MDPE WORK PROCEDURE For Gail

WORK PROCEDURE
MDPE PIPELINE LAYING

DOC. No. DOC. No. LIL/PL/KL-AKT CGD/WP-22
Rev. No.00
PROJECT - LAYING OF STEEL PIPELINE & ASSOCIATED

WORKS AKT-GA
CLIENT - M/S. AGP CITY GAS PRIVATE LIMITED
TPIA - M/S. MEENAAR GLOBAL CONSULTANTS LLP & TUV INDIA

PVT LTD
CONTRACTOR - M/S. LIKHITHA INFRASTRUCTURE LTD.
WORK PROCEDURE FOR MDPE PIPELINE LAYING
Issued for
12.02.2022
Approval
Reviewed APPROVED BY
Reviewed By TPIA
DATE DESCRIPTION Prepared By LIL By LIL AGP
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CONTENTS
S. No Description Page
1 Handling and Storage of Pipes 03

2 Trenching 06
3 Laying 10
4 Jointing 15
5 Backfilling 18
6 Valve Chamber Installation 21
7 Testing 25
8 Permanent Marker Installation 29
9 Purging 33
10 Commissioning 36
11 Restoration 40
12 Records 44
13 HSE 46
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HANDLING AND STORAGE OF PIPES
01.SCOPE
This procedure covers the method of taking over/receipt, transportation, handling
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and storage of PE Pipes and other free issue materials during the execution of Steel
Pipeline Construction.
02.REFERENCE DOCUMENTS
 AGP – Specification
 PNGRB Guidelines
If the contractor finds any discrepancy, ambiguity or conflict in between the

requirement of this procedure and that of above referred specification, the later
shall govern.
03.REQUIREMENT
 Clean surface with normal soil.
 Secured area
 Proper manpower (Labor) or Crane machine to unloading of pipes.
04.MANPOWER
 Project Manager/Co-Ordinator
 Site Engineer
 Supervisor
 Labors
05.PROCEDURE
 Transport the pipes directly from AGP Store.
 Place the Pipes in ordered manner with proper protection to avoid damages.
 Shifting the pipes from store to job site as per the job requirement only.
 Enough labors and proper vehicle should be used.
 Store the different materials in different area with proper order.
Contractor to take necessary precautions as follows:

Compulsory:
 To take the necessary precautions to prevent damage during the loading,
transportation, unloading and various other operations involving the handling
of pipes and fittings;
 To stack the pipes on a flat surface and to support and clamp them
sufficiently during transport;
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 To organise the movement of the pipes so that the pipe or the ends of it do
not drag across the ground.
Prohibited:
 To roll pipes across the ground or the road surface;
 To lift up or move pipes or pipelines with cables, chains or other hard or
squeezing ropes;
 To bring the pipes into contact with a naked flame, oil or bituminous
products.
TRENCHING
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01.SCOPE
The Content of in this procedure is to establish guidelines and requirements for
trenching and its related works and inspection to be carried out during executing the PE
Pipeline Construction by the contractor.
 ASME B31.8
 OISD
 AGP - Specification
 If the contractor finds any discrepancy, ambiguity or conflict in between the

shall govern.
03.REQUIREMENT
 Excavation tools with Insulation
 Rock Breaker
 Barricades
 Drinking water facility
 Rodo meter
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 Measuring Tape
 Insulated crow bar
04.MANPOWER
 Site Engineer
 Supervisor
 Labors
05.PROCEDURE
 Follow the typical trench drawing is enclosed as in tender document. The
performance of excavation works so as to enable the pipe to be laid in
conformity with the levels, depths, slopes,
 curves, dimensions and instructions shown on the Drawings, Specifications or

as otherwise directed by AGP.
 While trenching care shall be taken to ensure that all underground structures
and utilities are disturbed to the minimum.
 Suitable crossing shall be provided and maintained wherever necessary to
permit general public, property owners or his tenants
to cross or move stock or equipment from side of the trench or another.
 Trenching shall be made with sufficient slopes on sides in order to minimize
collapsing of the trench.
 On slopes wherever there is danger of land slide, the pipeline trench shall be
maintained open only for the time strictly necessary.
 Before trench cuts through water table, proper drainage shall be ensured,
both near the ditch and ROU in order to guarantee the soil stability.
 Shall be ensure that trench bottom is maintained in the square form as far as
possible, with equipment, so as to avoid/ minimize the hand grading at the
bottom of the trench.
 Must do all such handwork in the trench as required to free the bottom of
trench from loose rock, pebbles and to trim protruding roots from the
bottom and sidewalls of the trench.
 The minimum depth of cover shall be measured from top of pipe to the top
of undisturbed surface of the soil or top of the graded working strip or top of
road or top of rail, whichever is lower.
 The depth of the trench will be such as to provided minimum cover as
stipulated below:
For Distribution Main and Service Lines
i) Minor Water Crossing/ Canal 2.5 meter
ii) Uncased/ Cased Road Crossing 1.5 meter
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iii) Rail/ Road Cased Crossing 1.5 meter

