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Reliance

Industrial Infrastructure Limited


JNPT Terminal and Pipelines
PAGE NO.
A.
1.0

LIST OF GENERAL SPECIFICATIONS


SCOPE

2.0

REFERENCE CODES, STANDARDS AND SPECIFICATIONS

3.0

PIPE HANDLING, HAULING AND STRINGING

4.0

EQUIPMENT S AND MATERIALS

5.0

LINING UP

6.0

BENDING

7.0

WELDING

8.0

TRENCHING

17

9.0

STRINGING

17

10.0

PIPE COATING

18

11.0

PIPE LOWERING

18

12.0

BACKFILLING

20

13.0

SPECIAL INSTALLATION ON THE PIPELINE

20

14.0

HYDROTESTING OF CROSS COUNTRY PIPELINE

22

15.0

HOOK UP ACTIVITY

35

16.0

SITE RESTORATION CLEARANCE

36

17.0

QUALITY CONTROL AND QUALITY ASSURANCE MANUAL

36

18.0

AS-BUILT DRAWING SPECIFICATIONS

39

Prepared By:
Signature:

Reviewed By:

Approved By:

Reliance Industries Limited


JNPT Terminal and Pipelines
1.0

SCOPE :

1.1

This specification covers the minimum requirements for the various activities to be
carried out by contractor for the construction of cross country pipelines for the rerouting
of existing twin 8 dia JNPT to Kalamboli pipelines.

1.2

The various activities covered in this specification include the following works of pipeline
construction.
-

Construction of all temporary facilities required in connection with the works.


lining up
pipeline laying
road/rail crossings
quality control activity.
installation of valve,
final clean up and restoration.

1.3

This specification shall be read in conjunction with the conditions of all specifications and
documents included in the tender.

1.4

Work shall be executed with the care and diligence and compliance with all laws, bylaws, ordinances, regulations etc., and shall provide all services and labour, inclusive of
supervision thereof, all material, excluding the material indicated as Company Supplied
Materials in the Tender, equipment, appliances or other things of whatsoever nature
required in or about the execution of the work, whether of a temporary of permanent
nature.

1.5

Utmost care shall be taken 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 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, rail
and road traffic condition, the extend and the nature of the work, and the means of
access to the work area(s).

1.7

Contractor shall in connection with the work, provide and maintain all lights, guards,
fencing, watching etc, when and where necessary or required by RILs authorised
representative or by and duly constituted authority and/or by the authorities having
jurisdiction thereof for the protection or of the safety and the convenience of public and/or
others.

1.8

Unless otherwise specified, all sections of this specification shall apply to all the
specifications referred in this specification. The contractor shall abide local regulations
w.r.t. safety, risk and environment pollution, the contractor shall use sound engineering
pratices.

2.0

REFERENCE CODES, STANDARDS AND SPECIFICATIONS :


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Reliance Industries Limited


JNPT Terminal and Pipelines
2.1

The following documents (latest editions / revisions) are referenced in the specifications
and are a part of the specification. In case on conflict between reference standards or
specifications the more stringent shall apply.
-

ASME / ANSI B31.4


Liquid Petroleum Transportations Piping Systems.

NACE RP-02-74
Recommended Practice, High Voltage, Electrical Inspection of Pipeline Coating
prior to Installation.

DIN 2413 - JUNE 1972


Steel Pipe Calculation of Wall thickness subjected to Internal Pressure.

SIS 055900 - 1967


Pictorial Surface Preparation Standard for Painting Steel Surfaces.

API 1105Bulletin on Construction Practices for Oil and Products Pipelines.

API RP 1104
Standard for Welding Pipelines and Related Facilities.

API RP 1109
Recommended Practices for Marking Liquid Petroleum Pipeline Facilities.

API RP 1110
Recommended Practice for Hydotesting of Cross Country Pipelines.

API 5L
Specification for Line Pipe.

API RP - 5L1
Recommended Practice for Line Pipe during Hauling, Transportation and
Storage.

API RP - 5L5
Recommended Practice for Bevel and Protection.

API 599
Steel Plug Valves, Flanged or Butt Welding Ends.

API 600
Steel Gate Valves, Flanged or Butt Welding Ends.

API 598
Valve Inspection and Test.
API 6D - 1982
Pipeline Valves.

IS - 2490 (Part 195)


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JNPT Terminal and Pipelines
Transportation of Liquid by Pipeline (US Department of Transportation - Pipeline
Safety Standards.)
THE INDIAN PETROLEUM ACT, 1934
The Petroleum Rules, 1976.
3.0

PIPE HANDLING, HAULING AND STRINGING:

3.1

SCOPE

3.1.1. This specification covers the minimum requirements for the materials, inspection,
handling, transportation of Line pipes.
3.1.2. Contractor shall, with utmost 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, equipments, appliances or the things of whatsoever
nature required in or about the execution of the work, whether of temporary or permanent
nature excluding the materials to be supplied by the client as free issue. Contractor shall
be fully responsible for all materials and their identification until such time that the pipes
and other materials are installed in permanent installation. Contractor shall be fully
responsible for arranging and paying for storage areas for the pipeline materials.
3.2.0

REFERENCE DOCUMENTS

3.2.1. Refer para 2.1 for relevant codes and standards.

4.0.0

EQUIPMENT AND MATERIAL

4.1.1. Contractor shall load, stockpile and transport Bare or coated pipes/cold bends using
suitable means in a manner to avoid damages to pipes.
4.1.2. The pipes & bends 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 handling
equipment viz. Crane Side Boom, Vacuum lifting equipment etc.
4.1.3. Lifting hooks when used shall be equipped with copper or brass lined plate curved with
soft material like rubber, Teflon or equivalent, so as not to cause damages to bevel or
pipe ends.
4.1.4. Stacks shall be suitably secured against falling down and shall consist of pipe sections
having the same diameter and wall thickness.
4.1.5. Dragging and skidding of pipes shall not be permitted, unchecked rolling of pipes from
stringing should not occur.
4.1.6. Transportation of pipes shall be done on skid mounted flat bed/low bed trailers. Skid/
Pipe support shall be having as many round hollow beds as the number of pipes to be
placed on the bottom of the trailer bed. Skid shall be mounted on the trailer in such
fashion so as to avoid any bending of pipes. Skids shall preferably be lined by using thick
rubber sheets to absorb any impact during the movement of trailer.
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JNPT Terminal and Pipelines
4.1.7

Pipes & bends shall be transported by the contractor from RILs designated stockyard
including the handling of material to and from the yard(s)/ job site when necessary.
Contractor shall carry loading, hauling, unloading and storing of materials/ line pipes in
such a way to avoid damage.

4.1.8

Any damage to the pipe shall be reported to the Company. Damaged pipe ends shall be
repaired by the contractor.

4.1.9

Damaged pipe ends shall be repaired by grinding, if possible. Ends, which in the opinion
of authorised representative cannot be repaired by this manner shall be re-bevelled using
pipe bevelling machine. Hand bevelling shall be not permitted.

4.1.10 The stringing of line pipe on the right of way shall be carried out by the contractor in
accordance with the EIC or authorised representative or approved alignment sheets.

4.1.11 stringing of the pipe shall be done in such a manner as to cause the least interference
with the normal use of land and construction activities. Gaps shall be left at intervals to
permit the use of land and the passage to traffic across the right of way.

