Vol IE Tender Drawings

T E N D E RS P E C I F I C A T I O N
NO: BHE/PW/PUR/PIPVG-CVL/1145
CIVIL WORKS RELATED TO REPAIR OF GRP PIPE LINE FOR CW
SUPPLYAND RETURNLINEINMAIN PLANT AND BOP AREA
AT
2X350MW CCPP, GPPCL, PIPAVAV, GUJARAT.
VOLUME-I-E – Tender Drawings-1145
BHARAT HEAVY ELECTRICALS LIMITED

(A GOVERNMENT OF INDIA UNDERTAKING)
POWER SECTOR - WESTERN REGION
SHREEMOHINI COMPLEX
345, KINGSWAY - NAGPUR 440 001
BHARAT HEAVY ELECTRICALS LIMITED
(A GOVERNMENT OF INDIA UNDERTAKING)
POWER SECTOR - WESTERN REGION
SHREEMOHINI COMPLEX
345, KINGSWAY - NAGPUR 440 001
T E N D E RS P E C I F I C A T I O N
NO: BHE/PW/PUR/PIPVG-CVL/1145
CIVIL WORKS RELATED TO REPAIR OF GRP PIPE LINE FOR CW SUPPLYAND

RETURNLINEINMAIN PLANT AND BOP AREA
AT
2X350MW CCPP, GPPCL, PIPAVAV, GUJARAT.
EARNEST MONEY DEPOSIT: Please see Notice Inviting Tender.

LAST DATE FOR: Please see Notice Inviting Tender.
TENDER SUBMISSION:
THESE TENDER SPECIFICATION DOCUMENTS CONTAINING VOLUME-I-Tech Bid, VOLUME- II-Price Bid, Vol-IE-
Tender Drawings AND VOLIME-IBCD Rev-01 Rev-01 ARE ISSUED TO:
M/s. ……………………………………………
PLEASE NOTE:
THESE TENDER SPECS DOCUMENTS ARE NOT TRANSFERABLE.
For Bharat Heavy Electricals Limited
AGM (Purchase)
Place: Nagpur
Date:
METHODOLOGY FOR GRP RECTIFICATION WORK

A) Further to MOM dated 06.05.2013 at PEM, NOIDA rectification activities along
with their areas of implementation for Unit‐2 are listed below :
1. Correction of backfilling
Area has been identified & highlighted in yellow color in the attached annexure‐I.

2. Extension of thrust block wherever coupling provided at edge is laminated
Area has been identified & marked in orange color in the attached annexure‐I.

3. Concrete encasing of piping
Area has been identified & marked in blue color in the attached annexure‐I.

4. Rectification near ACW trench
Area has been identified, refer view F1‐F1 in the attached annexure‐I.

5. Relocation of Fire water trench in Unit‐2
Area has been identified & marked in pink color in the attached annexure‐I.

6. Backfilling & re‐compaction of soil near CW pump house in Supply line
To be done in‐line with pt. no. 1 at the exit of Tee for blow‐down in the supply line (marked in
green color in the attached annexure‐I).

7. Erection of vent valves on Manholes & 2100NB Equal Tees

8. Modification in road access to BFP building
Area has been identified & marked in pink color in the attached annexure‐I.

9. Checking of annubar flanges in supply line

10. Concrete encasement of manhole tees upto neck area

Detailed methodology of the above rectification work is elaborated in the following
section.
1

1. Correction of backfilling
References:
 Serial no. 5.1, 5.2 & 5.5 of Method Statement for
underground installation of GRP Pipe
 Identified area highlighted in yellow color in the
attached annexure‐I
 PE‐DG‐292‐165‐M002‐R4 : CW/ ACW PIPING LAYOUT
BETWEEN A‐ROW & PUMP HOUSE/ COOLING
TOWER
a. Remove soil upto 300mm above pipe top with
machine. (Refer Fig‐2)
b. Carefully remove further soil (soil+sand) upto pipe
top and on sides upto 300mm from pipe top in
pockets and keep the soil at separate place so that
the same can be utilized later for backfilling above
pipe top. (Refer Fig‐2)
c. Manually remove the sand upto 300mm below pipe
top and keep the sand at separate location so that
the same be utilized later for backfilling. (Refer Fig‐2)
d. Leave the excavated zone for a day for pipe to regain
shape
e. Inspect the soil for compactness and pipe ID for pipe
ovality.
f. Excavate the soil further if soil near pipe surface
shows sign of sand movement or pipe deflection is
still more than 0.75%. (Refer Fig‐3)
g. Leave the excavated zone for a day and repeat step‐
e above.
h. If the Pipe deflection comes within 0.75%, start layer
by layer (~200mm thick) compaction of sand by
adding water to achieve optimal sand moisture and
compact with plate compactor to sand compaction
level 80% relative density. Sand taken out in step‐c
to be utilized for backfilling in pipe sides and sand
taken in step‐b to be used for backfilling above pipe
top. Further backfilling upto FGL is to be carried out
with soil removed in step‐a and layer by layer in
300mm with SPD 85%. However, big boulders are to
be removed before backfilling.
i. In case, pipe ovality in step‐g is more than 0.75%, the
same is to be brought to the notice of GIL
representative and PEM for suggesting further
course of action.

2

2. Extension of thrust block wherever coupling provided at edge is laminated
References:
 Serial no. 6 of Method Statement for underground installation of GRP Pipe
 Identified area highlighted in orange color in the attached annexure‐I
 PE‐DG‐292‐165‐M002‐R4 : CW/ ACW PIPING LAYOUT BETWEEN A‐ROW & PUMP HOUSE/ COOLING
TOWER
 PE‐DG‐292‐651‐C001‐R7 : CW PIPE ‐ LAYOUT & DETAILS OF THRUST BLOCKS AND MANHOLES FOR
CW PIPING, PUMP HOUSE, COOLING TOWER B/W PHB A‐ROW

a. Excavate the stretch and keep soil & sand separately for utilizing the same as per original trench
arrangement.
3

b. Excavate near edge of the concrete block to the level of PCC to remove backfilling near thrust block
without disturbing pipe. Hilti/equivalent bars Ø12 @250 c/c 800 long to be drilled to a depth of
150mm in the existing concrete. Bottom area to be filled with PCC as per Fig‐4.
c. Wrap the rubber padding as per arrangement indicated in Fig‐4 and Method statement section‐6.
d. Reinforcement bars to be overlapped with Hilti bars so that new concrete block around rubber
padding is joined with old concrete to prevent separation. Also existing concrete surface is to be
roughened before pouring of concrete. Fresh concrete to be poured after tying rebars & concrete
block is to be casted first upto construction joint in first phase as per Fig‐4.
e. The portion of pipe bed near excavated area adjacent to new thrust block is to be filled with sand
and hydraulically compacted. Afterwards backfilling of the pipe zone and above is to be carried out
Layer by layer as per guidelines given for correction of backfilling.

