PIPELINES CONSTRUCTION

MANAGEMENT
 PIPELINE CONSTRUCTION
MANAGEMENT
Activities of Pipeline
construction
PROCEDURE
Right of Way clearing and grading
Delivery, Transportation, Handling,
Hauling, Stringing of pipes
Trenching Normal & Rock
Bending
Lining up and Welding
Radiographic Inspection
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MANAGEMENT
Activities of Pipeline
construction
Application of Joint Coating
Lowering & back filling
Tie-ins
River and Road crossings
Cleanup and Restoration of ROW
Air Pigging cleaning and Gauging
Hydrostatic testing
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MANAGEMENT
Activities of Pipeline
construction
De watering cleaning and Swabbing
Golden Tie ins
Valve installation
Caliper survey and dent repairs
Line Preservation
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MANAGEMENT
WORK PROCEDURE
Purpose:
The purpose of work procedure is to
stipulate the method that shall be used
for a particular activity covering even
minute steps in details.
 The work procedure is to be prepared by agency
responsible for execution of work.
 The work procedure is examined criticaly and
approved by owner/owner representative.
 No deviation from work procedure is
accepted.
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MANAGEMENT

NEED FOR WORK PROCEDURE

It helps:
1.In clearly defining the procedure to be
adopted in execution of activity.
2.In establishing QAP a tool for
inspection.
3.In developing records for future
reference.
4.In case of any dispute arising
at later
stage.
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MANAGEMENT
 PIPELINE CONSTRUCTION
MANAGEMENT
Document Number TITLE/Remarks
XX/WP/100 Survey,Clearing & Grade
XX/WP/101 Trench
XX/WP/102 Blasting
XX/WP/103 Pipe Handling And Stringing
XX/WP/104 Bending
XX/WP/105 Concrete coating by casting procedure
XX/WP/106 Tie-in
XX/WP/107 NDT Procedure for Mainline Welding
XX/WP/108 Applications of Heat shrinkable sleeves
XX/WP/109 Lowering in and rock shield applications
XX/WP/110 Backfill
XX/WP/111 Cathodic protection installation
XX/WP/112 Pre testing of Pipeline crossings
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Document Number TITLE/Remarks
XX/WP/113 Pipeweld numbering
XX/WP/114 Casting and placing of precast weights
XX/WP/115 Concrete coating of pipes impingement method
XX/WP/116 handling over coated pipes at Coating yard
XX/WP/117 Cased crossings
XX/WP/118 Repair of accidental arc strikes
XX/WP/119 TCP
XX/WP/120 Ultrasonics
XX/WP/121 DP & MPI
XX/WP/122 final cleanup and restoration
XX/WP/123 Open cut Crossings
XX/WP/124 Major River crossings
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MANAGEMENT
ROW Clearing and Grading
Centre line of ROW is marked based on IP and TP
fixed during detailed route survey
Wooden pegs are put on either side of the center
line at a distance of 9 meters for 18 m ROW.
ROW width is kept as 6 m on left of Pipeline for
storing the excavated soil and 12 m on right side
for movement of equipments.
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MANAGEMENT
ROW Clearing and Grading
Dozer with flat front blade is used to clear the
vegetation and trees
Prior information to land owners to clear the land
of their crops before entering
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MANAGEMENT