4.1.12 stringing of pipe shall preferably be done on / skids gunny bags filled with soil free of
stone pieces. Polythene bags consisting of germ-free straw may also be used in addition
to soil gunny bags/skids.
4.1.13 Materials other than line pipes.
4.1.14 RIL supplied material shall be taken over at RILs designated stockyard/stores,
Contractors shall be perform visual inspection and defects, if any noted, shall be
recorded separately.
4.1.15.1 Care shall be exercised in handling, hauling, stringing and distribution of materials in
order to avoid damage and deterioration of these materials and prevent theft or loss.
4.1.15.2 Materials excluding line pipe shall be stored in storage. Such materials shall not be
strung on the Right-Of-Way but shall be transported for the use only at the time of
installation.
4.1.15.3 All valves and whenever applicable, other materials shall be fitted with suitable end
covers. 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.
4.1.15.4 The manufacturers instructions regarding temperature and procedure for storing
materials which are subject to alteration of the original properties and characteristics due
to unsuitable storage shall be strictly complied with.
4.1.15.5 When supplied in containers and packages, they shall not be thrown or dropped, nor
does handled using hook which could damage the contained or the materials, either
during loading, unloading or during successive handling, until their final use.
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JNPT Terminal and Pipelines
4.2.0

INSPECTION, MEASURING AND LOGGING

4.2.1

The contractor shall prepare the inspection report for Hauling and Stringing separately
containing all the relevant data of individual pipe including heat number (if available),
diameter, length, wall thickness, defects, damages, date, any other information
considered to be relevant and required. The contractor shall submit this report on daily
basis.
At the time of taking over of pipes from RIL JNPT Stockyard, contractor shall inspect the
pipes thoroughly. Any defect/damage shall be recorded in the Hauling report.
The hauling report shall be verified by RIL representative before the pipes are
transported from Stockyard
Before commencing the above job, the contractor shall submit the procedure of Hauling
and Stringing to RILs authorised representative for approval alongwith the proposed
format of Inspection Report for Hauling and Stringing.

4.2.2
4.2.3
4.2.4

5.0

LINING UP :
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 or proper diameter or any other methods
approved by the RIL authorised representative. Damaged pipes shall be kept separate.

5.1

PIPE DEFECTS AND REPAIRS


It is CONTRACTORs responsibility to repair all internal and or external defects (if
required) as per the approved procedure of RILs authorised representative.

5.1.1. Acceptability of defects in the pipe during inspection at the work site shall be determined
in accordance with latest edition on ANSI 31.4.
5.1.2. No dents shall be permissible on the pipes.
5.1.3. Dents which contain a stress concentrator such as scratch, gauge, and dents located at
the circumferential weld shall be removed by cutting out the damaged portion of pipe as a
cylinder.
5.1.4. Any repair of line pipe shall be avoided as far as possible. If at all required it
shall be executed as specified in Code ANSI 31.4. A record of all repairs shall be
maintained. This record, provided with the pipe identification number shall be submitted
to the RILs authorised representative.
5.1.5. Repair of damaged pipe ends by hammering and/or heating is not allowed. If the dented
area is minor and at least 200 mm away from the pipe end and the steel is not stretched,
severed or split in the COMPANYs opinion, the pipe may be straightened with a proper
jack.
5.2

PIPE HANDLING AND SKID SPACING

5.2.1

When lifting pipe, care must be taken not to kink or overstress it. Proper pipe slings shall
be used. A strip of soft material shall be placed in between skid and pipe to protect the
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JNPT Terminal and Pipelines
external coating of the pipe.
5.2.2. Skids shall be at east 1.20 metre long. 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 300 mm above ground. Crotches shall be installed at frequent intervals (at
least every 10th support) with a greater number required at bends and undulating
grounds.
5.3.

NIGHT CAPS
At the end of each days work or every time when joining and welding operations are
interrupted, the open ends on welded strings of pipe shall be capped with a securely
closed metal cap 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 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.

5.4.

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, etc., temporary
caps approved by COMPANY shall be welded to the ends of the pipe.

5.5

INSPECTION, MEASURING AND LOGGING :

5.5.1

The Contractor shall prepare the inspection report for lining up of pipes containing all the
relevant data of individual pipe including heat number, diameter, length, wall thickness,
defects, damages, datas etc. and shall ensure that the wall thickness of pipes are in
accordance with the requirement of approved alignment sheets. The contractor shall
submit this report on daily basis.

6.0

BENDING :
RIL will provide 45 deg & 90 deg hot bends made from 9.5mm thk. Pipes.
Contractor will consult EIC in case of any specific bend requirement arises.

6.1

COLD FIELD BENDS:

6.1.1

The contractor shall have cold bending machine at site to fulfill the requirement of cold
bends depending on the site requirement. Radius of cold field bends shall not be less
than 40 times the pipe nominal diameter. Cold bends shall be installed after inspection by
the RILs authorised representative.

6.1.2

The maximum ovalization caused on each pipe by bending shall be less than 2.5% of the
nominal diameter at any point. Ovalization 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 RILs authorised representative by passing
a guage consisting of two discs with a diameter equal to 95% of the nominal internal
diameter of the pipe connected rigidly together at a distance to 300 mm.
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JNPT Terminal and Pipelines
6.2

UNSATISFACTORY BENDS

6.3

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 mitre 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.
Cutting of factory made bends and cold field bends for any purpose are not permitted
without prior approval of COMPANY.

7.0

SPECIFICATION FOR WELDING :

7.1

SCOPE
All welding procedures and all welders performing welding shall be qualified in accordance
with para 434.8.3, ASME B31.4.

Any cutting and welding shall commence only after

compliance with para 434.8.1 (c).


The qualification test for welding procedures shall consider the cooling effects of the pipe
contents on the soundness and physical properties of the weld.
Welding procedure qualifications shall include impact tests.
The requirement stated herein shall be followed for the fabrication of all types of welded
joints of carbon steel, piping system connected with the pipeline and related facilities.
Any approval granted by the RILs authorized representative shall not relieve the Contractor
of his responsibilities and guarantees to perform the welding as per the standards applicable.
7.2

APPLICABLE CODES AND STANDARD


All welding work, equipments for welding, heat treatment, other auxiliary functions and
the welding personnel shall meet the requirements of the latest editions of the Codes,
Standards and specifications listed in para 2.1.

7.3

BASE MATERIAL
In general Carbon steel as base material is used in this specification. 8" CS pipe API 5L
gr X-42 WT. 7.04mm & 9.52 mm will be provided by RIL.

7.4

FILLER MATERIALS
a.The contractor shall provide all the necessary welding electrodes, filler materials, etc.
required for execution of the work.
b.The welding electrodes supplied by the Contractor shall be of make approved by the
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JNPT Terminal and Pipelines
RILs authorised representative or EIC.
c.The electrode shall be suitable for the welding process recommended and base metal
used. Physical/ Chemical properties of the welds produced by an electrode
recommended for the welding shall not be lower than minimum values specified for the
base metal and shall correspond to the properties of the class of electrodes adopted. The
choice of electrode shall be of Lincoln make only, confirming to the test requirement of
AWS-A5.1 & ASME-SFA5,1 and AWS-A5.5 & ASME-SFA5.5, and shall be sole
prerogative of the Company.
d.Electrode qualification test records should be submitted as per Exhibit A of this
specification in respect of electrodes tested by the Contractor for obtaining the approval
of RILs authorised representative.
e.The Contractor shall submit batch test certificates from the electrode manufacturers
giving details of physical and chemical test carried out by them for each batch of
electrodes to be used.
f.All electrodes shall be purchased in sealed containers and shall be stored properly to
prevent deterioration. Electrodes shall not be used if found defective by RILs authorised
representative. Normally excessive moisture is indicated by a noisy arc and high spatter,
rusty core wire at the holder end, or objectionable coating blisters while welding.
Contractor shall especially ensure that Shield-Arc electrodes do not get wet because they
are used to weld high strength steels which are more sensitive to cracking.
g.The electrode used shall be free from rust, oil, grease, earth and any other foreign
matter which may affect the quality of weld.

7.5

WELDING CONSUMABLES
The contractor shall provide at his own expense all welding consumables necessary for
the execution of the job such as electrode, grinding wheels, oxygen, acetylene, gloves
etc. and these should bear the approval of RILs authorised representative.

7.6

EQUIPMENT AND ACCESSORIES

7.6.1

The contractor should have sufficient number of mobile welding machines, field pipe
bevel cutting machines, grinding machines, auxiliaries and accessories of sufficient
capacities to meet the target schedule and should be in good working condition.

7.6.2

The contractor should also have external line up clamp for fit ups and welding of line
pipes in sufficient numbers to take up the work at various fronts.

7.7.0

WELDING PROCESSES

7.7.1

Welding of various materials under this specification shall be carried out using Shielded
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Metal Arc Welding Process (SMAW) with the approval of RILs authorised representative.
7.7.2

7.7.3

The welding processes to be employed shall be as per the approved welding procedure
specifications. Any deviation desired by the contractor shall be obtained in writing from
RILs authorised representative.
A combination of different welding processes or a combination of electrodes of different
class could be employed for a particular joint only after duly qualifying the welding
procedures to be adopted and obtaining the approval of the RILs authorised
representative.