iv) Normal Areas 1.0 meter
 In case the depth could not be achieved due to practical problems and the
same is demonstrated, AGP after examining thoroughly and considering the
codes and standards may allow the contractor to provide suitable protection
by way of concrete casing pipes or slabs without extra cost to AGP.
 The width of the trench shall be wide enough to provide bedding around the
pipe and to prevent damage to the pipe inside the trench.
 The trench bottom shall be cut or trimmed to provide a uniform bedding for
the pipe, and shall be free of stones, metal, wood,
vegetation, clods of earth or other debris before placement of the pipe.
 Unless otherwise approved, the following clearances shall be maintained
between the external wall of the gas pipe and the external surface of other
underground assets in the vicinity of the Works.
 150-300 mm where the gas pipe crosses other assets, other than electric
cables, whereupon the clearance shall be 300 mm.
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LAYING
01.SCOPE

laying and its related works and inspection to be carried out during executing the PE
 ASME B31.8
 OISD
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requirement of this procedure and that of above referred specification, the later shall
govern.
03.REQUIREMENT
 MDPE Pipes
 Padding sand
 Ruler
 Rodo meter
04.MANPOWER
 Site Engineer
 Supervisor
 Technicians
 Labors
05.PROCEDURE
Main line
CONTRACTOR shall intimate well in advance before laying of pipe to TPI / EIC. Laying of
PE pipelines shall be commenced only after ensuring proper dimensions and clean surface
of the trench and after clearance from TPIA/EIC. The trench bottom shall be free from the
presence of cuts, stones, roots, debris, stakes, rock and any other material, which could lead
of deep, scratches/tearing of the pipe wall. After ensuring above and sand bedding of trench
bottom, the PE pipe coil shall be uncoiled smoothly through proper equipment’s/care inside
the trench ensuring no damage to pipe coil during laying. Special care shall be taken to
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ensure that the uncoiling is properly controlled and cannot hit persons nearby the work
area.
Also, the area, where the pipe is to be uncoiled, shall be made free of sharp objects.
CONTRACTOR shall examine Pipe bore / inside of pipe for cleanliness prior to lining up
and all extraneous matter shall be removed and the extreme end shall be capped
before laying.
Contractors shall ensure open ends of pipe placed in the trench shall be securely capped or
plugged to prevent the ingress of water or any foreign material as this could cause a future
blockage of pipe or regulator malfunction due to dust, etc.
In case trench is flooded with water due to damage of utilities or due to rain, dewatering
shall be carried out prior to laying of pipe. No laying shall be allowed if the trench is not
completely de watered.
Direction change, turning of PE piping shall be made by welding PE EF fittings. However,

use of elbows for change in direction shall be minimized and natural bending of PE pipes
shall be used wherever possible and as per instruction given by TPIA/EIC.
Minimum radius of curvature shall be maintained as given below-
SDR With joint Without joint
11 15D 25D
17.6 15D 45D
All drains / culverts / nala should be crossed below the bed level and PE pipe to be laid
through RCC /PCC / Hume pipe, provided by contractor, unless and until specific approval
is obtained from Site Engineer in writing.
PE pipes shall be laid at a centre of trench with a minimum clearance of 150 mm from both
the wall of trench unless otherwise agreed with the Site Engineer for proper padding of soft
soil /sand etc. as per requirement.
Contractors shall ensure adequate cleared spacing at PE insertion point to avoid difficulty in
PE insertion/ laying, in case of open cuts and moling, where two pipes are to be laid parallel
in same trench or same pits.
Valves shall be installed at locations directed by the EIC and joined with PE pipes by electro
fusion techniques. After installation of PE Valve, valve chamber to be constructed as per the
approved specification and drawing of AGP.
Rough sketches of AS-Built Drawings with details of depth, length, offsets from fixed
references, other utility crossings, fittings, sizes of the casing pipe used for the pipeline shall
be prepared on daily basis and to be submitted to EIC.
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Activities partially completed during tenure of current contract will be paid as per the
prevailing SOR applicable for achieved milestone. Balance work executed against new
contract attended by same contractor or other contractor will be paid as per the respective
line item new contract.
Inspection Report Sample
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JOINTING
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01.SCOPE
Jointing and its related works and inspection to be carried out during executing the PE
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 ASME B31.8
 OISD
 If the contractor finds any discrepancy, ambiguity or conflict in between the
shall govern.
03.REQUIREMENT
 Approved Fittings
 Fusion Machine
 Cleaning solution
 Generator set with vehicle
04.MANPOWER
 Site Engineer
 Supervisor
 Approved Technician
 Helper
 Operator
05.PROCEDURE
JOINTING OF PE PIPE BY ELETROFUSION FITTINGS