Transportation Handling and Stringing
of the Pipes
To prevent transit damage nylon rope rings are tied
at every three meter distance
Profiled wooden supports are required to place first
layer of the pipes on the trailer
To avoid damage to pipe bevel, though the bevel
protectors are provided on pipe ends, crane
hooks shall be provided with rubber pads for
additional safety.
Careful stacking of pipes over sand bags, visual
inspection of bevel ends to avoid welding
defects.
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MANAGEMENT
TRENCHING
In cultivable land, to strip top soil (30 cm depth) & store separately along ROW for
replacement on top of backfilled ditch.
Provide suitable crossings across open ROW for land owners/ public.
Width of trench : Pipe OD + 300 mm.
Depth of trench to be measured from original ground/ graded surface/ top of road/
bottom of rail, whichever is lower.
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MANAGEMENT
TRENCHING
Provide 300 mm additional cover where pipeline is within 15 m of private dwelling,
industrial buildings or public places.
Provide temp. diversions/ bridges at road crossings to allow passage of normal traffic
with min. inconvenience.
Provide warning/ traffic signs, lights, barricades, fencing, watchmen as required by local
authorities.
Provide extra depth to fit min. radius of bend at crossings.
 COVER TO PIPELINE
Sl. Location Min. Cover
No. (m)
1 Industrial, Commercial, Residential Areas 1.25
(Normal Terrain)
2 Uncased/ Cased Road Crossings 1.25
& Cart-Track Crossings
3 Railway Crossings 1.70
4 Normal Terrain / Drainage ditches at Railways, 1.20
Highways etc.
5 Minor Water Course Crossings 1.50
6 Marshy Areas/ Water reservoir Areas/ Ponds 1.50
7 Submerged River Crossings 2.50
8 Rocky Areas 1.00
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MANAGEMENT
BENDING
Cold field bends for change of vertical & horizontal
alignment by using bending machine & mandrel.
Bends to be made without causing wrinkles, buckles,
stretching & damage to pipe coating.
Bending procedure to be established including step
length & max. degree per pull per foot (0.9550 for
18” OD pipes).
Over bends to be made to clear high points of the
trench bottom.
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MANAGEMENT
BENDING
Sag bends to fit the bottom of the trench.
Side bends to leave min. clearance to trench wall.
Radius of curvature > 40 D upto 18” OD & > 60 D for
above 18” OD pipes.
End of bend should not be closer than 2 m from
girth
weld or pipe end.
Bends to be installed by positioning longitudinal
welds in upper quadrant.
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MANAGEMENT
BENDING
Ovality of bent pipe < 2.5 % of nominal dia. at any
point; to be checked by passing a gauge consisting
of two discs of 95% nominal pipe internal dia.
To layout pipes in such a way that Nos. of pieces cut off
less than 2 m are held min.
No Mitre bends are permitted.
Hot pulled bends may be used in unavoidable
circumstances.
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MANAGEMENT
MAINLINE WELDING
STANDARDS/CODES.
WELDING TECHNIQUES.
WELDING PROCEDURES.
WELDER’S
QUALIFICATION TEST.
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MANAGEMENT
STANDARDS/CODES
FOLLOWING STANDARDS/CODES ARE REFFERED IN INSPECTION &
TESTING OF WELD.