7.8.0

BEVEL CLEARING/BEVEL INSPECTION

7.8.1

All rust, dirt, scale, lamination, grease, paint, slag and any foreign matter shall be
removed from the bevelled ends by power operated tools prior to welding.

7.8.2

The bevel cleaning shall be effected inside and outside and for a minimum distance of
25mm from the edge of the weld bevel. At this stage bevels shall be thoroughly inspected
for bevel angle and squareness.

7.8.3

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 bevelled to the
satisfaction of RILs authorised representative, with an approved bevelling machine.

7.8.4

Manual cutting and weld repairs of bevel shall not be permitted.

7.8.5

If laminations, split ends or inherent manufacturing defects in the pipe are discovered,
the length of pipe containing such defects shall be removed from the line to the
satisfaction of the RILs authorised representative.

7.8.6. On pipes which have been to the cut back, a zone extending 25mm back from the new
field bevel, shall be tested ultrasonically requirement of the line pipe specification to
ensure it is free from laminations at the discretion of RILs authorised representative. The
new bevel shall be 100% visual test and 100% dye penetrant/MPI tested.
7.8.7

Inspection report shall be submitted by Contractor for all such tests carried out and
record shall be kept.

7.9.0

ALIGNMENT AND SPACING

7.9.1

Immediately prior to line-up, Contractor shall inspect the pipe ends inside and outside for
damage, dents, lamination etc.

7.9.2

Pipe for welding shall be set up correctly spaced, allowing for temperature change during
welding, incorrect alignment shall in no circumstances be strung into position.

7.9.3

Temporary attachments of any kind shall not be welded to the pipe.

7.9.4

Every effort shall be made to reduce misalignment by the use the outer line up clamp for
tie-ins, and the rotation of the pipes to the best fit. For pipe of same nominal wall
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thickness the off-set should not exceed 1.6mm. The off-set may be checked from outside
using dial guages.
7.9.5

The welds for fitting shall be so located that the toe of the weld shall not come within
50mm of any other weld.

7.9.6

Cold dressing shall be permissible only in cases of slight misalignment and may only be
carried out with a bronze headed hammer.

7.9.7

Hot dressing shall not be permitted.

7.9.8

When welding pipes of different wall thickness a separate procedure for grinding down
the higher thickness of pipe shall be adopted on specific approval of RIL authorised
representative.

7.9.9 The root gap shall be accurately checked and shall confirm to the qualified welding
procedure.
7.9.10 When external line up clamp is used at least 60% of the first pass shall be welded before
the clamp is released.

7.10

CONDITIONS
The parts being welded and the welding personnel should be adequately protected from
rain and strong winds. In the absence of such protection, no welding shall be carried out.
The completed welds shall be suitably protected in case of bad weather conditions. If in
the opinion of RILs authorised representative the weather is not favourable, no welding
shall be carried out.
In rainy season/ early mornings the surface moisture on the bevel ends shall be removed
by preheating to maximum 700C. The electrodes shall be placed in the oven for 10-20
minutes to remove moisture at temperature of 200-3000F as specified by the
manufacturer.

7.11

WELDING

7.11.1 ROOT PASS


a)Root pass shall be made with electrodes recommended in the welding specifications.
The size of electrodes used shall be as per the approved welding procedure.
b) Position or roll welding may be permitted. Separate procedures shall be submitted and
qualified for up hill, down hill & roll welding method of welding shall be used for the root
pass of the tie-ins, fillet, welds, repairs. The down hill welding may be used for root run
welding of tie-ins and special crossings when the edges are machined or have equivalent
preparation, the fit up is geometrically and mechanically similar to one of the ordinary line
welding without misalignment or unevenness.
c)The root pass of the butt joints should be executed so as to achieve full penetration
with complete fusion of the root edges. Weld projection inside the pipe shall not exceed
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1.5 mm wherever not specified by the applicable code.
d)Any deviations desired from the recommended welding technique and electrodes
indicated in the welding specification should be adopted only after obtaining approval of
the RILs authorised representative.
e)Welding shall be continuous and 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 shall be taken to avoid any kind of movement of
the components, shocks, vibrations and stresses to prevent occurrence of weld cracks.
h)Fillet welds shall be made by shielded metal arc welding process irrespective of the
thickness and class of piping.

7.11.2 JOINT COMPLETION


7.11.2.1The number of welders and the allowable welding sequence shall be as 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 be
minimum. The welding speed shall be approximately same as that established in the
qualified welding procedure specification.
7.11.2.2The pipe shall always be adequately supported and must not be bumped or shaken
during welding. The internal/external line up clamp shall be removed, as indicated earlier.
Before starting the second pass, the first pass shall be cleaned and flattened with
rotating grinders.
7.11.2.3.The interruption between completion of the first pass and starting the second pass shall
be as stated in the procedure specification, normally not exceeding four minutes.
7.11.2.4.The welding speed selected shall enable production of a bead which is sufficiently thick
and which shows no under cutting.
7.11.2.5.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 wall thickness. Upon restarting, depending on the material, wall thickness and
welding process, a pre-heating at least 1000C shall be carried out. Subsequent passes
upto weld completion shall be protected to avoid rapid cooling, if meteorological
conditions so dictate.
7.11.2.6.Cleaning between passes shall be done carefully so as to reduce the possibility of the
inclusions.
7.11.2.7.Electrode starting and finishing points will be staggered from pass to pass.
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7.11.2.8.Arc-strikes outside the bevel on the pipe surface are not permitted. Arc-strikes or arc
burns or the pipe surface outside the weld, which are caused accidentally by electrical
arcs between the electrode, electrode holder, or welding cable shall be removed by
grinding
in accordance with the procedure approved by Company and the repair checked by
UT/DP tests which the RILs authorised representative feels necessary. The pipe wall
thickness limit after grinding shall not be less than the minimum thickness limit permitted
for the pipe repair of arc strips by welding is prohibited.
7.11.2.9The completed weld shall be carefully brushed and cleaned and shall be free from
spatter, scales etc.
7.11.2.10

All main line welding shall be done by downhill technique unless other wise
instructed by RIL EIC.

7.12.0 CLEANING OF THE WELD JOINTS


All welds shall be free from adherent weld shatter, slag, swarf, dirt or foreign matter. This
can be achieved by brushing.

7.13.0 INSPECTION AND TESTING


7.13.1 GENERAL
7.13.1.1.The RILs authorised representative shall have free access to all concerned areas,
where the actual work is being performed. The contractor shall also afford the companys
inspector all means and facilities necessary to carry out for inspection.
7.13.1.2.The RILs authorised representative shall have free access to the shop or feel where
pre-fabrication and erection of pipeline are being done, with (but not limited to ) the
following objective :
To check the conformance to relevant standards and suitability of various welding
equipments and the welding performance.
-

To supervise the welding procedure qualification.

To supervise the welders performance qualification.

To check whether shop/field welding being executed is in conformity with the


relevant specification and codes of practice followed in pipe line construction.

7.13.1.3.Contractor shall intimate sufficiently in advance the commencement of qualification


tests, welding works and acceptance tests to enable the RILs authorised representative
to be present for supervision.
7.13.1.4.Contractor shall also depute their experienced and qualified engineer for quality control
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and quality assurance at shop/ field welding.