3. Concrete encasing of piping
References:
 Serial no. 6 of Method Statement for underground installation of GRP Pipe
 Identified area highlighted in blue color in the attached annexure‐I
TOWER
Procedure will be similar to that provided for thrust block extension except that rubber padding is not
required in this case and encasing will be carried out in stretches of ~3‐4m with reinforcement bar
extending outside concrete for continuation. The excavated area near thrust block is to be compacted
with native soil to SPD95%.
4. Rectification near ACW trench
References:
 Serial no. 7.1 & 7.2 of Method Statement for underground installation of GRP Pipe
 Refer view F1‐F1 highlighted in the attached annexure‐I
TOWER

a. Remove ACW pipe by opening flanges and cut the ACW trench above GRP piping.
b. Excavate the area to pipe bottom carefully up to manhole encasing.
c. Tee & pipe to be inspected for damage and to be repaired/replaced as suggested by GIL.
d. Concrete encasement to be provided as per civil drawing PE‐DG‐292‐651‐C001‐R7 taking care of
backfilling in extra excavated zone. [Refer Method statement section‐7.1 & 7.2]
4

e. Joint provided at edge of the encasing is to be checked for lamination. If the same is original
coupling joint, check for gasket position. Incase gasket is properly located, extension of thrust block
with rubber padding is not required. In case of chance of leakage, laminate the coupling joint and
extend thrust block as per procedure given at point‐2.
f. ACW trench & piping to be restored as per civil drawing no. PE‐DG‐292‐651‐C001‐R7 & layout
drawing no. PE‐DG‐292‐165‐M002‐R4.

5. Relocation of Fire water trench in Unit‐2
References:
 Identified area highlighted in pink color in the attached annexure‐I
TOWER
 PE‐V0‐292‐552‐A205‐R6 : COMPOSITE PIPING LAYOUT OF HYDRANT & SPRAY SYSTEM
 PE‐DG‐292‐677‐C003‐R1 : LAYOUT & RC DETAILS OF MISC ‐ OUTDOOR FIRE FIGHTING TRENCHES

a. Fire water trench to be relocated between ACW strainer skid and GRP return piping in Unit‐2.
[Refer Annexure‐1 for location]
b. Fire water trench which has got buried in the soil near CW supply line to be excavated and disposed
off.
c. Fire water trench which is presently in good condition & is to be relocated may be cut in pieces and
reused at new location as per site suitability. Incase reuse of existing fire water trench is not
feasible; the width of new fire water trench can be reduced to 575mm (internal) as per new layout
for which the typical section detail is given in Fig‐5.

5

6. Backfilling & re‐compaction of soil near CW pump house in Supply line
References:
 Serial no. 5.1, 5.2 & 5.5 of Method Statement for underground installation of GRP Pipe
 Identified area highlighted in green color in the attached annexure‐I
TOWER
Remove soil and back fill as per procedure given in point‐1 above.

7. Erection of vent valves on Manholes & 2100NB
Equal Tees
References:
 PE‐DG‐292‐165‐M002‐R4 : CW/ ACW PIPING LAYOUT
BETWEEN A‐ROW & PUMP HOUSE/ COOLING TOWER
 PE‐DG‐292‐100‐MSK09‐R1 : GRP PIPING LAYOUT
(BETWEEN A‐ROW & PUMP HOUSE / COOLING TOWER)
18 nos. of 150NB Butterfly valves supplied for vent purpose of
CW system are available at site and these are to be erected as
per Fig‐6 on all the manholes and 2100NB Equal Tees.
8. Modification in road access to BFP building
References:
 Identified area highlighted in pink color in the attached annexure‐I
TOWER
 PE‐DG‐292‐100‐MSK09‐R1 : GRP PIPING LAYOUT (BETWEEN A‐ROW & PUMP HOUSE / COOLING
TOWER)
 PE‐DG‐292‐603‐C002‐R7 : LAYOUT DETAILS OF ROADS & PAVING

a. GRP pipe below modified road (refer annexure‐I) to be encased in concrete as per ponit‐3.
b. Coupling for this zone to be checked & if found to be laminated, rubber padding arrangement to be
provided at the end of encasing as per guidelines given in point‐2.
c. Native soil above encasement to be compacted before proceeding for road construction.

9. Checking of annubar flanges in supply line
Flanges to be checked & properly tightened with gasket before charging of the system.

6

10. Concrete encasement of manhole tees upto neck area
References:
 Identified area highlighted in green color in the attached annexure‐I
TOWER
 PE‐DG‐292‐100‐MSK09‐R1 : GRP PIPING LAYOUT (BETWEEN A‐ROW & PUMP HOUSE / COOLING
TOWER)

Concrete encasement to be done upto neck area of all manhole tees as per civil drawing no. PE‐DG‐
292‐651‐C001‐R7.
B) Methodology for GRP rectification work of Unit‐1 will be similar to given for Unit‐2. However after
inspection at site if any new problem is encountered, methodology will be revised accordingly.
C) Hydro‐Test of GRP Piping :
After carrying out all the rectifications & generic modifications of GRP pipes, GRP pipe shall be hydro
tested at 5 Kg/sq cm(g) for a period of 30 minutes maximum as per guidelines given in the document
"METHOD STATEMENT FOR FIELD HYDRO TEST OF GRP PIPE". if leakage still persists, pipe will be
rectified/ replaced as needed after dewatering and will be re‐tested at 5 Kg/sq cm(g) till it is successful.
Reference documents & drawings :
1. Method Statement for Field Hydro Test of GRP Pipe

2. Method Statement for underground installation of GRP Pipe

3. Annexure‐I (for identification of respective working areas)

4. PE‐DG‐292‐165‐M002‐R4 : CW/ ACW PIPING LAYOUT (BETWEEN A‐ROW & PUMP HOUSE/ COOLING
TOWER)

5. PE‐DG‐292‐100‐MSK09‐R1 : GRP PIPING LAYOUT (BETWEEN A‐ROW & PUMP HOUSE / COOLING
TOWER)

6. PE‐DG‐292‐651‐C001‐R7 : CW PIPE ‐ LAYOUT & DETAILS OF THRUST BLOCKS AND MANHOLES FOR CW
PIPING, PUMP HOUSE, COOLING TOWER B/W PHB A‐ROW [04 sheets]