 API 1104, Welding of pipelines and related facilities.

 ASME Sec IX, Boiler & Pressure vessel Code.
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MANAGEMENT
Destructive Test
A) Tensile strength test

B) Nick break test

C) Root, face and side bend test

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MANAGEMENT
Radiography
Scope of work includes 100% Radiographic inspection of all joints for the
initial 1 Km of the pipeline in each spread. For balance portion of the pipeline
,20% of all joints shall be radio-graphically inspected except for specific
crossings and tie-ins which need 100% radio-graphic inspection
 PIPELINE CONSTRUCTION
MANAGEMENT
JOINT COATING
COATING CLEARANCE IS AVAILABLE FROM
RADIOGRAPHY CREW.
HUMIDITY <85%, IF BETWEEN 75% TO 85% PREHEAT
BEFORE BLASTING.
CLEANING OF JOINT AREA AND ADJACENT
COATING DONE UPTO 100MM ON CTE COATING ON
BOTH PIPES
CHAMPER THE PIPE COATING TO AN ANGLE<30
PREHEAT THE WELDED JOINT AREA TO 60-80 C
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MANAGEMENT
JOINT COATING
SANDBLASTING IS DONE UPTO 100 MM ON CTE
COATING ON BOTH PIPES
ENTIRE SAND BLAST SURFACE IS FREE FROM
MOISTURE.
THE ROUGHNESS OF SAND BLASTED SURFACES IS
BETWEEN 50-70 MICRON AS MEASURED BY
PRESS-O-FILM/ELCOMETER.
PART A(60+10ml)PRIMER & PART B(30+10ml) EPOXY
IS MIXED FOR MIN 30 SEC
PREHEATING OF PIPE TO A TEMPERATURE OF 60-80o
C DONE.
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MANAGEMENT
JOINT COATING
THE OVERLAP POSITION OF THE SLEEVE IS AT 2 OR
10 ‘O’ CLOCK.
WET FILM THICKNESS OF PRIMER IS BETWEEN 50-70
MICRONS.
SIDE OF OVERLAP PORTION HEATED & PRESSED
WITH SILICON ROLLERS.
THE CLOSURE PATCH IS HEATED, PRESSED &
SEALED ON THE SLEEVE.
DIRECTION OF FLAME IS CIRCULAR & FROM
ONE
END TO OTHER END.
THE SLEEVE IS COMPLETELY SHRUNK AND
CONFORMS TO PIPE
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MANAGEMENT
JOINT COATING
SLEEVE IS FREE FROM WRINKLES, COLD SPOTS,
ENTRAPPED AIR IS EXPELLED BY HEATING &
PRESSING WITH ROLLER OR BY HAND.
THICKNES OF SLEEVE ON WELD SEEM IS MIN 1.7MM
AND ON PARENT METAL IS MIN 2MM.
PEEL TEST DONE ONE IN EVERY 100 JOINTS OR
DAY’S PRODUCTION WHICHEVER IS LOWER ON
SUBSEQUENT MORNING.
 PIPELINE CONSTRUCTION
MANAGEMENT
JOINT COATING
PEEL TEST PROCEDURE
PEEL SIZED 1” BY 8” PEEL CUT UPTO BARE PIPE

ANY LOCATION- AT WELDED SEAM, ON PIPE AND

ON CTE COATING
FAILS IF PEEL OF FORCE IS LESS AT OBSERVED
TEMP. OR ADHESIVE LAYER OF SLEEVE IS PEELED
OFF FROM PIPE.

PEEL TESTED PORTION IS REPAIRED.

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MANAGEMENT
PIPELINE LOWERING IN TRENCH
Before lowering of pipeline in the trench,
To clear the trench of all debris, stones, pipe cut pieces, welding rods, hard clods, skids
etc. before lowering of pipeline.
To drain out water from the trench (if any) to avoid floatation.
To carry out complete check by full circle holiday detector.
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MANAGEMENT
PIPELINE LOWERING IN TRENCH
Before lowering of pipeline in the trench,
To repair all coating damages.
To provide sand padding (150 mm thick) free from gravel/ pebbles in rocky areas.

Pipeline to be lifted & laid by using non-abrasive material (Teflon) coated hooks.
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MANAGEMENT
PIPELINE LOWERING IN TRENCH
Before lowering of pipeline in the trench,

No sling to be put around field joint coating.

Adequate Nos. of side booms to be used for holding the
pipeline in gentle S-curve maintaining elastic bend
radius.
Pipeline not to be laid in tension. Trench to be rectified
(if required) so that the pipeline fits the excavation
and rests on the trench bed.
To avoid movement of pipeline in the trench.
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MANAGEMENT
PIPELINE LOWERING IN TRENCH
BACKFILLING OF PREVIOUS SECTION HAS BEEN
COMPLETED.
LOWERING CLEARANCE FROM JOINT COATING
SITE IS AVAILABLE.
RADIOGRAPHY CLEARANCE FOR LEFT OUT
JOINTS IS AVAILABLE.
COATING CHECKED VISUALLY FOR DEFECTS AND
REPAIRS DONE, IF REQUIRED.
HOLIDAY DONE AT 15 KV
DEPTH AT 4 LOCATIONS IS CHECKED AND FOUND
.1.5 M
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MANAGEMENT