7.13.2 WELDING PROCEDURE QUALIFICATION


7.13.2.1The contractor shall submit a welding procedure specification in accordance with latest
addition of API-1104 providing in details the required welding conditions. The welding
procedure specifications shall define in detail the variables involved in welding. Typical
variable such as welding process, joint design and tolerances, type of material, thickness
or thickness/diameter ranges, welding consumables, electrical parameters and travel
speed, pre-heat and interpass temperature, number of appearance of weld beads,
welding position etc.
7.13.2.2.The welding procedure specifications shall be proved by Contractor by procedure
qualification tests. The test shall include visual, NDT and destructive testing.
7.13.2.3Responsibility for the content, qualification status, and use of WPS rests upon the
Contractor. The approval stamp of RILs authorised representative shall not be relieving
contractor of his responsibility and guarantee.
7.13.3 WELDER QUALIFICATION
7.13.3.1Welder shall be qualified in accordance with the API-1104 latest edition and other
applicable specifications by the contractor.
7.13.3.2The RILs authorised representative shall witness the test and certify the qualification of
each welder separately. Only those welders who have been approved by RILs
authorised representative shall be deployed for welding.
7.13.3.3.Contractor shall submit welder qualification test report in the standard format and obtain
express approval, before commencement of the work. It shall be the responsibility of the
contractor to carry out qualification tests of welders.
7.13.3.4.The welder shall always have in their possession the identification card as given in API1104 and shall produce it on demand by the RILs authorised representative. It shall be
responsibility of the Contractor to issue the identify cards after it has been duly certified
by the RILs authorised representative.
7.13.3.5.No welder shall be permitted to work without the possession of the identify card.
7.13.3.6If 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.
7.13.4. VISUAL INSPECTION
Inspection of all welds shall be carried out by Contractor QA/QC Engineers as per the
latest edition of API-1104. All finished welds shall be usually inspected for parallel and
axial alignment of the work, excessive reinforcement, concavity of welds, shrinkage,
cracks, under-cut, dimensions of the weld, surface porosity and other surface defects.
The field welding inspection report shall be furnished by the Contractor on daily basis for
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approval of RILs authorised representative.
7.13.5. NON DESTRUCTIVE EXAMINATION
7.13.5.1.

The non-destructive examination shall mainly consist of examination using XRay/Gamma Ray as detailed in API 1104.

7.13.5.2

Radiographic tests shall be carried out as follows :

a)

100% radiography shall be performed on all welded joints.

7.13.5.3.
Radiographic film interpretation shall be carried out as per latest edition of API1104. In addition to the API-1104 requirements the welds containing cracks including
crater cracks regardless of size or location are unacceptable.
a)
Any length of inadequate penetration of the root bead as defined by API-1104
which exceed 2 times the thickness, subject to a maximum of 12mm is not acceptable.
b)
Any amount of incomplete fusion between the root and bevel as defined by API1104 which exceeds 2 times the thickness subject to a maximum of 12mm is not
acceptable.
c)

Unrepaired burn through areas are unacceptable.

7.13.5.5.
Suitable records shall be maintained by the Contractor as desired by the
Company on the day to day work done on welding, radiography, etc. The Contractor shall
present the records to RILs authorised representative on day to day basis and whenever
demanded, for approval.
7.13.6. DESTRUCTIVE TESTING
7.13.6.1.The RILs authorised representative has the authority to order the cutting of upto 0.5%
of the total number of welds completed for subjection to destructive tests without any
additional liability to RIL.
7.13.6.2.In addition, welds already cut out for defects for any reason may also be subjected to
destructive testing for information. The sampling and the re-execution of the welds shall
be carried out by the Contractor. If the results are unsatisfactory, welding operations shall
be suspended and may not be re-started until the causes have been identified and the
Contractor has adopted measure which guarantees acceptable results. If it is necessary
in the RILs authorised representative. Opinion, the procedure shall be re-qualified.
7.13.6.3.The weld joint represented by unsatisfactory welds shall stand rejected unless
investigation proves otherwise, irrespective of the approved weld visual inspection
reports.
7.13.6.4.Destructive Testing of welds shall be carried only at the approved laboratories by RILs
authorised representative.
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7.14.0. REPAIR OF WELDS
7.14.1.Welds which do not comply with the standards of acceptability shall be repaired or the
joint cut out and rewelded with the prior permission of RILs authorised representative.
7.14.2.A separate welding procedure specification 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)
b)

Through thickness repair.


External Repair.

7.14.3.Welders shall be qualified in advance for repairs. The root pass, for repairs opening the
root, shall be replaced by the vertical uphill technique. The procedure shall be proven by
satisfactory procedure tests to API-1104 including the special requirements of the
specification.
7.14.4.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.
7.14.5.The repair shall be subjected, as a minimum requirement, to the same, testing and
inspection requirements as the original weld. The entire repair portion shall be reradiographed. At the discretion of RILs authorised representative 100% UT/DP test may
be required to be carried out by the Contractor.
7.14.6.Any repaired area that is wide, irregular or rough shall be rejected and full cut out shall be
done.
7.14.7.Welds not meeting the specification after one repair shall be cut out depending upon the
extent of repair. All repairs shall be carried out the day after initial radiography or earlier.
7.14.8.A full report of all repairs shall be prepared by Contractor and shall be submitted to RILs
authorised representative on day to day basis.
7.14.9.Limitation on repairs - Only one attempt at repair of any region is permitted. Repairs are
limited to a maximum 30% of the weld length. For weld 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 RILs representative. The minimum length of a repaired
area shall be 50mm as measured over the recapped length. Welds containing cracks
shall be cut and rebevelled to make a fresh joint. RILs authorised representative shall
authorise all repairs.
7.14.10.At the discretion of RILs authorised representative the Contractor may also be required
to carry UT/DP tests on repaired joint.
7.14.11 Records of all welding and NDT activities shall be recorded daily in the format approved
and submitted RILs authorised representative

8.0.0 TRENCHING:
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Excavation for trenching shall be done as per the approved SMP by RIL JNPT.
The contractor shall mark on the ground the trench alignment based on the proposed
route drawing and in consultation with the NHAI/DFCC/CIDCO representative. The trench
alignment shall be approved by RILs authorised representative before starting trenching
work.
The contractor shall take trial pits along the proposed alignment to identify underground
utilities if any other than those mentioned in the drawings. Trial pit shall be taken
manually.
The trenching in normal soil shall be done by manual means however machinery can be
used after taking permission from the RILs authorised representative which shall be on
case to case basis. Trenching in hard rock can be carried out using pneumatic or
hydraulic machinery after taking clearance from RILs authorised representative.
Trenching shall be strictly done by manual means in case of presence of other utility in
the vicinity of the trench to be dug.
The width of trench shall be such that a minimum clear distance of 200mm for trench
normal soil and 300mm for trench in rock is maintained between edge of pipe and the
trench wall at the bottom of trench. The minimum clear distances between the twin
pipelines shall be 300mm. The depth of the trench shall be such that the minimum soil
cover on the pipeline shall be as mentioned in the OISD -141 or as directed by RILs
authorised representative. Excavated soil shall be dumped at least 1.0m away from the
trench. Proper welding pit shall be prepared for welding the field joints.
8.0.1 Trenching for water body crossing: Trenching for laying pipeline across any water body
shall be carried out by suitable means in coordination with EIC. Temporary nallah/water
diversion shall be arranged in coordination with the NHAI & RIL EIC. Proper
arrangements/engineering controls shall be executed in consultation with RIL EIC to
ensure river/nallah bank & bed erosion do not expose the pipelines in future. Depth of the
pipelines at water body shall be sufficient to avoid pipeline exposure during its design life
span.
9.0.0

Pipe stringing:
Pipe stringing shall be done adjacent to the trench on the side opposite to the one where
excavated soil is dumped. Pipe stringing report shall be prepared on daily basis for each
site. Total length of pipes stringed together at a given site shall be proportionate to the
length of rerouting to be done.

9.1.1 Pipes to be laid for normal ground profile shall be of 7.04mm wall thickness and for
rail/road/river/nallah it shall be of 9.52mm wall thickness.
10.0.0 Weld joint & hot bend coating & testing:
Main pipeline will be having factory applied PE coating. Field coating of the weld joints
and hot bends shall be done by applying Raychem make heat shrink joint coating as per
the approved procedure of the manufacturer. Pipe joint/bend coating/wrapping can also
be done with cold applied PE coating as per approved procedure and instruction from
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RIL EIC.
Factory coated pipes will be tested for coating defects by carrying out Holiday test as
per approved procedure before lowering and after lowering of pipes. Coating defects
shall be repaired and retested as per the procedure.
Coating & testing records shall be maintained as per the procedure.