The procedure for jointing of PE pipes and fittings as mentioned below.
RFQ document number: AGP/RFQ/C&P/028/PE PNG Page 32 of 91
Only bar-coded electro-fusion machine (Automatically Readable) of AGP approved
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manufacturer that can read the bar code of the fittings automatically shall be used for
joining of the PE pipes/fittings. Manual feeding Electro-fusion machines are not acceptable
for jointing purpose. The contractor has to submit the calibration certificate of Electro
Fusion machine with bar coded control unit at the time of start of work and at fixed
intervals as per the instructions of Owner. Contractor shall ensure that the machines are
always available at site.
A. Taking power connection form electric poles, connections without written permission
from the concerned authorities or residential premises is strictly prohibited. Only electro
fusion fitting of approved manufacturer shall be used for PE jointing.
B. CONTRACTOR shall arrange all the tools required for Electro-fusion welding, as specified
below:
Cutting : Pipe Cutter for Pipe Cutting
Marking : Permanent type Marker
Scrapping : Scrapper with sharp edge blade
Degreasing / Cleaning: Isopropyl Alcohol (Acetone) and Lint free Tissue Paper for
Degreasing and cleaning
Clamping : Pipe Alignment clamp /Top load clamp for all sizes
Welding : Electro-fusion Machine with Voltage stabilizer, Generator Set
5 KVA and all Electrical accessories in working condition,
The Contractor shall ensure that polyethylene pipe is only cut with proper plastic pipe-
cutting tool.
Before fusion is attempted, the contractor shall remove the oxidised surface of the pipe
using Scrapper before inserting into the electro-fusion coupler. No fusion shall be allowed
without clamping device and the proper cutting tools.
The contractor has to supply all the consumables required for carrying fusion of the joints
(like tissue paper, napkin, isopropyl alcohol etc.).
C. After fusion is completed, Pipe alignment clamp used for coupler & top load clamp used
for saddle shall be kept in position till the cooling time mentioned on the fitting is over.
D. Contractor site supervisor shall prepare welding joint report as per the
approved format. Welding joint report shall be submitted to EIC for verification before
pneumatic testing of the particular site. Joint numbers shall be written on each joint with
the help of permanent marker pen after cooling of the joint
If, upon inspection, the EIC determines a joint is defective, Contractor shall remove the joint
by an approved method. The cost of replacing joint shall be borne by the Contractor
including the cost of pipe and fittings removed.
Jointing of PE pipes shall be as per Owners technical specification. Jointing shall be carried
out by electro fusion method only.
E. Electro fusion unit input supply is to be from a nominal 240V generator, which is normally
of approximately 5kVA capacity. The nominal output of the generator is to be 240V + 15%, -
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10% between no load and full load. Control boxes are to include safety devices to prevent
excessive voltages being present at the control box output. The safety device shall operate
in less than 0.5 s.
Note that extension leads are not to be used on the control box outlet connections.
WARNING: Control boxes are not intrinsically safe and must therefore not be taken into
the trench.
F. The contractor has to submit the calibration certificate of Electro Fusion machine with bar
coded control unit at the time of start of work and at fixed intervals as per the instructions
of Owner. Contractor shall ensure that the machines are always available at site. No
stoppage of work due to the non-availability of machines shall be allowed.
G. For electro-fusion jointing, the contractor shall bring own tools, tackles and equipment
including DIESEL GENERATOR SET with / RCCB having an adequate capacity of power
required for electro fusion machine.
H. All electrical tools / equipment should be protected with RCCB of 30 mA rating installed
near power supply source.
I. Contractor shall also arrange double insulated cables, Industrial power board with 3- pin
plug, proper earthing of equipment etc. Contractor shall ensure that bare cable without
proper plug shall never be used by their manpower at any site for any purpose.
J. Failure in arrangement of tools, tackles and equipment in time shall be penalized as per
SCC of tender.
K. Only registered, qualified and certified welder shall be allowed to make joints on the PE
pipeline. Welder shall carry ID card issued by the approved welder training agency on site.
Welder shall not be allowed to make a joint in case if he is not carrying the ID card on site.
Any new welder shall be registered first with AGP and shall get training with AGP approved
training program at contractor’s expense.
Electro Fusion Jointing Method / Procedure
a. Ensure there is sufficient space to permit access to the jointing area in the pit/trench.
b. Check that the pipe ends to be jointed are cut at right angle or square to the axis of the
pipe
by using proper pipe cutters and any burrs removed. PE pipe cutting with Hacksaw blade
will not be allowed in any case.
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c. Check visually that the pipe/fitting surface is free of defects such as cuts, abrasion etc. and
wipe pipe ends using clean lint-free material to remove traces of dirt or mud or grease etc.
up to at least 100 mm length. Avoid using excessive oval sized pipes. Ovality of the pipes to
be removed by using Re-round tool.
d. Mark the area over which the oxidized pipe surface is to be removed, i.e. In excess of the
insertion depth, on each pipe to be joined by placing the EF fitting of the bagged fitting
alongside the pipe end. Trace a line round the circumference at the appropriate distance