7. PE‐V0‐292‐552‐A205‐R6 : COMPOSITE PIPING LAYOUT OF HYDRANT & SPRAY SYSTEM

8. PE‐DG‐292‐677‐C003‐R1 : LAYOUT & RC DETAILS OF MISC ‐ OUTDOOR FIRE FIGHTING TRENCHES [02
sheets]

9. PE‐DG‐292‐603‐C002‐R7 : LAYOUT DETAILS OF ROADS & PAVING

7

Graphite India limited (G.R.P. Division ) Method of Installation of GRP Pipe
METHOD STATEMENT
FOR UNDERGROUND INSTALLATION OF
GRP/FRP PIPES IN THE TRENCH
GRP SEA WATER PIPING SYSTEM – 700MW CCPP PIPAVAV PROJECT .
GRAPHITE INDIA LIMITED, NASHIK. INDIA

1. INTRODUCTION
This method statement covers the proc edure involved in handling and installation of
underground GRP/FRP piping in trench.
2. PURPOSE
The purpose is intended to assist the client, customer/ installer in understanding the
requirement for the successful GRP pipe handling and installation. The r ecommendations
given in this statement are easy to follow and implement.
3. SCOPE
This procedure provides detailed for underground pipe installation in soil conditions as
prevalent in the project area. The type of installation proposed based on the site conditions
and terrain in the project area is Underground installation in trenches .
4. GENERAL INSTRUCTION
4.1 Transportation and handling of GRP/FRP Pipes.
From the lay-down area to the trench site, the pipes shall be transported through trailers.
Spreader bars may be used when multiple support locations are required.
* Prior to unloading of pipes from trailers, all items shall be inspected for any
Visual / transportation damages.
* Single pipes must be unloaded and handled separately (one at a time). Use pliable
Straps, slings or ropes to lift single pipes.
* Do not use steel cables or chains to lift or transport the pipe. Pipe sections can be
Lifted with only one support.
* Care shall be taken to prevent pipes from rolling or fall ing from flat bed trailer
And this shall be attained by using proper supports, chocks.
* If at any time during handling or installation of the pipe, any damage such as
cracks, Delamination or fracture occurs, the pipe should be repaired before the
Section is installed. Contact GRAPHITE INDIA (G.R.P. DIVISION) for
inspection of damage and for recommendation for repair method or the
replacement.
* The rubber gaskets received along with the pipes and fittings shall be stored in
Shelter with original packing until it is used at site.
* The gaskets must be protected from exposures to grease or oils, which are
Petroleum derivatives, and from solvents and other deleterious substances.
* Lubricant is special vegetable soap (free from grease / petroleum products).
* Only this lubricant shall be used.
R using it.
4.2 Handling of nested pipes:
We propose to nest various diameter pipes during transportation.

Always lift nested bundles using at least two pliable ropes. Always keep n ested
Pipes on site in the original transporting package only. Stacking of these pipes is
not advisable.
De-nesting of pipes should be done carefully at pre allocated station. Inside pipe
May be removed by lifting it slightly with an inserted padded boom to suspend
the section & carefully move it out without damaging the outer pipe.
Nylon rope –with “C” Clamp Pulling Pipe “C”- Clamp Arrangement
on Roller Arrangement.
4.3 Storing & Stacking of Pipe
The “EVERFLOW” pipe can be stacked easily, with small precautions.

The ground area should be relative flat & dry, free of rocks or any other potentially
damaging debris. Place flat timber supports as four meter spacing, to facilitate placement &
removal of lifting slings around the pipe & Stack the pipes on them.
Insure the stack will be stable for condition such as high wind, unlevel storage area or
other horizontal loads. Maximum stack height is approximately three meters . Stacking
of pipes larger than 1400 mm d iameter is not recommended.
Rubber ring EPDM gaskets, being shipped separately, should stored in shade in their
original packaging and should not be exposed to sunlight, except during the pipe jointing.
The gaskets must be protected from the exposure to grease & oils, also from the solvents &
other deleterious substances.
Storing & Stacking of Pipe

4.4 Pipes Preparation at site storage area:
 It is convenient and more practical to fix one coupling at each pip e end
prior to lower into the trench. Following is the method to join the
coupling:
 Clean the coupling thoroughly from inside, specially the internal groove,
from dirt, grease or any material deposition.
 Insert the gasket into the grooves, leaving two o r more uniform loops of
rubber (depending on pipe diameter) extending out of the groove.
 Do not put any lubricant in the coupling grooves or on the gasket at this
stage. There should be a minimum of one loop for each 450 mm of gasket
ring circumference.
 With uniform pressure, push each loop of the rubber gasket into the gasket
groove.
 When installed, pull carefully on the gasket in the radial direction around
the whole circumference to check for well -distributed compression of the
gasket.
 Apply lubricant on gasket that will facilitate easily fixing of coupling to

the pipe.
 Cleaning Coupling Installing Gaskets Cleaning over Gaskets Pipe

spigot (DOS area) cleaning
 Also, apply a thin film of lubricant on pipe spigot (DOS area) & align the
coupling with pipe.
 Never use a petroleum based lubricant for FRP pipe Jointing.
 Fix a cross bar on the coupling face .Use two nylon slings & fix the
come-along jacks (pullers) at each side of the pipe spring line. The puller
capacity shall be 3 to 5 tons range.
 Ensure that the coupling & pipe is aligned.
 Start tightening the puller from both ends same time. The coupling will
insert the pipe spigot gradually.
 Make sure that the black home line marked on the pipe is matching
equally in circumference.
 Loose the pullers & move to other coupling
5.1 BED & Pipe Zone Backfill Materials

 Most coarse-grained soils, (gravel, crushed stone, good clean murrum and
sand) are the recommended bedding & pipe zone backfill materials. Gravel
is easier to compact than sand and allows the pipe to be installed deeper, if
required.
Maximum Particle
Size Pipe Maximum Gravel or Stone Size
Diameter
More than 600mm 25 mm
5.2 Use of Native Soils

 Where native soil is used as pipe zone backfill, the foll owing restrictions
apply:
a) No rocks greater than maximum gravel size
b) No soil clumps greater than 2 times the maximum gravel size.
c) No organic material.
d) No debris (tires, bottles, metals, etc.).
 Where compaction is specified: the native s oil must be granular in nature.
5.3 Pipe Bedding
 Pipe bedding material shall be sand or gravel in accordance to the

requirements.
 he bedding shall he placed after the trench bottom is compacted to
provide proper support.
 Minimum compaction of the bed shal l be 90% Standard Proctor Density
(70% of maximum relative density for crushed rock, crushed stone or
gravels).
 The bed must be over-excavated (manual digging is enough) at each
coupling joint location to ensure that the pipe will have a continuous
support and does not rest on the couplings. However, this area must be
properly bedded and backfilled after the joint assembly is completed.
5.4 Pipe Jointing in the Trench

• Position the crane near the trench (safe distance).
• Unload the pipe and place int o the trench.
 Make sure that the bedding is mechanically compacted prior to pipe laying as
per the required specification.
. • After placing the first pipe bring the second pipe near the pipe placed and
install it (by pulling to chain) with clamps, chain blocks/pullers as shown
. below.
5.5 Backfilling Pipe:

 When gravel or crushed stone is used as backfill, immediate backfilling after
joining is desirable, as it will prevent two serious hazards, floating of pipe and
thermal movements.
 Floating of pipe can damage the pipe and create unnecessary reinstallation
costs. This may not be the case in this project as the water table is not
encountered.
 Thermal movement caused by exposure to the elements can cause the loss of
seal due to movement of several lengths acting on one joint.
 Proper selection, placement, and compaction of pipe zone backfill are
important for controlling the vertical deflection and are critical for pipe
performance.
 Attention must be paid so that the backfill material is not c ontaminated with
debris or other foreign materials that could damage the pipe or cause loss of
side support.
 During backfilling, the granular material should flow completely under the
pipe to provide full support.
 A blunt tool maybe used to push and comp act the backfill under the pipe.
 Proper backfilling should be done in 150 mm to 300mm lifts depending on

backfill material and compaction material, 300mm lifts will be adequate since
gravel is relatively easy to compact. Sand needs more compaction effort s.
 The compaction of sandy backfill is most easily accomplished when the
material is at or near its optimum moisture content. When backfilling reaches
pipe spring-line, all compaction shall be done first near the trench sides and
proceeds towards the pipe.
 It is recommended that placing and compacting of the pipe zone backfill is
done in such a way as to cause the pipe to ovalize slightly in the vertical
direction.
6. Thrust blocks
RCC thrust blocks will be constructed (common thrust blocks for a ll pipes including product
lines) at the places of bends, tees & reducer. It is recommended to wrap a band of rubber
around the pipe prior to placement of any concrete. Rubber should protrude (25 mm) from
the pipe. Rubber thickness 10 mm & of 50 Durometer. Drawings as given by M/s GIL will be
used for construction. It is always recommended to cast thrust blocks as laying progresses.
Before the hydrotest all thrust blocks should be completed. It is always recommended to have
coupling on two edges when pipe co mes out of thrust block.
Immediately after thrust blocks we should provide one small pipe piece (1 to 2 mtr
length) with coupling on each side of block to take care of uneven settlement.
7. Buoyancy
Minimum cover required on pipe crown to avoid upliftment of empty pipes in high water
table areas is one meter or one diameter which ever is more. If sufficient cover is not
available and the area has the possibility of high water table RCC precast blocks or insitu
blocks of required weight are to be used to counteract unbalance uplift forces.
7.1 River/ Nalah crossing/ road crossing -
We need to encase the pipe min 300 mm all around with M20 grade concrete & balance
portion of the trench should be backfilled with crushed rock preferably. The min bac kfill
cover on the pipe should be 1.5 mtr. Backfill here should be type SC1 preferably upto the
ground level.
7.2 Concrete Encasement:

When pipes (or fittings) must be encased in concrete such as for thrust blocks, stress blocks,
or to carry unusual loads, specific additions to the installation procedures must be observed.
7.3 Flooded trench
When the ground water table is above trench bottom, the water level must be lowered to at
least the trench bottom (preferably about 200 mm below) prior to preparati on of the bed.
Different techniques may be used depending on the nature of the native material .for sandy
and silty soils a system of well point to a header pipe and a pump is recommended. The
spacing between individual well point and the depth at which th ey will be driven depends on
the ground water table and the permeability of the soil. It is important to use a filter around
the suction point (coarse sand or gravel) to prevent clogging of the well -point by fine grained
native material. When native materi al consists of clay and bedrock, well -point will not work.
Dewatering is more difficult to achieve in his case. The use of sumps and pumps is
recommended. If the water cannot be maintained below the top of the bedding, sub -drain
must be provided. The sub -drain should be made using single size aggregate (20 -25 mm)
totally embedded in filter cloth. The depth of the sub - drain under the bed depends on the
amount of water in the trench. If the groundwater can still not be maintained below the bed,
filter cloth should be used to surround the bed (and if necessary the pipe zone area as well) to
prevent it from being contaminated by the native material. Gravel or crushed stone should be
used for bed and backfill. The following cautions should be noted when dewateri ng:
 Avoid pumping long distance through the backfill material or native soil, which could
cause loss of support to previously installed pipes due to removal of material or
migration of the soil.
 Do not turn of the dewatering system until sufficient cover depth has been reached to
prevent pipe flotation
8. Post installation checks:
8.1 Checking the installed pipes
Procedure for checking the initial diametrical deflection for installed pipes:
 Complete backfilling of grade.
 Complete removal of temporary sheeting (if used)
 Turn off the dewatering system (if used)
 Measure and record the pipes vertical diameter.
 Calculate vertical deflection
Actual I.D. - Installed Vertical I.D.

Deflection % = ------------------------------------------------- x 100%
Actual I.D.
Deflection checks should be done when the first installed pipes are backfilled to grade
and continued periodically through out the entire project. Laying sha ll not get too far
ahead before verifying the installation quality. This will ensure early detection and
correction of inadequate installation methods. Pipes installed with initial deflections
exceeding the value given as above, shall be reinstalled so that the initial deflection is less
than the stated values.
Correcting Over Deflected Pipe: Pipes installed with initial diametrical deflections
exceeding the values shall be corrected to ensure the long term performance of the pipe
by re-excavating the re-backfilling with proper case.
Procedure: Excavate near the pipe invert / haunch depth. Excavation just above and at
the sides of the pipe should be done utilizing hand tools to avoid impacting the pipe with
heavy equipment.
Inspect the pipe for damage. Damaged pipe should be repaired or replaced.
Recompact haunch backfill, ensuring it is not contaminated with the native soil.
Backfill to grade and check the pipe deflections to verify they have not exceeded the
values as specified.
8.2 Correction Over –Deflected Pipes

Pipes installed with diametrical deflections exceeding the value in the above table must be
corrected to ensure the long- term performance on the pipe.
Procedure
For pipe deflected up to 8% of diameter:
1. Excavate down to the haunch area, which is approximately 85% of the pipe diameter.
Excavation just above at the sides of the pipe should be done utilizing hand tools
avoid impacting the pipe with heavy equipment.
2. Inspect the pipe for damage. Damaged pipe should be repaired or replaced.
3. Re-compact haunch backfilling, insuring it is not contaminated with unacceptable
backfill material soil.
4. Re-backfill the pipe zone in lifts with the appropriate material, compacting each layer
top required relative compaction density.
5. Backfill to grade and check the pipe deflection to verify they have not exceeded the
initial values in Table 9-1.
6. For pipe deflected greater than 8 % pipe diameter: Pipes with over 8 % deflection
should be replaced completely.
 Caution: Do not attempt to jack or wedge the installed over -deflected pipe into a
round condition. This may cause damage to the pipe.
If excavating multiple pipes, care must be taken to not mound the cover from one pipe
over the adjacent one. The extra cover and reduction of side support could magnify an
over- deflected situation.
Important note
For further assistance, Please contacts GIL. Ph.o2553-229400.

