shall be used unless specifically noted otherwise on
piping drawings.
Legend: TL - Thredolet
SW - Sockolet
ST - Socket Weld Tee
W - Weldolet
TT - Threaded tee
T - Butt weld tee
RT - Butt weld reducing tee
101176-S-M-014 2
Rev: D
Date: 04-Nov-15 516 of 911
SLURRY PIPE LINE, IRON ORE BENEFICIATION
PLANT, PELLET PLANT AND WATER PIPE LINE
PROJECT
(WATER PIPE LINE)
MECON LIMITED
NMDC Doc. No. MEC/05/28/Q794/000/1092

(WATER PIPE LINE)

MEC/05/28/Q794/000/1092
MECON LIMITED
DELHI 110 092

Page 1 of 7
517 of 911
PROJECT
(WATER PIPE LINE)
MECON LIMITED
NMDC Doc. No. MEC/05/28/Q794/000/1092
TABLE OF CONTENTS
1.0 SCOPE
2.0 CODES AND STANDARDS
3.0 MATERIAL SPECIFICATION
4.0 CLASS DESIGNATION CODE
5.0 PIPELINE
6.0 PIPING
7.0 FITTINGS
8.0 BENDS
9.0 FLANGES
10.0 GASKETS
11.0 BOLTING
12.0 THREAD SEALANT
13.0 QUICK OPENING END CLOSURE
14.0 HYDROTESTING VENTS AND DRAINS
15.0 PIPELINE SPECIALITY ITEMS
TABLE-1 INDEX OF PIPING MATERIAL SPECIFICATIONS

APPENDICES-I TO VI PIPING MATERIAL SPECIFICATIONS AS PER TABLE - 1
Page 2 of 7
518 of 911
PROJECT
(WATER PIPE LINE)
MECON LIMITED
NMDC Doc. No. MEC/05/28/Q794/000/1092
1.0 SCOPE
This specification covers the requirements of various piping materials

used in piping/ pipeline system handling Water and associated
utilities in the pipeline.
2.0 CODES AND STANDARDS
2.1 Pipeline and terminal facilities envisaged as a part of this project shall be
designed and Engineered primarily in accordance with the provision of
ASME B 31.4 Pipeline Transportation Systems for Liquids and Slurries.
2.2 All codes standards and specifications referred herein shall be t he latest
edition of such documents.
2.3 For sake of brevity, the initials of the society to which the codes are
referred are omitted in the specification, for example, B16.5 is a c ode
referring to ANSI/ ASME, A 105 is a code referring to ASTM.
2.4 In addition, MECON specifications for various piping and pipeline

materials shall also be applicable.
3.0 MATERIAL SPECIFICATION
Piping material specifications are classified for the general purpose of

selection of material for the class of services. The maximum design
pressure and design temperature together with the fluid in line governs the
selection of material specifications. Deviation of materials from class
specifications may occur due t o specific design condition. These
deviations are permissible if they are equal or better than the individual
class requirements.
4.0 CLASS DESIGNATION CODE
The piping class designation consist of three digits numbering system

made up of letter, number and letter e. g. A1A, B1A, D1A, etc as follows:
First letter indicates ANSI class rating e. g.

A-Class 150
B-Class 300
D-Class 600
519 of 911 Page 3 of 7

PROJECT
(WATER PIPE LINE)
MECON LIMITED
NMDC Doc. No. MEC/05/28/Q794/000/1092
The middle number indicates differences in the specification within the

same rating and material.
The last letter indicates type of material e. g.
A-Carbon Steel
5.0 PIPELINE
The material for linepipe shall be as per the requirements of specification