from the end of the pipe using a felt tip pen or an indelible marker pen or similar. The
scraping
area must be 10mm larger than the insertion depth of the fittings.
e. Remove the oxidized surface from the pipe by scraping.
f. AVOID ABSOLUTELY other scraping equipment such as abrasive paper, rasp, emery
wheels, saw blades etc. other than Mechanical/Manual scrapper.
g. A mechanical scraper could be used however; there is a considerable risk that the end
preparation will not be adequate with the use of such a tool, so extra care shall be taken
during scrapping with mechanical scrapper.
h. Before inserting the PE pipe into the PE fitting, clean the scraped surface using isopropyl
alcohol to remove the dust.
i. Remove the fitting from its packing and clean the scraped area of the pipe surface and the
bore of the fitting with a disposable or tissues wipe impregnated with isopropyl alcohol.
Ensure the prepared surfaces are completely dry before proceeding.
j. Note that the prepared pipe surface should not be touched by hand.
k. The aligning clamp must be used for all types and sizes of EF fittings to be joined which
protects, during the electro fusion and the subsequent cooling, mechanical stresses on the
jointing.
l. Top loading clamp shall be used for holding the tapping tee saddle during the fusion cycle.
In some cases, if the manufacturer’s procedure for holding the fitting is provided, then the
same should be followed during the fusion cycle.
m. In case of EF coupler jointing, sign a mark using an indelible pen on the two ends to be
welded corresponding to the depth of insertion, in general equal to half length of the
coupler.
n. Insert the coupler on both pipes up to marking and fasten the pipe into the aligning
clamp.
o. Connect the electro fusion control box input leads to the generator.
p. Check that the reset stop button, if fitted on the control box, is in the correct mode.
q. Check that there is sufficient fuel for the generator to finish the joint. Start the generator
and check that it is functioning correctly.
r. Switch on the control box, Connect the control box output leads to the fitting terminals
and check that they have been fully inserted and proceed with the set-up of the jointing
parameters, strictly following the instructions of the fusion unit.
s. Press the start button on the control box and check that the heating cycle is proceeding as
indicated on the display.
t. When the fusion cycle is completed, verify the fusion indicators coming out. The fusion
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indicators are located near the terminal connection of the fitting. If there is no apparent
move in the melt indicators, the joint should be cut out and a fresh joint made (See note
below).
u. If a satisfactory joint has been made, the joint is to be left in the clamps for the cooling
time specified on the fitting or the automatic control box. Cooling, in order to avoid possible
stresses on the jointing, strictly respect the cooling time indicated on the bar-code and do
not remove aligning clamp of the fittings. In no case artificial cooling by placing wet cloth or
sprinkling of water be allowed.
Note 1: Bar coded EF units are available which obviate the need to enter the fusion
time. Manually feeding of fusion time in EF unit shall not be allowed.
Note 2: Gloves and goggles should be worn during the Fusion process.
Note 3: If there is an accidental interruption during the joining cycle, operation can only
be repeated after the Electro fusion joint has totally cooled (min. 1 hour). This
operation can be done only once.
Note 4: If the fusion cycle terminates before completion of the countdown, check for
faults as indicated by the control box warning lights and check that there is
adequate fuel in the generator. DO NOT attempt a second fusion cycle within
one hour / cooling of joint at Ambient Temperature of the first attempt.
RECORDS
Records of appropriate servicing and calibration certificate of Electro fusion unit shall be
kept at site along with traceability of the master instrument.
SQUEEZE-OFF
a. To control the gas flow a special tool may be used to squeeze the pipe walls together.
Hydraulic squeezing tools are used to supply necessary force to compress the pipe walls for
sizes 125 or 90 mm and above. Manual squeezing tools can be used for squeezing 90mm
or below PE pipes.
b. As will be seen the squeeze-off equipment comprises two bars to apply pressure to the
outside of the pipe. The bars are brought together, either manually or hydraulically,
squeezing the pipe material together until a seal is formed where the upper and lower walls
meet.
c. The hydraulic squeeze off tool should have a locking to prevent accidental release of
pressure during operation. All squeeze-off machines should be fitted with check plate or
stops to avoid over compression of the pipe.
d. Where the pipe walls are compressed the polyethylene pipe will be severely deformed in
the
regions of maximum compression. The pipe will eventually regain its original shape after
squeezing but there will be some reduction in the pressure bearing properties.
e. A complete stop may not always be obtainable because of wrinkling of the inside of the
pipe.
If a complete stop is required then a second squeeze can be used. A second squeeze-off
distance should be a minimum of three pipe diameters and right angles to the initial
squeeze.
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f. While not essential it would be good practice to fit a reinforcing stainless steel band / do
not
squeeze again adhesive tape around the pipe upon the completion of a squeezing
operation.
g. Special squeeze-off sticker should be wrapped on pipe after completion of operation prior
to
backfilling. Placement of such tape/mat will facilitate to avoid another squeezing at the
same place in future.
BACKFILLING
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01.SCOPE