Method statement for field hydro -test of GRP/FRP PIPE .
Method statement for field hydro -test of

GRP/FRP PIPE.
GRAPHITE INDIA LIMITED, NASHIK. INDIA
[Type text]
Method statement for field hydro -test of GRP/FRP PIPE.
Field Hydro-testing:
Some job specifications require the completed pipe installation to be hydrostatically tested
prior to acceptance and service. This is good practice as it can permit early detection
and correction of some installation flaws, damaged products, etc. If a field hydro-test is
specified, it must be done regularly as installation proceeds. Good construction practice
would be to not exceed pipe testing with installation by more than approximately 1000 mtrs
in order to properly assess the quality of work. The first field hydro-test should ideally
include at l east one air valve or drainage chamber to assess the total pipeline system.
In addition to routine care, normal precautions and typical procedures used in this
work, the following suggestions should be noted:
Preparation Prior to Test – Inspect the comple ted installation to assure that all work has been
finished properly. Of critical importance are:
• Initial pipe deflection limited to the values specified.
• Joints assembled correctly.
• System restraints (i.e., thrust blocks and other anchors) i n place and properly cured.
• Flange bolting torqued as per instructions.
• Backfilling completed.
• Valves and pumps anchored.
• Backfill and compaction near structures and at closure pieces, has been properly carried
out.
Filling the Line with Water – Open the valves and vents, so that all air is expelled from the
line during filling, and avoid pressure surges.
Pressurize the line slowly. Considerable energy is stored in a pipeline under pressure, and
this power should be respected.
Ensure the gauge location will read the highest line pressure or adjust accordingly. Locations
lower in the line will have higher pressure due to additional head.
Normally the field test pressure is either 1.5 times of the working (operating) pressure or the
operating pressure plus a small incremental amount. However, in no case should the
maximum field test pressure exceed 1.5 x PN.
[Type text]
If after a brief period for stabilization the line does not hold constant pressure, ensure
that thermal effect (a temperature change), system expansion or entrapped air is not the
cause. If the pipe is determined to be leaking and the location is not readily apparent,
the following methods may aid discovery of the problem source:
• Check flange and valve areas.
• Check line tap locations.
• Test the line in smaller segments to isolate the leak.
A typical field hydro -test for buried / Underground pipeline
Unless there is no findings which prevent the test from continuing, the
segment/system shall be further pressurized to a field test pressure as per
specification 1.5 times of working pressure.
* THIS TEST PRESSURE SHALL BE MAINTAINED FOR
A PEROD OF MAXIMUM THIRTY MINUTES AFTER PRESSURE STABILZATION
Thorough inspection shall be made as FINAL INSPECTION. After the test pressures is
reached then check for any drop in pressure.
Fill up the inspection sheets accordingly.
The test shall be considered as “PASS” if no signs of leakage are observed; the
inspection sheet(s) shall be signed by the authorities .
POST HYDROTEST:
After completion the test, open all the vent valves. Drain or flush out the filled water from
the pipe segment/ system through drain valves . This pressure release shall be made
slowly@ 2bar/ 5minutes.
Remove the end cap from the segment as per procedure and close the same with
[Type text]
temporary cover to avoid any particles from e ntering inside the line. GIL
Installation/Site engineer will advice you in this process.
Prepare the pipe end to be ready for next installation.
Connect the adjacent segment ends with closure pipe piece.
Continue the installation for the other segments & conduct the hydro test in the similar
manner as described earlier, k eep connecting the segments through closure spools.
Note:
For further assistace please contact to GIL 02553-229400.
[Type text]
Bharat Heavy Electricals Limited
Piping Centre Chennai-17
ENGINEERING AND R&D
Specification Number Revision Number Sheet Number

PC:E:PU:001 01 1 of 15
Standard Technical Specification for Elastomeric Polyurethane Coating

for Mild Steel Pipe Line in contact with Sea Water
APPLICABLE TO UTILITY AND INDUSTRIAL UNITS
Adhesive
01 07.12.09 Strength and C.Kumar C.Karunakaran C.Karunakaran
hardness
changed
00 05.05.09 Fresh Issue C.Karunakaran C.Karunakaran S.Jayakumar
Rev Date Alteration Prepared Checked Approved

ENGINEERING AND R&D

PC:E:PU:001 01 2 of 15
CONTENTS
1 SCOPE
2 QUALIFICATION CRITERIA
3 CODES AND STANDARDS
4 GENERAL REQUIREMENT
5 COATING MATERIAL SPECIFICATION
6 SURFACE PREPARATION
7 PRIMING APPLICATION PROCEDURE
8 COATING APPLICIATION PROCEDURE
9 FIELD JOINT
10 INSPECTION AND TESTING
11 DOCUMENTS TO BE SUBMITTED WITH OFFER
12 RECORDS OF REVISION
ENGINEERING AND R&D

PC:E:PU:001 01 3 of 15
Technical Specification for Elastomeric Polyurethane Coating

for Mild Steel Pipe Line in contact with Sea Water
1 SCOPE
This specification covers the general requirements for materials, equipment,

application, inspection, testing, repair and handling aspects associated with the
coating of using 100% solids (solventless) two component, fast curing
elastomeric polyurethane coating classified under ASTM D-16, Type V. The
coating process of straight pipes/fittings shall be carried out at shop with
necessary cut-back areas at both ends of pipe and fittings for field jointing.
2 QUALIFICATION CRITERIA
2.1 The bidder must have executed such type of coating applications at least for two
identical or validly similar installations for sea-water service and that must have
been in service satisfactorily for at least two years.
2.2 Bidder shall furnish the reference list for coating material, application along
with the offer.
2.3 In case the bidder do not possess the requisite experience criteria as specified in
clause 2.1, alternatively bidder can submit the experience criteria of his
principal/collaborator or his associate experience with the principal/collaborator
for execution of such type of coating job. In such case, the back up guarantee
shall be extended by the principal to the bidder for execution of such coating job
covering selection of material, coating equipment, application procedure. This
shall be submitted along with the offer.
ENGINEERING AND R&D

PC:E:PU:001 01 4 of 15
3 CODES AND STANDARDS
The work shall conform to the following documents: (latest revision..)
3.1 SSPC-SP-1 Solvent cleaning