as indicated in Table-1.
6.0 PIPING
6.1 Carbon steel pipe shall be made by open hearth, electric furnace or basic
oxygen process only. The steel used shall be fully killed and made with
fine grain structure. The grade and wall thickness of various sizes of pipes
shall be as per piping material specification for the applicable class.
6.2 Pipe dimension shall be in accordance with ANSI B 36.10 for carbon steel
pipes and ANSI B 36.19 for stainless steel pipes.
6.3 All pipe threads shall conform to American Standard taper as per ANSI B
1.20.1 NPT, unless otherwise specified.
6.4 For butt weld end, bevel shall be in accordance to ANSI B 16.25/ API 5L
as applicable.
7.0 FITTINGS
7.1 Fully killed carbon steel shall be used in the manufacture of fittings.
7.2 Threaded joints, if used shall conform to American Standard taper as per
ANSI 1.20.1 NPT.
7.3 Dimension of socket weld/ screwed fittings shall conform to ASME B 16.11
7.4 Bore of socket welded fittings shall suit O. D. of pipe and its thickness.
7.5 Dimensions of butt welded carbon steel fittings shall be as per ASME B
16.9 / MSS-SP-75, as applicable.
520 of 911 Page 4 of 7

PROJECT
(WATER PIPE LINE)
MECON LIMITED
NMDC Doc. No. MEC/05/28/Q794/000/1092
7.6 Butt welding ends shall conform to ANSI B 16.25/ API 5L. In case of
difference in thickness of matching ends, requirements of ASME B 31.8
shall apply.
7.7 Integrally reinforced forged branch fittings such as sockolet, threadolet,

weldolet, nippolet etc. shall be as per MSS-SP-97. Fittings not covered in
ASME B 16.9 and MSS-SP-97 shall conform to manufacturer’s standard.
7.8 Fittings thickness tolerances shall match pipe thickness tolerance.
8.0 BENDS
8.1 Unless otherwise specified for terminal piping, the elbow of radius R = 1.5
D shall only be used.
8.2 The radius of cold field bend shall be 3 0 times the nominal diameter for
pipes. Limited use of long radius bends R=6D for water application may be
permitted for reason of space constraints.
9.0 FLANGES
9.1 Flange rating shall be same as ANSI B 16.5/MSS-SP-44/ B 16.47 Series

A as specified.
9.2 Dimensions of flanges shall be in accordance with ANSI B 16.5/ B 16.47

Series A, as applicable.
9.3 Neck of Weld Neck (WN) flanges to suit pipe bore and thickness.
9.4 Bore of Socket Welded (SW) flanges shall suit pipe O.D. and its thickness.
9.5 Threads for screwed flanges if used shall conform to American Standard
taper as per ANSI B 1.20.1 NPT.
9.6 Sizes for blind flanges shall be indicated by nominal pipe sizes.
9.7 Carbon steel flanges faces shall have smooth finish as indicated in the
material specification. Flanges faces shall have smooth finish to 125-250
micro inches AARH as per MSS-SP-6.
9.8 Butt welding ends of WN flanges shall conform to ANSI B 16.25.
521 of 911 Page 5 of 7

PROJECT
(WATER PIPE LINE)
MECON LIMITED
NMDC Doc. No. MEC/05/28/Q794/000/1092
9.9 Spectacle blind/ spacer & blinds shall be i n accordance with ASME B
16.48 / Manufacturer’s Standard. Spectacle blind shall be used for sizes
up to 8” NB and spacer & blind for 10” & above shall be used.
9.10 Two jack screws 180° apart shall be provided for all spectacle blind
assemblies. The jack screws shall be as per MECON’s standard.
10.0 GASKETS
10.1 Spiral wound metallic gaskets shall conform to B 16.20 and API 601 shall
be provided with graphite filler. All spiral wound gaskets shall be provided
with stainless steel centering ring.
11.0 BOLTING
11.1 Nuts for stud bolts shall be A merican Standard Hexagonal Heavy series
and double chamfered.
11.2 Dimension and tolerances for stud bolts and nuts shall be as per ANSI B
18.2.1 and 18.2.2 with full threading to ANSI B 1.1 Class 2A thread for
bolts and Class 2B for nuts. Diameter and length of stud bolts shall be as
per ANSI B 16.5/ ASME B 16.47 with full threading.
11.3 Threads for nuts shall be as per ANSI B 1.1, as follows:
Nuts for stud dia ¼” to 1” : UNC-2B