backfilling activity and inspection to be carried out during executing the PE Pipeline
Construction by the contractor.
 ASME B31.8
 OISD
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If the contractor finds any discrepancy, ambiguity or conflict in between the requirement of
this procedure and that of above referred specification, the later shall govern.
03.REQUIREMENT
 Proper Hand tools
 Backhoe (if required)
 Warning mat
04.MANPOWER
 Site Engineer
 Supervisor
 Labors
05.PROCEDURE
renches excavated during the day shall be backfilled by evening before workmen
leave the site unless, otherwise as approved by the Owner Engineer In charge.
Backfilling shall be done after ensuring that appurtenance have been properly fitted and the
pipe is following the trench profile at the required depth that will provide the required cover
and has a bed which is free of extraneous material and which allows the pipe to rest
smoothly and evenly. The Contractor shall supply all necessary pumping equipment and
power sources to de-water trenches and excavations as required by Owner at no extra cost.
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Prior to backfilling it should be ensured that the trench is filled with fine sand/soft
soil/sieved soil/ around the pipe as per the specification given in this document and soft
graded soil layer up to 500 mm to be backfilled above layer of sand immediately after
lowering where required.
The surplus material shall be neatly crowned directly over trench and adjacent excavated
areas on both sides of the trench to such a height which will provide adequately for future
settlement of the trench. Contractor shall be responsible for remedial work at no extra cost
to Company. Surplus material, including rock left from this operation shall be disposed off to
the satisfaction of landowner or authority having jurisdiction at no extra cost to Owner.
When the trench has been dug through driveways or roads, all backfilling shall be executed
with sand/suitable material in layers as approved by Owner’s representative and shall be
thoroughly compacted. Special compaction methods as specified may be adopted. All costs
incurred there upon shall be borne by the Contractor.
The Contractor shall ensure laying of PE Warning Mat 250 mm wide and 300 Micron thick,
approved marking and colour of Owner, shall be placed on PE pipeline in the trench after
backfill of the trench up to a height of 500 mm on the top of the PE Pipes. The warning mat
is to be unrolled centrally over the pipe section and thereafter further backfilling will
commence.
Backfilling activity shall include watering and proper compaction of backfilled soil by
jumping jack compactor/ manual compactor, wherever required as per instruction of EIC;
Proper crowning of not more than 150mm shall be done
Electro-fusion of joints is to be undertaken immediately after lowering and the activity shall
not be kept pending for lack of Electro-fusion jointing. The backfilling shall be considered
complete only after the jointing of pipes.
All the excavated material that could be used during the Restoration process shall be
stacked
and kept separately and properly
Contractor has to ensure the backfill, watering, compaction and carryout a temporary
reinstatement of all premises of statutory authorities work such as Road, Railway etc.,
immediately after completion of PE Laying and jointing work.
During random inspections if back filling is not found to be as per the specifications,
the Contractor will have to re-open the trench and rectify the back filling as per the Owner
specification without any additional charge.
Debris and other surplus material shall be removed immediately after the back filling.
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If the trenches are settled after backfilling due to reasons like rainfall it is the responsibility
of the contractor to rectify the settlement as per the instructions of EIC without any
additional financial implication to AGP.
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VALVE & CHAMBER INSTALLATION
01.SCOPE
Content of in this procedure is to establish guidelines and requirements for Valve &
Chamber Installation and inspection to be carried out during executing the PE Pipeline
 ASME B31.8
 OISD
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shall govern.
03.REQUIREMENT
 BV Valves
 Insulated Hand tools
 Civil work materials