PIPELINE LOWERING IN TRENCH

WIDTH CHECKED AT BOTTOM OF TRENCH AT 4
LOCATIONS AND FOUND . 1.2 m
TRENCH BOTTOM IS FREE FROM ROCKY STRATA
SOFT PADDING ON THE BOTTOM OF TRENCH
DONE
NIGHT CAPS ARE PROVIDED ON OPEN ENDS OF
PIPE SECTION.
SLING OF SIDE BOOM IS NOT BE ON FIELD JOINT
COATING.
PIPE IS LOWERED IN THE RIGHT SIDE OF THE
TRENCH.
DISTANCE OF HDPE PIPE FROM MAIN PIPE IS
400MM.
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MANAGEMENT
PIPELINE LOWERING IN TRENCH
SPIKES PROVIDED AT 10 M INTERVAL ALONG THE
ROUTE OF HDPE PIPE.
SPIKE REMOVED AFTER PADING.
WARNING TAPE IS LAID AT 400 MM ABOVE HDPE
PIPE
 PIPELINE CONSTRUCTION
MANAGEMENT
Tie- Ins
The gaps which are left out during mainline welding due to road/railway
crossing, canal/river crossings etc are connected in the form of Tie-in joints
 PIPELINE CONSTRUCTION
MANAGEMENT
TYPES OF CROSSINGS
1.Cased crossings for Railways & Highways (NH/
SH) Casing pipe: 24” OD x 0.281” WT API 5L Gr. B
Carrier Pipe: 18” OD x 0.250” WT API 5L X65
2. Uncased crossings (open cut) for minor roads/ cart –
tracks using heavy wall pipe (18” OD x 0.281”
WT API 5L X65).
3. Minor water course crossings (open cut) using normal
pipe (18” OD x 0.250” WT API 5L X65)
 PIPELINE CONSTRUCTION
MANAGEMENT
TYPES OF CROSSINGS
4. Submerged river crossings (open cut) using heavier
wall pipe (18” OD x 0. 375” WT API 5L X65) with
concrete coating/ HDD XING
5. Crossings for existing underground facilities like
pipelines, cables using normal pipe (18” OD x 0.250”
WT API 5L X65) with min. clearance of 500 mm.
Crossings at Sl. No. 2, 3 & 5 above are part of mainline
item.
Cased and submerged river crossings are separate
items.
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MANAGEMENT
CROSSINGS
Execute crossing work as per concerned Statutory Authority
permission conditions.
Highways, main roads, rail roads & their verges and banks of
water courses not to be used for loading, unloading or stacking
of materials or equipment.
Roads or water courses not to be closed or diverted without prior
permission of concerned Statutory Authority.
Before execution of cased and submerged river crossings,
detailed methodology to be submitted by contractor containing:
Time schedule,
Working method,
Equipment to be
deployed
Test procedure
Manning
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MANAGEMENT
CASED CROSSINGS
To be executed by horizontal boring technique.
Casing pipe to be 6” larger in dia. than carrier pipe.
Carrier pipes to be 3 LPE coated. No coating of casing pipes.
Ground water table (if encountered) over length of boring to be lowered up to at least
0.5 m below bottom of the pipeline.
 PIPELINE CONSTRUCTION
MANAGEMENT
CASED CROSSINGS
Dia. of bored hole to be almost same as casing pipe OD.
Vent pipes to be provided on both ends of casing in such a way that there is no contact
with carrier pipe.
100% radiographic inspection of weld joints of carrier pipes.
 PIPELINE CONSTRUCTION
MANAGEMENT
CASED CROSSINGS
Prior to installation, hydrostatic pre-testing of the carrier pipeline section to be carried
out at a pressure corresponding to 95% SMYS of pipe material (120.62 kg/cm2 for
SSPL) . Test pressure to be maintained for min. 4 hrs.
Insulators to be securely fastened to carrier pipes @ 1 m c/c.
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MANAGEMENT
CASED CROSSINGS
At both ends of casing, double set of insulators to be installed.
Carrier pipe to be pulled/ pushed into casing in such a way that insulators are not
disturbed.
Annular space between casing and carrier pipes at both ends to be packed tightly with
jute and bitumen before fixing end seals in order to prevent ingress of moisture/
water.
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MANAGEMENT
CASED CROSSINGS
After installation, electrical test to be conducted to determine resistance between
carrier pipe & casing pipe or carrier pipe & soil, which should be min. 1 mega ohm.
The earth to be properly compacted up to a distance of 3 m from end of casing pipe on
both sides to avoid uneven settlement of carrier pipe.
 PIPELINE CONSTRUCTION
MANAGEMENT