Nov.1, 1982
3.2 SSPC-SP-10/NACE Near white blast cleaning

Nov.2,Sep.15,1994
3.3 SSPC-SP-COM Surface preparation commentary

July 1, 1995
3.4 SSPC PA2 Measurement of dry paint thickness with

magnetic gauges
3.5 ASTM D 4541 Method for pull off strength of coatings using
Portable adhesion testers
3.6 RP 0188-90 Holiday testing
3.7 RP 0169-94 NACE International

Control of external corrosion on underground
Of submerged metallic piping systems
3.8 RP 0675-88 NACE International

Control of External corrosion on offshore steel
Pipelines
3.9 ANSI/AWWA C222 Polyurethane coating for the interior and exterior of
Steel water pipe fittings.
4 GENERAL REQUIREMENT
4.1 The bidder shall perform all work in accordance with this specification and other
requirements noted herein.
4.2 It is envisaged that the polyurethane on the steel surface will provide a hard yet
flexible, impermeable barrier with outstanding adhesion, impact and abrasion
ENGINEERING AND R&D

PC:E:PU:001 01 5 of 15
resistance to protect the surface, from corrosion and abrasion in the operating
conditions of sea water handling.
4.3 Bidder shall submit a detailed written description in the form of manual covering
coating equipment, procedure. materials, inspection, tests and repair etc. for
BHEL’s approval.
4.4 PROCEDURE QUALIFICATION
Applied coating will be tested for dry film thickness and adhesion. All coating
operations shall be performed after the pre-qualification test carried out on 5
pipes.
4.4.1 The following coating parameters shall be recorded during procedure

qualification test.
Spray tip(nozzle) size

Fluid pressure
Temperature of the activator and base
Speed of the painting boom
Pipe rotation speed
Number of passes
4.4.2 The following tests shall be carried out on each pipe during pre-qualification.
Inspection of blast cleanliness and profile using Press-O-Film.

Inspection of inside pipe for evacuation of blast abrasive.
Visual inspection of coating.
Coating thickness inspection.
Holiday inspection.
4.4.3 The following tests shall be carried out on one pipe after curing.
Adhesion test
4.5 The bidder shall provide access, during all phases of work to BHEL and their
representatives.
ENGINEERING AND R&D

PC:E:PU:001 01 6 of 15
4.6 The materials shall be applied by airless spray system, as per the standards
specified by the material manufacturer.
4.7 The bidder has to install all preventive equipments necessary to avoid health
and fire problems. All safety precautions warranted by good industrial hygiene
practices and regulated by local, state or central laws must be taken into
consideration while applying these coatings.
5 COATING MATERIAL SPECIFICATION
5.1 Primer
The following is approved primer for the elastomeric urethane coating.
Two component, chemical cure, urethane primer
Other primers, if recommended by material manufacturer, shall be used only

after approval by BHEL.
5.2 Spray applied impermeable, 100% solids, elastomeric aromatic urethane

coating, as per ASTM D-16, Type V (two components, chemical cure) shall
meet following criteria. All tests shall be at ambient (25°C) condition unless
otherwise specified.
5.2.1 Nominal thickness : 2000 microns
5.2.2 Tensile strength as per ASTM D-638 : 17 N/mm²(min.)
5.2.3 Adhesion ASTM-D-4541 : 10 N/mm²

(Elcometer pull off)
5.2.4 Recoverable elongation ASTM D-638 : 10% (min.)
5.2.5 Surface Hardness as per : 60 (min.)

ASTM D-2240 (Cured Film-Shore D)
5.2.6 Water vapour permeability as per : 0.3 gm / 24 hr / M²(max.)

ASTM E-96 / F-1249-90
ENGINEERING AND R&D

PC:E:PU:001 01 7 of 15
5.2.7 Operating temperatures : 0°C to 60°C

5.2.8 Salt spray test 6000 hour as per : No effect
ASTM B 117-73
5.2.9 Impact resistance as per ASTM G-14 : 0.23 x 10 gm – cm (min.) or

200 inch – lb (min.)
5.2.10 Abrasion resistance ASTM D 4060/ : Weight loss 0.05 gm max.

FTMS 141 Taber Abrasion 11-10
Wheel 1,000 gm, 1,000 cycles
5.2.11 Flexibility as per ASTM D 1737 : No effect bending through

Pass over 12 mm mandrel
180° bend – 0.5inch thick

plate coated with 0.5mm
thick coating
5.2.12 Cathodic Disbondment (ASTM G-8) : Pass <5mm (28 days @

25 Deg C)
5.2.13 Accelerated weathering ASTM G-154/ : No effect except some

BS-3600, 2000 Hrs discoloration.
5.2.14 Chemical Resistance: ASTM D 543

Immersion of 30 days in sea water
followed by
(%)weight change : < 1.0%
(%) Hardness (Shore D) change : < 5.0%
(%) Tensile strength change : < 5.0%
5.3 The bidder shall furnish copies of test reports conducted by an

internationally reputed test agencies evidencing that materials conform to
minimum performance requirements as above along with the offer.
ENGINEERING AND R&D

PC:E:PU:001 01 8 of 15
5.4 The bidder shall also furnish test reports conducted for each manufacturing
lot/batch. One sample copy shall be furnished with offer.
6 SURFACE PREPARATION
6.1 The steel surface shall be blast cleaned to SSPC SP-10/NACE No.2 near
white blast cleaning.
6.2 A near-white blast cleaned surface, when viewed without magnification,

shall be free of all visible oil, grease, dust, dirt, mill scale, rust, coating,
oxides, corrosion products and other foreign matter, except for staining.
6.3 Random staining shall be limited to not more than 5 percent of each unit area
of surface and may consist of light shadows, slight streaks, or minor
discolorations caused by stains of rust, stains of mill scale or stains of
previously applied coating.
6.4 Acceptable variations in appearance that do not affect surface cleanliness

include variations caused by type of steel, original surface condition,
thickness of the steel, weld metal, mill or fabrication marks, heat treating,
heat affected zones, blasting abrasive, and differences in the blast pattern.
6.5 Anchor profile obtained by blast cleaning will be >75 microns when
measured with a surface profile gauge such as Elcometer 123.
6.6 The bidder shall immediately bring BHEL’s attention any unacceptable
metal defects detected at the time of surface preparation and hold the steel
piece till such time as cleared for further action.
6.7 Compressed air used for blast cleaning shall be clean, dry and free of
moisture and oil. Moisture separators, oil separators, traps or other
equipment may be necessary to achieve clean, dry air.
6.8 Blast cleaning operations shall be done in such a manner that no damage is
done to partially or entirely completed portions of the work.
6.9 Dry blast cleaning shall not be conducted during times when the surface will
become wet after blast cleaning or when ambient conditions are such that
ENGINEERING AND R&D