 Steel tape
04.MANPOWER
 Site Engineer
 Supervisor
 Approved EF Technician
 Labors
 Helper
 Fusion Machine Operator
05.PROCEDURE
INSTALLATION OF PE VALVE & CHAMBER
PE VALVE
The location for installation of PE valve shall be proposed by contractor and decided by EIC
and shall be installed at every 1.0 km. for PE pipes of dia 63mm and onwards, including for
LP Network.
Pre cast valve chambers (RCC) shall be constructed as per drawing given in the tender.
Prior approval shall be taken from the Owner / Owner’s representative for Pre Cast of valve
chambers as per enclosed tender drawing before start of production, without any extra cost
to owner.
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The PE Ball valve shall be supported on a bed of firmly compacted soil and construction of
Valve chamber shall be as per drawing given in the tender.
Payment for the construction of valve chamber shall be as per tender terms & conditions.
The installation of the valve chambers shall be taken up immediately after installation of
valve, before commissioning of the pipeline network.
Materials for pre-cast RCC Valve chamber with Frame and Cover
Pre-cast RCC Valve chamber with Frame and Cover shall be supplied & installed by
CONRACTOR.
Workmanship
The excavation work shall be done at a location decided by Engineer-in-Charge. All care
shall be taken not to damage existing facilities and surface of construction shall be
restored to its original state. Approved quality of sand or equivalent shall be filled below
pipeline without disturbing the laid pipe and the valve shall be supported on a bed of
firmly compacted soil by using fine sand or equivalent. Care for proper rammed shall be
taken so that pipe / PE Valves firmly place.
PCC shall be placed below the pipe and pre cast valve chamber as indicated in the
applicable standard drawing of pre-cast valve chamber. Once PCC is set then Pre Cast
valve chamber shall be installed / placed to cover the PE Valves. Care shall be taken
during installation/Construction of valve chamber to protect PE Pipes as well as PE
valves. Fine sand shall be filled in the valve chamber as per instruction of Owner EIC.
The supply of sand is included in the rates of supply and installation of valve chamber.
No separate payment shall be made against supply of Fine sand required for installation
of valve chamber.
Supply and installation of Valve chamber excluding precast RCC cover of valve chamber
for PE valve installation.
Surrounding area to be properly cleared and restored its original conditions and to
satisfactory of Owner or Owner’s representative.
Inspection Report Sample –Chamber
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TESTING
01.SCOPE
Content of in this procedure is to establish guidelines and requirements for
pneumatic testing inspection to be carried out during executing the PE Pipeline Construction
by the contractor.
 ASME B31.8
 OISD
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 The American Gas Association Document - Purging Principles and Practice.
If the contractor finds any discrepancy, ambiguity or conflict in between the requirement
of this procedure and that of above referred specification, the later shall govern.
03.REQUIREMENT
 Pressure Gauge With valid calibration certificate
 Proper fittings
 Soap solution
 Portable Air Compressor set
04.MANPOWER
 Site Engineer
 Supervisor
 Approved Technician
 Labors
 Helper
05.PROCEDURE
TESTING
Pressure testing shall be carried out either with compressed air (free from oil and greases)
or nitrogen and no other test medium shall be used. Compressed air or Nitrogen gas shall
be provided by Contractor for testing purposes and is to be included in the laying rates.
Nitrogen shall be supplied in labelled, tested and certified cylinders and complete with all
necessary regulators, hoses and connections which shall be in good order and working
condition. No extra payment will be made for any delays incurred, or repair or rectification
work found necessary as a result of test failures, where this is the result of faulty
workmanship or negligence on the part of the Contractor.
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For both main & service pipeline laying, the Contractor shall perform progressive pressure
testing & pneumatic testing to ensure no leaks in long lengths of pipe.
Schematic drawing of PE network to be tested shall be prepared with clearly marked