TYPICAL CASED RAILWAY

CROSSING
HDPE Insulators HDPE End Seal
@ 1 m c/c
Vent Pipe
(80mm dia. MS pipe) Railway
1.25 m
GL
GL
1.7 m Min.
0.3 m. 1.0 m Min. 1.0 m Min.

0.5 m

18 OD x 0.250” WT API 5L-X65 Grade Carrier Pipe

24 OD x 0..312” WT API 5L Grade B Casing

Boring Pit Pipe Exit Pit
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MANAGEMENT
Clean-Up and Restoration
Clear the site by removing all rubbish,broken skids,
empty canes,pieces of electrodes and other
construction material

Restore ROW to the satisfaction of farmers and

obtain NOC from them

Restore cut roads, canals, river banks etc and

obtain NOC from concerned Government
Department
 PIPELINE CONSTRUCTION
MANAGEMENT
Air pigging cleaning and Gauging
Cleaning with compressed air with the help of series of brush pigs
Gauge plate of softer metal like Al of 95% of ID of highest wall thickness pipe
is fastened to pig
Retrieved gauge plate is analyzed and preserved
 PIPELINE CONSTRUCTION
MANAGEMENT
Hydrostatic Testing
MECHANICAL CLEARANCE IS AVAILABLE. (Pipe book
completed)
INSTRUMENTS AND EQUIPMENT TO BE USED ARE
WITH VALID CALIBRATION AND OF REQUIRED
RATING.
WATER TESTING CERTIFICATE AND CORROSION
INHIBITOR DOSAGE RECOMMENDATION
AVAILABLE.
 PIPELINE CONSTRUCTION
MANAGEMENT
Hydrostatic Testing
GAUGE PLATE OF 95% ID AND 10 MM THICKNESS
SHALL BE PASSED THROUGH THE SECTION
AFTER CLEANING OF THE PIPE.
GAUGE PLATE WITH < 2 MM SCRATCH ON SIDE
WALL AND WITH NO DENT IS ACCEPTABLE.
CHECKING THE CONDITION AND SEQUENCE OF PIGS
IN THE HYDROSTATIC HEADER.
 PIPELINE CONSTRUCTION
MANAGEMENT
Hydrostatic Testing
ONLY QUALIFIED WELDER IS ALLOWED TO
PERFORM WELDING OF HEADER.
CHECK RATING AND CONDITION OF HEADER
FITTINGS.
USE THE FILLING WATER FROM TESTED
WATER
SOURCE ONLY.
FILL 500 MTRS. OF WATER BEFORE FIRST PIG
AND 1000 MTR WATER BETWEEN FIRST AND
SECOND PIG.
FINAL FILLING SHALL BE DONE WITH FILL
 PIPELINE CONSTRUCTION
MANAGEMENT
Hydrostatic Testing
AFTER RECEIPT OF PIGS AT RECIVER MINIMUM 2
HRS. WATER FLUSHING SHALL BE ENSURED.
TURBINE METER READING RECORDING SHALL BE
PRESERVED.
THERMAL STABILIZATION FOR 24 HRS. SHALL BE
DONE AND SECTION IS SAID TO BE THERMALLY
STABILIZED IF DIFFERENCE NOT HIGHER THAN
1 DEGREE IS ATTAINED BETWEEN THE
AVERAGE VALUE OF SOIL TEMPERATURE
READINGS
 PIPELINE CONSTRUCTION
MANAGEMENT
Hydrostatic Testing
PRESSURISE THE SECTION NOT MORE THAN 2
BAR/MIN RATE.
FOLLOWING THE SEQUENCE MENTIONED BELOW:-