11.0.0 Pipe Lowering:


Before lowering, clearance shall be taken from RILs authorised representative. When
already coated pipes are being lowered, a complete check of the pipe coating and field
joint coating shall be carried out and all damages repaired.
Care must be taken that during laying; the deformation caused during the raising of the
pipe from the support does not exceed the values for the minimum allowable radius of
elastic curvature, so as to keep the stresses in the steel pipe and on the coating within
safe limits.
Pipeline to be lowered on sand bags placed not more than 5.0m apart, with min ground
clearance of 200mm for normal soil and 300mm for rocky/hard murrum soil. Ensure end
caps are intact.
It shall be ensured that the pipeline laid shall be not under tension.
Lowering report to be prepared and approve by RIL EIC.
11.1.1. Crossing of Utilities
A minimum clearance of 500mm shall be maintained at the point of crossing and the
utility or pipeline shall be installed at a uniform depth for the full width of the right of way.
HDPE sheet, sand padding shall be done between the two u/g utilities as directed by RIL
EIC. HDPE sheets will be issue by RIL free of cost. Clits shall be welded on the pipeline
at the foreign pipeline crossing location for providing TLP station. Welding shall be tested
by DP test and report to be prepared.
Unless told otherwise, RIL pipeline shall be laid below the existing Petroleum or gas
pipeline. For any other utility crossing, soil cover and the required gap shall determine the
mode of crossing.
When laid parallel to, along or near underground power and/or communication cables,
conductors or conduit, underground pipes shall maintain a horizontal clearance between
vertical planes through the adjacent external surfaces on the pipelines and cables,
conductors or conduct, or structures of the underground utility of at least 500 mm.

All crossings records including proper drawing shall be maintained in the approved
format.
11.1.2 Laying of Optic Fiber Cable
OFC shall be laid along with the pipelines after soft soil padding is done in coordination
with RILs Telcom engineer. OFC & HDPE duct will be issued free of cost by RIL. Utmost
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care shall be taken while backfilling so that the OFC is not damaged. Joining of old &
new OFC will be done through the separate contractor appointed by RIL. All possible
support for providing safe working place for OFC jointing shall be provided.
11.1.3 CP installation: RIL will depute separate CP contractor for providing temporary CP for the
buried pipelines before hook-up. Mainline contractor shall provide clits at all desired
location as decided by RIL CP I/C. Further work of TLP installation and cable termination
will be done by the CP contractor. Clit material will be provided by RIL. Clit weld shall be
tested by DP test and record shall be maintained.
11.1.4 Rail/road/river crossing:
Depending upon the site condition, contractor shall make all the arrangements for lying
pipeline across rail tracks, road or a river crossing as per the approved procedure
1)Horizontal Boring and installation of casing pipe: Contractor shall carryout
horizontal boring in all sorts of soil by appropriate means as instructed by RIL EIC for
installing casing pipe cross railway lines/road at an appropriate depth including
installation of vent/drain pipes, casing end seals, handling/shifting of free issue materials
at site,supply & application of 3 coats of coal tar epoxy paint on the casing pipes &
vent/drain pipes, supply/installation/operation of all equipment /machinery/tools/tackles
for horizontal bore, excavation, shoring & barricading for the push & pull pits, making the
horizontal bore of adequate dia,installation of carbon steel pipe in the horizontal bore,
including cutting/grinding/heating/beveling/fit up/welding for casing pipe, pneumatic
testing of the casing @ 3 kg/sqm,carrying out all temporary & enabling works, supply of
all
materials
except
for
free
issue
material
by
RIIL/Power/Water/Air/consumables/manpower/supervision, taking all the required safety
measures as per EIC & RA, collection/handling/disposal of surplus materials, area
restoration to the satisfaction of EIC, accounting and return of surplus free issue
materials to RIL JNPT, obtaining NOC from all concerned authority, as built drawing
preparation, etc. as per the instructions from RIL EIC.

12.0.0. Backfilling of trench


Once the twin pipelines & OFC are laid, excluding the ends of the pipelines, remaining
portion shall be backfilled after taking clearance from RIL EIC.
Prior to backfilling, the contractors shall remove boulders/rocks from the excavated soil.
Soft soil padding shall be done on all sides and upto min. of 300mm from the pipe top.
Soft soil adding shall be done manually in the presence of RILs authorised
representative. The decision to use available soil or get soil from outside for padding
shall be taken by RIL EIC.
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Further backfilling may be than carried out with the available soil which shall be free from
boulders. Minimum soil cover as prescribed in the OISD shall be maintained. However,
extra soil cover shall be provided considering the probable soil erosion which may take
place during the subsequent rainy season. Decision of the same will lay with the RILs
authorised representative.
The exposed ends shall be temporarily backfilled till the hydrotest/hook up activity or may
be protected by laying soil filled gunny bags as approved by the RILs authorized
representative.
12.1.1 Installation of Pipeline markers : The contractor shall fabricate and install pipeline Turning
Post, Warning post and Kilometer posts as per the approve drawings as the desired
location as per the instructions from the RIL EIC.

13.0.0 SPECIAL INSTALLATIONS ON THE PIPELINE


13.1

GENERAL

13.1.1. In addition to constructing the pipeline, certain other auxiliary facilities and appurtenances
shall be installed.
Contractor shall do all work necessary each of the installations to provide facilities which
are complete in all respects and ready for operations.
Without limiting the generality thereof, the work required to complete the installations
shall, where applicable, include all site surveys, site preparation, foundations, installation
of block valves, pipe work, pipe supports, pressure gauges, mechanical facilities,
painting, and installation of all piping, valves and fittings.
On completion, all elements of each entire installation shall be checked out and tested for
full and correct operation in the presence of, and to the satisfaction of RILs authorised
representative. All work shall be carried out strictly in accordance with the appropriate
codes, the approved drawings, and this and other related specifications.
All piping fabrication and installation of valves and fittings shall be done as per detailed
engineering drawings.
It shall be ensured that the piping assemblies are not in a strain prior to the final bolting
or welding. It shall also be ensured that all equipment and piping are thoroughly swabbed
clean of all dust, refuse, welding spatter, scale or any potentially detachable matted prior
to the tie-in or final bolting.

13.2.

INSTALLATION OF VALVES AND VALVE STATIONS

13.2.1.Block and sectionalising valve stations shall be installed as shown on the approved
drawings. Units shall be completely assembled, tested and made fully functional.
13.2.2.The Civil and Structural work shall be carried out in accordance with the relevant
specifications and in accordance with the approved drawings. This work as a minimum
shall include cleaning, grading fencing, foundations, etc. as required. All above ground
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structure shall be painted as per the specification and colour code given by the

13.2.3.Valves with flow arrows shall be installed according to the normal flow in the pipeline.
During welding, the valve shall be in fully open position. In addition all manufacturers
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.
13.2.4.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.
13.2.5.Sectionalizing valves shall be installed on sections of the pipeline in the horizontal position
only or with an inclination not greater than that allowed by the valve manufacturer.
Installation shall be done in such a way that there is no strain in the welded joint while the
pipeline at upstream and downstream side are straight.
13.2.6.All valves shall always be handled using equipment and methods to avoid impact, shaking
and other stresses. In particular, the equipment and tools and lifting and handling shall
never be done through handwheel, valve stem, flange joints and other parts which may
suffer damage.
13.2.7.All sectionalizing valves and other inline assemblies shall be prefabricated and tested
hydrotesting ex-site as per applicable specification. All such assemblies shall be installed
at the locations shown in the drawings only after successful completion of the hydrostatic
test and dewatering. Thereafter the ends of the assembly shall be closed off. Necessary,
excavation, cutting bevelling and welding of the tie-ins required for the installation of such
assembly shall be carried out. All works shall be executed in accordance with the relevant
specification issued for the purpose.

14.0.

SPECIFICATION FOR HYDROTESTING OF PIPELINE

14.1

SCOPE

14.1.1.After getting clearance from the RILs authorised representative, the contractor can go
ahead with the hydrotesting of the twin pipelines at various rerouting locations as directed
by RIL EIC. One location shall be taken at a time. The twin pipelines can be hooked up to
each other or can be tested individually. Contractor shall prepare detail procedure and
get it approved by RIL EIC.
14.1.2.Final cleaning, gauging and hydrotesting of the pipeline shall be carried out for 24 hours
after completion of all tie-in joints.
14.1.3.The Contractor shall supply all the necessary manpower, equipments, pumps,
compressors, gauges, recorders, dead weight tester, pigs cups, brushes, gauge plates,
tools and tackles to successfully perform cleaning, gauging, hydrostatic test and leak test
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of the installed pipeline.
14.1.4.The Contractor shall prepare and submit a detailed Test Procedure for pre and post
Hydrostatic Testing about pipeline cleaning and gauging, pipeline waterfill, thermal
stabilisation, pressurisation, air volume calculations, recording of various parameters,
hold period, hydrotest acceptance, line depressurisation, addition of chemical inhibitors
etc. RILs authorised representative for necessary approvals prior to commencement of
any tests.
14.1.5.The procedure submitted by Contractor shall also include the drawings of air pigging
headers, test headers and layout for air pigging, water filling, pressurisation, 24 hour hold
period, dewatering etc. It should also include format of record sheets, hydrotest
calculations, equipment, instrument and manpower lists to be deployed.
14.2.