Nuts for stud bolts dia 11/8” to 3 ¼” : 8UN-2B
11.4 Threads for stud bolts shall be as per ANSI B 1.1, as follows.
Studs bolts dia ¼” to 1” : UNC-2A

Stud bolts dia 11/8” to 3 ¼” : 8UN-2A
11.5 Heads of jack screws shall be heavy hexagonal type. Jack screw end shall
be rounded. Stud bolts shall be fully threaded with two hexagonal nuts.
12.0 THREAD SEALANT
12.1 Threaded joints shall be made with 1” wide PTFE Jointing tape.
522 of 911 Page 6 of 7

PROJECT
(WATER PIPE LINE)
MECON LIMITED
NMDC Doc. No. MEC/05/28/Q794/000/1092
13.0 HYDRO TESTING VENTS AND DRAINS
High point vents and low point drains required for the purpose of hydro
testing shall be o f size 1” and consist of sockolet, Plug & Ball valve for
vent, Globe & Ball Valve for drain, flange & blind flange.
14.0 PIPELINE SPECIALITY ITEMS
Pipeline Specialty items viz., Scrapper Traps, Flow Tee, Insulating Joints,
LR bends, shall be as per respective data sheets, specifications and
Project Specific drawing showing Mainline & Terminal materials.
TABLE-1
INDEX OF PIPING MATERIAL SPECIFICATIONS
Pipeline Section Dia. API 5L W.T. Length Design

(NB) Grade mm (in km) Code
Nagarnar to Bacheli Water 24” X-60 11.1 0-25 ASME B
pipeline 31.4
(24” x 135 km) 24” X-60 10.3 25-40 ASME B
Length indicated is from 31.4
Nagarnar 24” X-60 9.5 40-120 ASME B
31.4
24” X-60 8.7 120-135.2 ASME B
31.4
523 of 911 Page 7 of 7

524 of 911
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532 of 911
SUPPLY, LAYING & CONSTRUTION OF SLURRY AND

NMDC LTD. WATER PIPELINE ALONG WITH ASSOCIATED MECON LTD.
FACILITIES

PRE-COMMISSIONING AND
COMMISSIONING OF SLURRY & WATER OF
PIPELINE

MEC/05/28/Q794/000/1093
MECON LIMITED
DELHI 110 092

533 of 911
SUPPLY, LAYING & CONSTRUTION OF SLURRY AND WATER PIPELINE
ALONG WITH ASSOCIATED FACILITIES
TECHNICAL SPECIFICATION FOR PRE-COMMISSIONING & COMMISSIONING
NMDC LTD. OF SLURRY AND RETURN WATER PIPELINES MECON LTD.
Doc. No. MEC/05/28/Q794/000/1093, R0
CONTENTS
SL. NO. DESCRIPTION
1.0 INTRODUCTION
2.0 GENERAL
3.0 THE WORK
4.0 PRE-COMMISSIONING
5.0 PRE-COMMISSIONING CHECKS
6.0 COMMISSIONING
7.0 DOCUMENTATION
Page 1 of 1
534 of 911
TECHNICAL SPECIFICATION FOR PRE-COMMISSIONING &
COMMISSIONING OF SLURRY AND RETURN WATER
NMDC LTD. PIPELINES MECON LTD.
Doc. No. MEC/05/28/Q794/000/1093, R0
AMENDMENT STATUS