PC:E:PU:001 01 9 of 15
visible rusting occurs before coating. If any rust forms after blast cleaning,
the surface shall be re-blasted before coating.
6.10 Before blast cleaning, visible deposits of oil and grease shall be removed in
accordance with SSPC SP-1.
6.11 Before blast cleaning, any surface imperfections remaining (after fabrication)
such as sharp pins, weld spatter, or burning, slag shall be removed from the
surface
6.12 Any of the following methods of surface preparation may be used to achieve
a near white blast cleaned surface.
6.12.1 Dry abrasive blasting using compressed air, blast nozzles and abrasive.
6.12.2 Dry abrasive blasting using a closed cycle, re-circulating abrasive system,
with compressed air, blast nozzle and abrasive, with or without vacuum for
dust and abrasive recovery.
6.12.3 Dry abrasive blasting using a closed cycle, re-circulating abrasive system
with centrifugal wheels and abrasive.
6.13 Wet abrasive blasting shall not be permitted by this specification.
6.14 Steel grit (not shot), non-metallic mineral abrasive – silica sand, garnet,
staurolite and olivine, as well as by product abrasive – coal slag are approved
abrasive media for blast cleaning. No other abrasive media shall be used by
the bidder without prior approval. Selection of abrasive media for the
blasting operation will depend upon the type of system employed. Bidder
shall adopt good blasting practices such as those recommended in SSPC SP-
COM.
6.15 The cleanliness and size of recycled abrasive shall be maintained to ensure
compliance with this standard.
6.16 The blast cleaning abrasive shall be dry and free of oil, grease and other
contaminants.
ENGINEERING AND R&D

PC:E:PU:001 01 10 of 15
6.17 Bidder shall use abrasive media of size that will ensure the necessary anchor
profile height specified. The maximum size of abrasive media permitted
under this specification is 16 mesh screen, U.S. series.
6.18 Visible deposits of oil, grease or other contaminants shall be removed

according to SSPC SP-1.
6.19 Dust and residues shall be removed from prepared surface by brushing,
blowing off with clean, dry air or vacuum cleaning. Moisture separators, oil
separators, traps or other equipment may be necessary to achieve clean, dry
air.
7 PRIMING APPLICATION PROCEDURE
7.1 Priming shall not be done when ambient conditions are dusty or condusive
to condensate formation on the steel substrate.
7.2 Before beginning priming and coating, measure the humidity using a sling
psychrometer and calculate the dew point. The relative humidity must be
lower than 85%. Temperature of steel surface must be at least 3°C higher
than the dew point. Under controlled conditions, it is possible to heat the
steel surface to eliminate condensation problems.
7.3 The type of primer used shall be as described in the coating specification.
7.4 The blast cleaned steel shall be primed preferably within 2 hours of after blast
cleaning, but not more than 24 hours and under no circumstances, shall the
primer be applied to a surface where corrosion has occurred.
7.5 Primer shall be sprayed on to the cleaned surface in a fog coat, as thin as
possible (approx. 25-30 microns wet), so as to tint but not mask the colour of
the substrate. The primer on application shall be free from runs or drips or
areas of excessive thickness.
7.6 The primed surface shall be protected so that it will not come into contact
with rain, dust or other substances until completely hardened and coated with
the elastomeric urethane top coat.
ENGINEERING AND R&D

PC:E:PU:001 01 11 of 15
7.7 The time interval between the application of primer and polyurethane coating
shall be as recommended by the manufacturer.
8 COATING APPLICATION PROCEDURE
8.1 100% solids, two component elastomeric urethane are specialized coatings
characterized by very short pot lives. The coating shall be applied only by
applicators who have been trained and certified by the coating manufacturer
and who possess the necessary specialised equipment and trained crew
required for their application.
8.2 Nominal thickness of the elastomeric urethane shall be 2000 microns. The
finished coating shall be generally smooth and free of sharp protuberances.
A minor amount of sags, dimpling and “curtaining” which otherwise meets
specification requirements shall not be considered cause for rejection.
8.3 Equipment for the spray application shall be airless spray equipment with
system specification meeting minimum specified by the coating
manufacturer. Equipment shall consist of material feed pumps, purge pump,
proportioning pump, mix manifold, static mixer, interconnecting hoses etc.
System shall normally be capable of 1500-3000 psi fluid pressure (at tip) and
a material supply rate of 4-10 litres/minute.
8.4 Applicator must follow standard written instructions from coating

manufacturer on material storage, handling and spray.
8.5 Partially used and unused material drums must be tightly sealed and contain a
blanket of nitrogen to prevent moisture contamination when not in use. Use
a log sheets for the mix no. and test piece shall be maintained.
8.6 Before application on the substrate apply a test patch for runs or drips and gel
time as well as tack free time. Test for adhesion if in doubt.
8.7 The proportioning pump shall be fitted with a numeric counter to keep track
of the volume (the proportioning pump delivers a precise volume of
materials per stroke) of materials being used while spraying. The applicator
shall calculate the steel “unit” area, material volume and counter numbers
required, approximate speed (litres / minute) based on spray size as well as
ENGINEERING AND R&D

PC:E:PU:001 01 12 of 15
number of passes and spray coating materials according to these criteria.

While applying on the joints after installation, same process shall be
followed.
8.8 Entire thickness shall be built up in a single application (with a number of

passes). If the surface is large enough to require more than one day for the
coating, the edges of the coated areas shall be feathered and roughened with
a grinding tool prior to beginning priming and coating.
8.9 Areas not to be coated shall be masked with disposable plastic sheets,
cardboard etc.
8.10 Any holidays or skips shall be repaired with elastomeric urethane hand mix
kit with slower pot life after roughening the edges.
9 FIELD JOINT
9.1 Standard Hold backs
When the pipe sections are joined together by field welding, a holdback that
is free of interior or exterior coating shall be left uncoated. This holdback
shall be of sufficient width, as required by the constructor, to permit the
making of field joints without damage to the interior or exterior coating.
9.2 Protection During Welding
During the welding process the coating shall be protected from welding
sparks and spatter using a nonflammable protective barrier. Any coating
damaged by the welding process shall be repaired as per Section-8 of this
specification. This repair may be made at the same time the welded joint is
being coated.
9.3 Surface Preparation
After welding, the joint shall be cleaned so as to be from mud, oil, water,
grease, welding flux, weld spatter, dust, and loose residues. The cleaned
metal surfaces of the joint shall then be abrasive blast cleaned to provide a
surface that complies with Section-6. Other methods of surface preparation
shall be permitted as long as they provide the same surface as defined in
ENGINEERING AND R&D