PRELIMINARY INVESTIGATIONS

14.2.1.The medium to be used for cleaning, filling and subsequent testing of the pipeline shall be
fresh potable water. The contractor shall submit Lab test report in this regard.
14.3.

CLEANING AND GAUGING

14.3.1.After obtaining the clearance for hydrotesting from RILs authorised agency Contractor
shall perform pipeline cleaning operation.
14.3.2.The cleaning pig shall have sufficient number of cups and minimum one circumferential
brush or set of spring loaded brushes to dislodge debris and mill scale from inside the
pipeline.
14.3.3.The cleaning pig shall be propelled using compressed air package capable to deliver air
at pressure of 7-10 Kg/sq.m. and shall ensure the continual movement of the pigs at
approximate speed of 3 to 6 Km per hour.
14.3.4.A 24 hour low pressure chart recorder and gauge shall be connected at the launching end
of the section to record pressure/time reading during each air pigging operation.
14.3.5.The cleaning pig shall be installed in the launcher in presence of RILs authorised
representative.
14.3.6.Receiving times of pigs and the quantity and type of dislodge debris or completion of
each run will be noted. The pig receiver shall also be opened in the presence of RILs
authorised representative.
14.3.7.If in the RILs authorised representatives opinion the line is not cleaned satisfactorily
Contractor shall carry out the cleaning operation until satisfactory cleaning of pipeline is
achieved.
14.3.8. If no unusual debris is discharged the gauging pig shall be launched.

14.4.

PIPELINE GAUGING
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14.4.1.The Contractor shall launch a gauging pig in presence of RILs authorised representative.
The gauging pig shall also be propelled as per para 9.3.3 and 9.3.4 of this specification.
14.4.2 The aluminium alloy gauging plate of 8mm thickness shall have the minimum diameter
equivalent to 90% of internal diameter the heaviest wall pipe in the section. The length of
the gauge pig shall be of standard.
14.4.3 The gauge pig shall be taken out from pig receiver in the presence of RILs authorised
representative.. If the gauge plate is found to have objectionable dent, buckle of damage
necessary corrective measures shall be taken by the Contractor. The gauging operation
shall be repeated until successful results are achieved.
14.5

PIPELINE FLUSHING AND WATERFILLING

14.5.1 On successful completion of pipeline gauging operation, pipeline shall be prepared for
flushing and waterfilling by the Contractor.
14.5.2 The pipeline flushing and waterfilling operation shall be performed simultaneously.
14.5.3 A quantity of uninhibited water as desired by RILs authorised representative shall be put
in front of the first pig for flushing.
14.5.4 The Contractor shall construct the waterfill package taking into account the ability to
overcome the accumulative head generated by filling together with a suitable flow rate.
14.5.5 It is anticipated that as the test water will be relatively good quality potable water enabling
testing and dewatering to be scheduled to reduce the retention times in the pipelines to a
level whereby the use of inhibitors and biocides can be eliminated.
This is preferred method to minimizes the problems of disposal of test water and the
possibility of pollution.
9.5.6 The first waterfilling pig comprising of four cup pigs shall be launched with a
suitable flow rate.

14.5.7 If required the Contractor may launch another pig after pumping in sufficient volume of
water between pig one and two.
14.5.8 During the line filling, the valves at the receiving end of the section may be adjusted to
ensure a sufficient back pressure to eliminate the possibility of air ingression in the
waterfill.
14.5.9 During the line filling operation, readings of pressure/water volume input/time shall be
taken after fixed intervals. The filling pressure and inlet water temperatures shall be
recorded continuously or chart recorder.
14.5.10 Upon completion of the section filling, the section shall be pressurised until 1 kg/cm 2
pressure is reached at the highest point of the section, after which the section will be
closed in and disconnected from the line fill package.
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14.6

PRESSURISATION

14.6.1 The Contractor shall install pressurisation package during thermal stabilisation period.
14.6.2 After achieving the thermal stabilisation contractor shall perform pressurisation at a
moderate and constant rate not exceeding 2 kg/cm2 per minute. 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 pressurisation as follows :
each 5 kg/cm2 increment upto 80% of test pressure as recorded by dead weight
tester.
each 2 kg/cm2 increment between 80% and 90% of test pressure as recorded by
dead weight tester.
each 1 kg/cm2 increment between 90% of the test pressure to full test pressure
recorded by dead weight tester.
14.6.3 The pressurising shall be cycled by Contractor according to the following sequence:
a)

Pressurise to 50% of test pressure, hold pressure for 1 hour.

b)

Drop pressure to static head.

c)

Pressurise to 75% of test pressure, hold pressure for 1 hour.

d)

Drop pressure to static head.

e)

Pressurise to test pressure.

During the pressurisation, to each test pressure, 2 tests will be carried out for the
calculation of air volume in the pipeline under test. In case, during the hold pressure
indicated above, a decrease in pressure is observed, the above operations shall not be
repeated more than twice, after which the line shall not be considered capable of test,
until the cause of lack of water tightness has be isolated and eliminated.
14.6.4 Minimum hydrostatic test pressure shall be 1.5 times the internal design pressure and
maximum hydrostatic test pressure shall be 90% SMYS of pipeline.
The test shall be repeated as per the above procedure until above estimated tolerances
are satisfied. The pressuring can then continue, to reach the value of the test pressure.
14.7

HYDROTEST ACCEPTANCE

14.7.1 The hydrotest hold period shall be maintained for a minimum of 24 hours.
14.7.2 Upon completion of the test period, the data collected will be used to evaluate the
hydrotest.
14.7.3 The data will be input into the calculation set out in para 9.17.0
be considered as acceptable if the difference is less than value or equal to 0.3 kg/cm2 . In
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case of doubt the testing period shall be extended by 24 Hrs.
14.7.5 Upon receiving the RILs authorised representative authorised representatives written
acceptance of the test, preparations shall be made for line depressurisation.

14.7.7 Should data collected indicate a possible section leak, preparations should commence to
locate and identify the fault.
14.7.8 Should a fault be located the pipe shall be repaired and the hydrostatoc test shall be
repeated in full as per this document.

14.8

LINE DEPRESSURISATION

14.8.1 Upon acceptance of the hydrostatic test, the section shall be prepared for
depressurisation.
14.8.2 Depressurisation rates shall be regulated to ensure a moderate and constant reduction in
pressure. A rate of maximum 3 kg/cm2 per minute is allowed.
14.8.3 Care shall be taken to ensure line pressure is not reduced below static head.
14.8.4 Positioning of depressurisation hose to prevent scouring by water shall be considered.
14.8.5 Upon completion of section depressurisation, the line shall be prepared for dewatering.

14.9

PIPE DEWATERING

14.9.1 Dewatering of a section can take place by :


14.9.2 Pushing the water back to the source with compressed air or,
14.9.3 Pushing the water with compressed air to the receiving end of the test section by
propelling the standard pipeline cup pig.
14.9.4 Care shall be taken to prevent damage to any existing construction of natural boundary
during water discharge.
14.9.5 If chemicals have been added to the water, dewatering will take place in such a way that
the composition of the effluent water does not exceed the limits set in IS 2490 (Part - I) 1974 table tolerance limits for industrial effluents discharged into inland surface waters.
14.10 FAILURES
14.10.1Failures in the pipeline disclosed by loss of pressure shall be located and repaired by the
Contractor. Air shall be used for displacement of water. Following repairs, all air shall be
removed from the pipelines and the test repeated until a continuous test period has been
satisfactory attained.
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14.10.2The Contractor shall keep complete records of failures occurring during the test including
their locations, type and cause of failure, and method of repair. Pipe, fittings and valves
which failed and are replaced shall be marked with their pipeline locations and pressure
at which they failed. Such materials shall be held for disposal by the Contractor if the
same were supplied by him.