Page 1 of 1
535 of 911
Doc. No. MEC/05/28/Q794/000/1093, R0
1.0 INTRODUCTION
This specification covers the minimum technical requirements for pre-commissioning and
commissioning of onshore pipeline, including commissioning activities such as pre-
commissioning checks, flushing of terminal piping, dewatering and inertisation.
2.0 GENERAL
The scope of work for testing and commissioning including pre-commissioning activities
shall include, but not be limited to the manpower, machinery & equipment, detailed
procedures, materials and consumables, communications etc. to perform the work
satisfactorily.
Contractor shall prepare detailed procedures for flushing of terminal piping, dewatering,
inertisation, and commissioning of the pipeline, covering all aspects of work for company’s
approval. This shall include, but not be limited to, the sequence and description of all
operations, data on materials, equipment, instruments, consumables, communications
systems, necessary calculations, detailed time schedule and organisation chart.
The Contractor shall be responsible for demonstrating the successful completion of all the
activities i.e. flushing of terminal piping, dewatering, inertisation and commissioning of the
pipeline. All necessary work to perform the job successfully including necessary
modifications required shall be the responsibility of the Contractor.
Contractor shall design and supply all temporary line connections, valves, instruments, etc.
as required during the various operations.
In the event of any detail which is not fully addressed, it is warranted by Contractor that work
shall be performed in accordance with company’s specification and the best recognised
practices in the on-shore pipeline industry.
3.0 THE WORK
The work to be performed by the Contractor shall consist of the following activities :
Pre-commissioning : Entire pipeline project shall be checked with respect to

latest P&ID’s and other design specification.
Dewatering : Removal of hydrotest water from the entire pipeline
network system.
Idle Time Preservation : Idle Time Preservation of the entire pipeline with water
and corrosion inhibiting agents.
Commissioning : Charging the entire pipeline network with the
water/slurry and achieving normal operating conditions
of the pipeline.
Page 1 of 7
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Doc. No. MEC/05/28/Q794/000/1093, R0
4.0 PRE-COMMISSIONING
In order to execute and perform pre-commissioning activities, the pipeline contractor shall
be responsible for (but not limited to) the following:
• Carrying out pre-commissioning checks of the pipeline system including Pressure

Monitoring Stations, and their associated facilities under the scope of work to
ascertain that the project has been mechanically completed in all respects.
• Checking of field instruments, laying out survey of pipeline, checking of

communication system, checking of Electrical, Instrumentation system, controls &
interlock etc.
• Dewatering of Pipeline and above ground piping (if any), flushing / air-blowing and
leak testing of piping i.e. piping and equipments under their scope of work.
• Operation of machinery (if any) and equipment (if any) for pre-commissioning.
• Supply and use of materials / consumables as required for the pre-commissioning

activities.
• Erection of all temporary facilities like pig launcher / receiver, line connections, spool
pieces, pigs and requisite accessories, valves, instruments, manpower etc. as
required during various operations.
• Preparation of detailed pre-commissioning procedures, activity schedules, bar

charts, schemes etc.
This shall include preparation of detailed procedures for dewatering, electronic

geometric pigging / calliper pigging, 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 (e.g. Pigs and associated Items),
communication systems, necessary calculations, detailed time schedule and
organization Chart.
• All necessary work to perform the job successfully including all modifications that
would be required at various stages.
The pipeline contractor shall demonstrate to the OWNER / CONSULTANT (for