PC:E:PU:001 01 13 of 15
Section-6. The existing coating shall be abraded approximately 1 to 2 in (2.5

to 5 cm) from the edge of holdback so that a surface profile in the existing
coating meets the manufacturer’s recommendations. The entire area to be
coated shall be clean, dry and uncontaminated.
9.4 Coating Application:
The coating system shall be applied to the welded joint in accordance with
Clause F. The joint material may be the originally applied coating or another
material designed specifically for joint coatings as approved by the
manufacturer. Apply joint materials to the same thickness or greater as
originally specified for the main coating system.
9.5 Material selection at the option of the purchaser, weld areas may be protected
with materials and methods conforming to ANSI/AWWA C217 and
ANSI/AWWA C222 that are compatible with the originally applied coating
material.
10 INSPECTION AND TESTING
10.1 All work under this specification shall be subject to inspection by BHEL or
its representatives. All parts of work shall be accessible. The bidder shall
correct such work as is found defective under the specifications.
10.2 The following tests shall be made by the applicator prior to during and after
priming and coating application.
10.2.1 Blast surface profile using elcometer 123 or equivalent surface profile gauge.
The average of readings from five randomly selected areas shall constitute the
average surface profile. Test area to be flat (without culvature).
10.2.2 The dry film thickness shall be checked with a magnetic mil gauge (positest
by Defeisko or equivalent). The average of readings from five randomly
selected areas shall constitute the film thickness. Individual readings shall
not vary by more than 25% from the mean.
ENGINEERING AND R&D

PC:E:PU:001 01 14 of 15
10.2.3 Holidays testing using high voltage holiday detector (Tinker Rasor or
equivalent) as per NACE International RP 0188-90 “Holiday Testing”.
Coating to have cured at least 24 hours prior to holiday test. Due care should
be taken not to use voltage exceeding the dielectric strength of the coating.
The location of the holidays shall be noted on the coated surface for repair.
10.3 Pull of Adhesion to steel shall be measured using Elcomeer/ Postitest /

Equivalent adhesion tester as per ASTM D 4541. Average reading from three
(3) randomly selected spots shall constitute one test and shall be at least 10
(ten) N/mm2. Adhesion test shall be carried out on fully cured coating (7
days at 25 Deg C) & on flat (without curvature) test area.
Minimum 5 nos. tests shall be carried out in one (1) Km at locations desired
by Engineer in charge/site engineer/Project Manager on behalf of Employer.
If the adhesion is not satisfactory, a systematic inspection (adhesion test) of
all pipe shall be carried out and all pipes not meeting this adhesion
requirement shall be rejected. Damaged test areas of acceptable pipe shall be
repaired as indicated in clause above. The rejected pipes shall be cleaned by
blasting and re-coated.
10.4 All previously carried out test-certificates on material shall be furnished for
Employer’s scrutiny that have done already by manufacturer.
11.0 DOCUMENTS TO BE SUBMITTED WITH OFFER
a) Coating material details (test reports, (Cl.5.3)
b) Application Procedure (Cl.4.3)
c) Experience (Reference List) for the coating material(Cl.1.2.2)
d) Experience (Reference List) for the applicator(Cl.1.2.2)
e) Sample test reports that will be furnished along with material supply
(Cl.5.4)
f) Quality Plan
ENGINEERING AND R&D

PC:E:PU:001 01 15 of 15
12.0 RECORDS OF REVISION
Rev 01 clause no.5.2.3, 5.2.4, 5.2.5, 5.2.11, 5.2.13 corrected.
5.2.12 Added.
Section 9 from 9.1 to 9.5 added.

TO BE RECOMPACTED
WORK STILL TO BE DONE FOR GRP

PIPING UNIT-2

Vol IE Tender Drawings

Загружено:

Сведения о документе

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Vol IE Tender Drawings

Загружено:

Авторское право:

Доступные форматы

T E N D E RS P E C I F I C A T I O N

VOLUME-I-E – Tender Drawings-1145

BHARAT HEAVY ELECTRICALS LIMITED

CIVIL WORKS RELATED TO REPAIR OF GRP PIPE LINE FOR CW SUPPLYAND

EARNEST MONEY DEPOSIT: Please see Notice Inviting Tender.

For Bharat Heavy Electricals Limited

GRP SEA WATER PIPING SYSTEM – 700MW CCPP PIPAVAV PROJECT .

GRAPHITE INDIA LIMITED, NASHIK. INDIA

4.1 Transportation and handling of GRP/FRP Pipes.

4.2 Handling of nested pipes:

We propose to nest various diameter pipes during transportation.

4.3 Storing & Stacking of Pipe

The “EVERFLOW” pipe can be stacked easily, with small precautions.

Storing & Stacking of Pipe

 Apply lubricant on gasket that will facilitate easily fixing of coupling to

 Cleaning Coupling Installing Gaskets Cleaning over Gaskets Pipe

5.1 BED & Pipe Zone Backfill Materials

5.2 Use of Native Soils

 Where compaction is specified: the native s oil must be granular in nature.

5.3 Pipe Bedding

 Pipe bedding material shall be sand or gravel in accordance to the

5.4 Pipe Jointing in the Trench

5.5 Backfilling Pipe:

 Proper backfilling should be done in 150 mm to 300mm lifts depending on

7.1 River/ Nalah crossing/ road crossing -

7.2 Concrete Encasement:

7.3 Flooded trench

8. Post installation checks:

8.1 Checking the installed pipes

 Complete backfilling of grade.

 Complete removal of temporary sheeting (if used)

 Turn off the dewatering system (if used)

 Measure and record the pipes vertical diameter.

 Calculate vertical deflection

Actual I.D. - Installed Vertical I.D.

8.2 Correction Over –Deflected Pipes

For further assistance, Please contacts GIL. Ph.o2553-229400.

Method statement for field hydro -test of

GRAPHITE INDIA LIMITED, NASHIK. INDIA

Method statement for field hydro -test of GRP/FRP PIPE.

• Initial pipe deflection limited to the values specified.

• Joints assembled correctly.

• Flange bolting torqued as per instructions.

• Valves and pumps anchored.

• Check flange and valve areas.

• Check line tap locations.

• Test the line in smaller segments to isolate the leak.

A typical field hydro -test for buried / Underground pipeline

Specification Number Revision Number Sheet Number

Standard Technical Specification for Elastomeric Polyurethane Coating

APPLICABLE TO UTILITY AND INDUSTRIAL UNITS

00 05.05.09 Fresh Issue C.Karunakaran C.Karunakaran S.Jayakumar

Rev Date Alteration Prepared Checked Approved

Specification Number Revision Number Sheet Number

3 CODES AND STANDARDS

5 COATING MATERIAL SPECIFICATION

7 PRIMING APPLICATION PROCEDURE

8 COATING APPLICIATION PROCEDURE

10 INSPECTION AND TESTING

11 DOCUMENTS TO BE SUBMITTED WITH OFFER

Specification Number Revision Number Sheet Number

Technical Specification for Elastomeric Polyurethane Coating

This specification covers the general requirements for materials, equipment,

Specification Number Revision Number Sheet Number