14.11.0

EQUIPMENT AND INSTRUMENTS

14.11.1All test equipment, instruments, test manifolds test medium and inhibitors shall be
supplied by the Contractor.
14.11.2A complete inventory of equipment and spares shall be furnished to the Company prior to
start of testing. The equipment which affects the accuracy of the measurements upon
which the validity of the hydrostatic test depends must conform within the range to be
measured. Certified proof of accuracy of gauges and test equipment shall be submitted
prior to the start of the testing and shall be included in the final test report.
14.11.3The Contractor shall deploy at least, but not limited to, the following equipment and
materials :
a)Fill pump with sufficient pressure and capacity to propel filling and cleaning pigs. The
suction hose shall have filter with 100 mesh screens and airtight at junctions.
b)Air compressor with sufficient pressure and capacity to successfully dewater the
pipeline.

c)Positive Displacement Pump of variable speed equipped with a stroke counter to


pressurise the line with a known volume per stroke and capable of exceeding the
maximum test pressure by at least 6 kg/cm2.
d)Flow meter with an accuracy of 0.3 to 0.4 percent to measure volume of water filling
the line.
e)Portable tank of sufficient size to provide a continuous supply of water to the pump
during final pressure adjustment.
f)High pressure deadweight gauge - 4 - 130 kg/ cm2 range with 0.05 kg/ cm2 intervals of
pressure.
g) Portable type temperature recorder, range 00 to 700 spring wound, chart drive, 24
hour movement, capillary inking system preferable with mercury bulb. One each of water
temperature and ambient air temperature.
h)Portable type pressure recorder, / range 0-130 kg cm2 spring wind, chart drive, 24 hour
movement capillary inking system, 15 long high pressure, flexible hose, 1/4 NPT both
ends.
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i)Pressure gauge 0-130 kg/ cm2 range, minimum 5 Nos.
j)Portable type pressure recorder, range 0-130 kg/ cm2, spring wind, chart drive, 24 hour
movement capillary inking system, 15 long high pressure flexible hose 1/4 NPT both
ends.
k)Means to measure the volume of water necessary to drop the line pressure by 0.5kg/
cm2. Container on scales or graduated cylinder may be chosen.
l)Communication equipment.
m)Test heads with all associated valves, fittings and connections, also suitable for use as
pig launcher and receiver during filling, testing, cleaning and dewatering of the line.
n)Temperature recorder (1 No.) & Temp gauge (2 Nos.)

14.12.0

DOCUMENTS

14.12.1Upon successful completion of the hydrostatic test, the Contractor shall submit in bound
form the following records in triplicate.
a)

Completed hydrostatic test forms in the Format, Form I given in the Appendix E.

b)

The testing procedure.

c)

The additives specification, supplier and amounts injected.

d)

A profile of the pipeline, test sites over the entire length of the test section, noting
all instrument and injection connection.

e)

Certificate of accuracy for instruments.

f)

Temperature Data.

g)

Barometric Data.

h)

Dead-weight tester log.

I)

Pressure recording charts with appropriate information spelled out.

j)

Theoretical and hand plot pressure - volume curve.

k)

Theoretical and hand plot temperature-volume curve.

l)

Records of failure as outlined in clause 9.10.0

m)

Records of rectification/ repairs of leak joints undertaken indicating their locations


and pressures at which the failure has taken place.
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n)

COPIES OF RECORD SHEETS

o)

PIPELINE GAUGING ACCEPTANCE CERTIFICATE

p)

PIPELINE FILLING, LOG OF OPERATIONS

q)

PRESSURE RECORDER CALIBRATION

r)

PIPELINE PRESSURISATION, LOG OF OPERATIONS

s)

HOUR HOLDING PERIOD, LOG OF OPERATIONS

t)

HUDROSTATIC TEST CALCULATIONS

u)

HYDROSTATIC TEST EVALUATION

The Contractor and RILs authorised representative authorised shall sign all the reports.

14.12.2
PIPELINE GAUGING
ACCEPTANCE CERTIFICATE
INTERNAL PIPE DIAMETER ___________________ MM
GAUGE PLATE DIAMETER ___________________ MM
LENGTH OF SECTION

___________________ MM

PRESSURE DURING GAUGING RUN ____________ KG/CM2


MAXIMUM PRESSURE DURING GAUGING RUN _____________ KG/CM2
GAUGE PLATE ARRIVED IN DAMAGED/ UNDAMAGED CONDITION
GAUGE ACCEPTABLE/ UNACCEPTABLE.
NO. OF GAUGING RUN :

_____________________

REMARKS (IF ANY)

__________________________________________
__________________________________________
__________________________________________

SIGN :

____________________

SIGN : ____________________

NAME : ____________________

NAME : ____________________

DATE : ____________________

DATE : ____________________

FOR RIL JNPT

FOR CONTRACTOR
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14.12.3
PIPELINE FILLING
LOG OF OPERATIONS
CONTRACTOR ____________________________________________
PIPELINE LOCATION FROM ______________ TO ______________
FILLING POINT (KP) ___________________________
PIPE DIAMETER ___________ IN PIPE WALL THICK ___________
IN LENGTH _______________M
ESTIMATED PIPELINE VOLUME _________________________M3
CHEMICAL INJECTION RATE ___________________________ppm
PIG TYPE (S) : _____________________________________________
REMARKS : _______________________________________________
TIME
(HOURS)

LINE
(KG/CM2)

WATER
FLOWMETE
R READING
(M3)

CUMULATIVE
VOL.WATER
PUMPED (M3)

FILLING
RATE
M3/HR.

SIGN : __________________

SIGN : __________________

NAME : _________________

NAME : _________________

FOR RIL JNPT

NOTES

FOR CONTRACTOR
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14.12.4
HYDROSTATIC TESTING
PRESSURE RECORDER / GAUGE CALIBRATION
INSTRUMENT :

PRESSURE RECORDER / GAUGE


MAKE & SERIAL NO. ___________
DEAD WEIGHT TESTER
MAKE & SERIAL NO. ___________

SR.NO
.

DEAD WEIGHT
TESTER KG/CM2

DATE

TIME

CALIBRATION READING
PRESSURE RECORDER
DECREASI
GAUGE INCREASING
NG

SIGNATURE :

SIGNATURE :

NAME :

NAME :

FOR RIL JNPT

%
DEVIATION

FOR CONTRACTOR

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14.12.5
PIPELINE PRESSURISING
LOG OF OPERATIONS
Contractor _________________________________________________________
Pipeline Location ________________ From ___________ To ______________
Service ____________
Presurising Location __________________ Testing Location _________________
Pipe Diameter __________ In Pipe Wall Thick __________ In Length _________
Estimate Pipeline Volume ______________________________________ M3
Chemical Injection ____________________________________________ ppm
Maximum Test Pressure _______________________________________ Kg/Cm2
Test Pressure at Testing Location ________________________________ Kg/Cm2
Theoretical Additional Water Volume for Pressurisation _______________Ltrs.
Remarks : _________________________________________________________
Time
(Hours)

Line
Kg/Cm2

Key to Chemical Type


Signature
Name
For RIL JNPT

Cumulative
Vol.Water
Pumped M3

Deducted
Flow Rate
M3/ Hr.

Dead Weight
Tester
Reading Barg

Notes

Signature
Name
For Contractor

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14.12.6
6 HOUR TEST
LOG OF OPERATIONS
Contractor : ___________________
Pipeline Location _________________ From _____________ To ___________
Pipe Diameter ________Wall Thickness________Length_______Section Volume______
Time

Dead
Wt.
Tester
Readin
g
Kg./M2

AMB.
Temp
0
C

Pipeline
(0C)
A
B

Signature : _____________
Name
: _____________
For RIL JNPT

Temperature Ground
(0C)
C
Avg. A
B
(A+B
+C)

Temperature Remark
s
C
Avg
.
(A+
B+
C)

Signature : _____________
Name
: _____________
For Contractor

14.12.7
HYDROTEST CALCULATION
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The theoretical water amount that is necessary for filling the section to be tested shall be
obtained from the geometrical volume of the section considering the pipe tolerance.
The theoretical water amount that is necessary for pressurising the section shall be calculated by
means of the following formula :
Vt = (0.884 _ri_ + A) x 10-6 x Vt x P x K
t
Where :
Vp = computed wate amount required to raise by P the press 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 pressurisation temperature in the P
range (bar - 1) x 106.
(Refer water compressibility factor Vs pressure and temprature chart.
K=
a diamensionless coefficient that is equal to a value of 1.02 for longitudinally welded pipe.
The pressure change due to a water temperature change shall be calculated through the
following formula :
P=