a) PRESSURE THE PIPE SECTION TO 50%HOLD FOR I

HR.
b) DROP 0.5 BAR DO AIR VOLUME CALCULATION.
c) DROP PRESSURE TO STATIC +1 BAR.
d) FOLLOW B & C FOR 75% PRESSURISATION.
e) IF AIR VOLUME CALCULATION VALUE IS BETWEEN
1
TO 1.06, THEN FILLING IS ACCEPTED.
 PIPELINE CONSTRUCTION
MANAGEMENT
Hydrostatic Testing
PRESSURE THE PIPE TO 125.18 TO 118.55 KG/CM2
(DEPENDING UPON PIPE SECTION PROFILE) AND
HOLD IT FOR 24 HRS.

USE DWT AND RECORDING SYSTEM DURING

TESTING.

THE TEST IS CONSIDERED ACCEPTABLE IF

DIFFERENCE IS LESS OR EQUAL TO 0.3 BAR IN
CASE OF DOUBT TESTING PERIOD SHALL BE
EXTENDED.
 PIPELINE CONSTRUCTION
MANAGEMENT
Cleaning and Gauging Operation
Need of cleaning and gauging
Cleaning with compressed air with the help
of series of brush pigs
Gauge plate of softer metal like Al of 95% of ID
of highest wall thickness pipe is fastened to
pig
Retrieved gauge plate is analyzed and preserved
 PIPELINE CONSTRUCTION
MANAGEMENT
Markers and Valve Installation
Boundary Pillars ( A set at every 250
m) Kilometer post
Turning Point marker
Direction Marker( Before and after a TP
200m)
Warning Sign
Valve Installation:
Pre tested valves are installed at designated
locations after completion of hydrotest
 PIPELINE CONSTRUCTION
MANAGEMENT
Caliper Survey
To establish a benchmark of internal conditions of pipeline viz dents,ovalities for
future references and surveys
Dewatering by foam pigging
Cleaning by brush pigging
Magnetic pigging
Programmed caliper pigging
Downloading and
interpretation
 PIPELINE CONSTRUCTION
MANAGEMENT
Line Preservation
To preserve the line from internal corrosion for a prescribed period due to non-
commissioning
Pressurize pipe with inhibited water
Dosage of inhibitor depending on duration of preservation monthly, half
yearly,yearly etc and Quality of water to be filled
Keep line in air tight condition by monitoring pressure
 PIPELINE CONSTRUCTION
MANAGEMENT
TYPICAL HEAVY WALL PIPE ROAD
CROSSINGS
GL ROAD TOP GL

DRAINAGE DITCH
1.25 M min. cover 1.0 M min. cover

δ PIPELINE
PIPELINE CONSTRUCTION
MANAGEMENT
PI PELINE CONSTRUCTION
ROW
MANAGEMENT
IndianOil
 OFC

HDPE PIPE
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AIR-VOLUME CALCULATION
AIR-VOLUME RATIO=Vi/Vp (Acceptable limit is 1.06
at 75%of test pressure cycle)
Vi=Actual volume of water drained to drop pressure
by
0.05 Kg/Cm2
Vp=(0.884 ri / ti+A)X10-6 X Vt X PXK
Vp=Computed water amount required to raise by P
the pressure in the section to be tested (M3)
Vt=Geomatrical volume of the section (M3)
ri=Nominal inner radius of the pipe (mm)(Average)
ti=Nominal wall thickness of the pipe (mm)(Average)
A=Isothermal compressibility value for water at the
pressurization tempreture in the P range (bar-1)x106.
Ref graph.
P=Pressure Raise (bar)
K=A dimensionless coefficient that is equal to 1.02
for longitudinally welded pipe.