approval) the successful completion of all the above-mentioned activities.
Page 2 of 7
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Doc. No. MEC/05/28/Q794/000/1093, R0
5.0 PRE-COMMISSIONING CHECKS
5.1 The pre-commissioning checks shall be carried out for the pipeline to ascertain that the
pipeline system has been mechanically completed in all respects. These checks shall cover
the main pipeline including distribution network system and pressure monitoring stations
sectionalising valve stations if any. The pre-commissioning checks shall include the
following:
i) System Checks
The entire facilities shall be checked against the latest P&ID’s, Engineering & Vendor
Drawings / Documents and other design specification codes. Any shortcoming
observed shall be listed down in the form of punch lists and these should be duly
attended or liquidated. The pipeline contractor should check the piping system &
monitoring stations from the angle of pre-commissioning and commissioning works
and spell out any additional requirement of vents / drains, temporary arrangement /
modification etc. that may be required during the pre-commissioning and
commissioning activities and arrange for the same in consultation with the OWNER /
CONSULTANT representative.
ii) Checking of Field Instruments
All the field instruments like control valves, sectionalising valves, transmitters,
solenoid valves, shut down switches, alarms etc. shall be checked physically and
also for their intended application by simulating the operating conditions. It will also
include checking of different meters, gauges, action of shutdown / Isolation valves
etc. as applicable.
iii) Survey of the Pipelines
This shall be performed to confirm that proper fittings / supports, route markers,
fencing around Pressure Monitoring Stations, protection of monitoring Stations etc.
have been installed along the pipeline.
iv) Checking of Communications System
This is to check that there is proper communications with adequate back-up power to
ensure uninterrupted communication.
v) Checking of Electrical Distribution System
This is to ensure safety and also to ensure an uninterrupted power supply during
startup and normal pipeline operation.
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Doc. No. MEC/05/28/Q794/000/1093, R0
vi) Checking of Instruments, Controls & Interlocks
This is to check that instrument controls and interlocks are functional as per the
normal operating conditions.
vii) Checking of Utilities
This is to check that utilities like power, compressed air, UPS system etc. is available
prior to startup.
viii) Any other checks as may be considered necessary.
5.2 DEWATERING
5.2.1 General
Dewatering of a pipeline section shall be done. During the dewatering operation the major
quantity of hydrotest water shall be removed from the main pipeline. It is the responsibility
of the Contractor to develop suitable dewatering procedure and submit for Company’s
approval.
The disposal of the water shall be performed such that no harm is done to the environment.
Note: In case of delay in commissioning, dewatering of pipeline shall not be carried out and
the pipeline shall be preserved with corrosion inhibitor.
5.3 Internal Cleaning of Equipment (if any)
5.3.1 General
Equipments like Scraper Launcher, filters, Corrosion Inhibitor Dosing Tanks, Sump Tanks
and Scraper Receiver are to be checked for Internal cleanliness and shall be ensured by the
pipeline contractor.
5.3.2 Acceptance Criteria
The laying contractor has to demonstrate cleanliness of the internals of all equipment to the
satisfaction of the Owner / Consultant and obtain approval for final box up of the equipment.
5.4 Idle Time Preservation
During the idle time preservation, pipeline shall be filled with water & corrosion inhibitor
before admitting the water/slurry that the pipeline will ultimately carry.
The preservation operation shall start as soon as possible after the successful completion of
Page 4 of 7
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Doc. No. MEC/05/28/Q794/000/1093, R0
hydrotesting. Contractor shall submit the detailed inertisation procedure for approval for the
company prior to its implementation.
Corrosion inhibitors needed for preservation of the pipeline, shall be provided by the
Contractor.
5.6.1 Safety Review before start of commissioning
A pre-startup safety review shall be carried out of the pipeline system before permitting entry
of water/slurry into the new facility. Owner/ Owner’s representative shall also participate in
the pre-startup safety review.
6.0 COMMISSIONING
6.1 Ready for Commissioning
After completion of pre-commissioning activities and Owner approved safety start-up review
followed by liquidation of review punch list points, the pipeline contractor shall notify the
Owner / Consultant that the pipeline systems in totally are ready in all respects for
water/slurry -in. ‘Ready for commissioning status’ shall be jointly assessed by Owner /
Consultant, composite work contractor, pipeline contractor.
After such joint assessment, if all the criteria are met, it will then be declared by the Owner
that the entire pipeline system has reached a stage of 'Ready for Commissioning'.
6.2 Commissioning and Stabilization
The pipeline contractor shall be responsible for providing all necessary assistance to carry
out commissioning activities under the overall guidance and supervision of Owner /
Consultant for the entire pipeline system.
Commissioning of pipeline shall be considered completed when the line is charged with
water/slurry at operating pressure and the total system operated at normal operating
parameters for a minimum period of 72 hours with all the instruments, controls and
interlocks working satisfactorily at normal operating conditions. Contractor shall submit a
detailed commissioning procedure for company’s approval.
7.0 DOCUMENTATION
Contractor shall submit for approval of the company the complete description, detailed
procedure and time schedule of all the dewatering, flushing / blowing, Inertisation and
commissioning operations, as applicable.
Documents shall also contain all procedures and safety plans to be followed while carrying
out the activities.
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Upon successful completion of the work, Contractor shall prepare a final report of the work
which shall include necessary charts, diagrams, graphs, calculations, recordings, daily logs,
measurements, details of the operation, etc. Report shall also include all certificates of
calibration of instruments required together with records of calibration performed at site prior
to the start of any operation.
7.1 Spares and Consumables
Supply of spares, tools and consumables for start-up & commissioning.
7.2 Safety
Follow the safety practice during execution of pre-commissioning/ commissioning works as

detailed in the scope of work. Maintain and follow all safety practices equivalent or better
than those being practiced for the pipeline during pre-commissioning and commissioning.
Page 6 of 7
541 of 911