.
0.884

P=
T=
B=
A=
ri =
t=

B
_i_ + A
t

T where

pressure change resulting from a temperature change (bar).


algebraical difference between water temperature at the beginning of the test and water
temperature as measured at the end of the test (Deg.C)
value of the difference between the thermal expansion water at the pressure and
temperature as measured at the end of the test and that of stee (0C-1) x 106.
Isothermal compressibility value of water as estimated the pressure and temperature
values obtained at the test (bar -1 ) x 106.
nominal inner radius of the pipe (mm)
nominal pipe wall thickness (mm)

14.12.8

SAFETY
i. During hydrostatic testing, Contractor shall take utmost safety precautions
to avoid any untoward incident.
ii. All the persons working or the hydrostatic testing spread shall be
instructed of the possible danger connected with the high pressure
operations.
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iii. Contractor shall nominate a responsible hydrotesting engineer who shall
ensure that all persons working on the hydrostatic testing spread are fully
aware of their individual duties.

iv. Contractor shall display safety sign boards in English and local language.
The display shall be as follows :Pipeline under high pressure, keep away.
v. All the test instruments shall be installed in a safe place near the
pressurising end to monitor the test.
vi. During poor visibility/ night Contractor shall install sufficient lights for
proper recording of data and work with safety.
vii. Contractor shall strictly follow all the safety procedures given by RIL from
time to time. for work in confined space as approved by RILs authorised
representative.
viii. Contractor shall strictly follow all the safety procedures given by RIL from
time to time. for work in confined space as approved by RILs authorised
representative.

15.0.

HOOK UP OF NEW PIPELINE WITH EXISTING PIPELINE (shutdown work)


After successful completion of final hydro testing and getting clearance from RILs
authorised representative; pipeline shall be hooked up with existing pipeline on a
preplanned date. The hook up activity may have to be carried out at one or more than
one location at a time or as decided by the RIL EIC. The contractor shall execute the job
round the clock so as to minimize the shutdown time as far as possible. He shall therefor
make all the necessary arrangements and shall depute sufficient manpower to carry out
the shutdown job at more than one location simultaneously.
The existing pipeline will be made hydrocarbon free by flushing sufficient quantity of
water through the pipelines The Contractor shall cut out the existing pipeline as per
approved procedure and as directed by RILs authorized representative. Mud plug having
capacity to hold water for sufficient time shall be inserted in the pipelines to stop
accumulated water entering the weld joints. All hook-up welds shall be 100%
radiographed and checked by UT/DP test if required by RILs authorized representative.

Merely hooking up the pipeline with existing pipeline shall not absolve the Contractor of
his responsibility from satisfactory functioning of the section tied-in. Proper disposal of
the flushed water collected after pipeline cutting and draining shall be in contractors
scope.
16.0 Site restoration & demobilization
After completion of the all works the site restoration shall be carried out to the satisfaction
of the RIL EIC. The contractor shall repair/restore at its own cost any damage done to
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the property of the land owner at site.
Demobilisation from the site shall start after getting clearance from the RIL EIC.
16.1.1 General penalties
Penalties as applicable as per the RIL procedure shall be levied on the contractor for any
non-compliance in regard to the safety recorded during the course of the work.
17.0

QUALITY CONTROL AND QUALITY ASSURANCE MANUAL

17.1

SCOPE

17.1.1 The Contractor shall submit their Quality Control and Quality Assurance Plan for approval
from RILs authorised representative.
17.1.2 The aim for QA/QC Manual shall be to ensure that all the quality requirements
established for the project are complied and provide relevant documentation.
17.2

GENERAL

17.2.1 The QA/QC Manual shall include but not limited to the following :
The activities within a system where organisational structure, functional responsibilities,
levels of authority, reporting, interface positions, as well as the lines of internal and
external communications shall be clearly defined.
The activities which shall ensure an integrated approach to the required quality objectives
and provide adequate quality control.
It shall indicate suitable measures that shall be established by Contractor to identify and
comply with RILs authorised representatives quality requirements and applicable codes
and regulations.
17.3

ORGANOGRAM

17.3.1 The quality assurance manual submitted by Contractor shall contain an organisation
chart giving a complete description of their organisation proposed to work at site for
planning, construction and testing.
17.3.2 Each section in the Quality assurance manual shall contain a separate organogram for
the activities involved.
17.4

Policy Statement : The QA/QC manual shall include a policy statement of contractor
stating that it is their policy to adhere to the specifications, procedures and to fulfil the
requirement drawn up.
The statement shall be signed by the Contractors top management.

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17.5

PLANNING

17.5.1 The Contractor is to have established a system for planning which ensures that all
activities can be performed in accordance with the bid specifications and stipulated time
period.
17.5.2 Through efficient and systematic planning Contractor shall accomplish a satisfactory
quality control at all stages of the construction process.
17.5.3 The planning shall comprise all quality affecting activities in connection with construction.
It shall include establishment of instructions and procedures to an extent necessary to
ensure that all stipulated contract requirements to design, construction and testing are
incorporated.
17.5.4 The Contractor, as early as possible, make a complete and adequate scrutiny of the
contract documents, as well as the rules and specifications on which they are based, in
order to identify all quality requirements.
17.5.5 The planning shall include preparation of time, resource and sequence plans for all
quality affecting activities.
17.5.6 Progress plans shall be systematically made out so that the Control activities can be
performed at convenient stages and so that faults and deficiencies may be connected in
satisfactory way.
17.6

PROCEDURES

17.6.1 The Contractor shall be responsible for preparations of procedures for various activities,
submission and getting approvals from RILs authorised representative.
17.6.2 The procedure shall indicate methodology of construction, equipments used, safety,
inspection and documentation etc.
17.6.3 The procedures shall also include inspection formats as detailed under :1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

Hauling Report
Stringing and Line-up Report.
Pipe Bending Report
Report Trenching
Lowering Report
Backfilling report
Welding Procedure Qualification Record.
Welder Qualification Record.
Field Welding Report
Radiography Report
Joint/bend coating test report
Dye Penetration Report.
Tie-in Joint Report
Joint Measurement Report
Pre-Hydrotesting Clearance Report
Pre-Hydrotesting Report
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17.
18.
19.
20.
21.

Final Hydrotesting Clearance Report


Final Hydrotesting Report
Final Clean-up Report
Pipe Book (Daily Pipe Tally Sheet)
Mechanical and Non-destructive Testing Clearance Report

17.6.4 The Contractor shall obtain the approval of the procedures along with the inspection
format before commencing that particular activity well in advance from RILs authorised
representative.
18.0

SPECIFICATION FOR AS-BUILT DRAWING PREPARATIONS

18.1

SCOPE
This specification covers the requirement for preparing as-built drawings for the entire
pipeline.

18.2

GENERAL

18.2.1 During execution of the Project Contractor shall collect all relevant and maximum
possible data and get the same data endorsed by RILs authorised representative.
18.2.2 The following drawings shall be prepared by the Contractor as as-built drawing :
-

Route maps for entire pipeline.


Alignment sheet for entire pipeline
Detail crossing drawings road crossing, which require detail drawing.
Detail installation drawing for piping, civil & structural drawings.

18.2.3 Contractor shall furnish the detailed pipe tally sheet prepared or the approved format by
RILs authorised representative. In these pipe tally sheets all relevant informations/ data
shall be incorporated by Contractor. All pipe tally sheets shall be signed by Contractor
and RILs authorised representative.
18.3

AS-BUILT DETAILS

18.3.1 Following minimum but not limited measurements shall be taken by the Contractor on
pipeline route.
18.3.1.1
18.3.1.2
18.3.1.3
18.3.1.4
18.3.1.5
18.4

Horizontal location of the pipeline.


Vertical location of the pipeline.
Location and type of bends and fittings, measurement of Chainage.
Details of crossings.
Location of change of pipe wall thickness.

Two sets of as-built drawings shall be submitted by Contractor to RILs authorised


representative to process any possible changes from the recorded information/ data.
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18.5

After incorporating all data and comments Contractor shall submit six sets of all drawings
alongwith the tracings in a proper documented fashion.

18.6

02 copies of approved pipe books properly bound shall be submitted to RIL along with
the original copy.

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