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NMDC LIMITED

SLURRY PIPELINE, IRON ORE BENEFICIATION PLANT, PELLET

SLURRY PIPELINE SYSTEM

TECHNICAL SPECIFICATION FOR

(PACKAGE NO. – SP01)

Chapter. No. DESCRIPTION Page No.

List of Tender Drawings Enclosed (Annexure I)

Sl no Description Drg no. Rev

Piping & Instrument diagram

19. Legend for P&ID MEC/05/28/Q794/BE/WP/0000 01

P&ID for Water System at MEC/05/28/Q794/BE/WP/3000

Equipment Location Plan Mine MEC/05/28/Q794 &

Piping Layout Pipeline Terminal MEC/05/28/Q794 &

Select Backfill for station

66. Typical Slope Breaker Details MEC/TYP/05/21/01A/007 00

Minimum Elastic Bend Radius for

69. Pipeline Symbols MEC/TYP/05/21/01A/011 00

70. Topographic Symbols MEC/TYP/05/21/01A/012 00

Hardness Testing of weld Joints

75. Charpy V- Notch Test Specimen MEC/TYP/05/21/02/005 00

Calibration piece for ultrasonic

78. Typical Stream Crossing MEC/TYP/05/21/04/001 00

Pipeline road / highway CASED

80. Typical Detail of railway crossing MEC/TYP/05/21/05/002 00

Typical lined Canal incased

85. Underground cable crossing MEC/TYP/05/21/05/008 00

86. Overhead power line crossing MEC/TYP/05/21/05/009 00

87. Typical ROW boundary marker MEC/TYP/05/21/10/001 00

88. K.M. Post MEC/TYP/05/21/10/002 00

89. Pipeline Warning sign MEC/TYP/05/21/10/003 00

Navigable water way pipeline

91. Aerial Marker MEC/TYP/05/21/10/005 00

92. Direction Marker MEC/TYP/05/21/10/006 00

93. Tolerances for fabrication MEC/TYP/05/21/06/001 00

Pipe Clamp for Bare Pipe Size

97. Butt Weld Details MEC/TYP/05/21/06/034 00

Welding of pipe with different

99. Fillet weld details MEC/TYP/05/21/06/036 00

100. Gasket thickness MEC/TYP/05/21/06/037 00

Stud Bolts RF 150# Dimensions

Control Room Building for NISP MEC/05/48/Q794/SP01/TD/ARC 0

System Architechture For

4. Support Details For Junction Box MEC/05/E5/SD/JB/009 00

Instrument Support Single

Standard sketch OFC joining pit /

Legends of Single line diagram MEC/05/E9/Q794/SP02/SP/29 00

Single Line Diagram of PMCC for MEC/05/E9/Q794&Q796/SP01/ 01

4. Pre-packed Magnesium Anode MEC/SD/05/E9/E/CP/1602 01

Magnesium Ribbon Anode For

Pipeline Grounding Through MEC/SD/05/E9/E/CP/1608

Details of Test Station For MEC/SD/05/E9/E/CP/1614

17. Deep Well Anode Bed MEC/SD/05/E9/E/CP/1615 01

Details of Thermit Weld For Cable

MATERIAL HANDLING DRAWINGS

Clearance diagram single girder MEC/05/P4/Q794&Q796/SP-

DATASHEETS TO BE FILLED BY THE TENDERER &

02.03.19 4 Hitesh Manju, SDE A K Jha, DGM Amit Gangal, DGM

Date Rev. No. PREPARED BY CHECKED BY APPROVED BY

A. TECHNICAL SPECIFICATION FOR MECHANICAL WORKS