pressurisation point, venting point, PE Valves Location.
Prior to pressure testing of PE network, proper flushing shall be done with Compressed air
or Nitrogen for the entire PE network to the satisfaction of EIC by the contractor and get
approval from Owner representative
The pneumatic test pressure shall be 100 Psig (7 barg), and there shall be no unaccountable
pressure loss during the test period. The holding period of test section is as below.
For PE pipeline network of length greater than 1 KM at least 24 hrs after pressure
stabilization period of 30 minutes.
For PE pipeline network of length shorter than 1 KM at least 4 hrs after pressure
stabilizationperiod of 30 minutes.
There shall be no pressure drop and measure of pressure unchanged during the test in
pressure gauge.
Contractor shall ensure following before starting of pneumatic testing.

Tested hoses at required pressure and clamps to be used.
Area of testing to be away from populated area or sand bags to be kept around so that
in case of accident it acts as barriers.
If compressed air is being used for pneumatic testing contractor, shall ensure that
compressor of appropriate capacity is being used.
If Nitrogen is being used for pneumatic testing, Contractor shall ensure industrial nitrogen
purity by checking oxygen % in the cylinder as per AGP guidelines.
Contractor shall ensure that testing section of PE pipeline is completely isolated
positively.
Measuring instruments shall have been calibrated and their accuracy and sensitivity
confirmed before the start of testing, where in calibrated pressure gauges of suitable
range shall be supplied & used for testing by the contractor.
The range of pressure gauge is minimum 1.5 times of test pressure and least count of
gauge should be 0.1 Kg/cm2.
The pressure gauges shall be calibrated from time to time as desired by EIC.
All testing shall be witnessed and approved by the EIC or his delegated representative.
Tie-in joints may be tested at working pressure following commissioning.
The testing shall include, but not limited to the provision of consumable and Non
consumable materials, tools, tackles and Equipment, Personal Safety Equipment, Fire
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Extinguisher, Adaptor, Polyethylene connecting pipe etc.
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33 | P a g e
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PERMANENT MARKER INSTALLATION
01.SCOPE
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Permanent Marker Installation inspection to be carried out during executing the PE Pipeline
 ASME B31.8
 OISD
If the contractor finds any discrepancy, ambiguity or conflict in between the requirement of
this procedure and that of above referred specification, the later shall govern.
03.REQUIREMENT
 Markers
 Vehicle
 Insulated Hand tools
 Concrete materials
 Ruler
04.MANPOWER
 Site Engineer
 Supervisor
 Labors
05.PROCEDURE
35 | P a g e
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Markers shall be installed as per the AGP guideline, drawing as instructed by EIC
The details written on marker shall be as per AGP specification.
Markers shall be fabricated, supplied and installed on the ROU at regular intervals as
per the instructions of the EIC immediately after laying of the Pipeline. The installation of
the type of the Marker shall be decided by the EIC depending on the site condition. The
contractor shall also ensure that a sample of all type of markers shall be inspected and
approved by Owner / Owner representative before shipment of the lot at site and prior to
installation at the site. The inspection of all types of markers shall be carried out lot wise.
RCC Markers shall be painted before installation as per the approved procedure.
Whereas the Pole marker (Markers with foundation) are to be supplied with powder
coated Golden Yellow paint. The supply of the paint and application as per the
specification is in contractor’s scope. Payment shall be done as per relevant line item of
SOR. Contractor shall obtain the approval lot wise & before installation at site from the
Owner or Owner’s representative.
Supply & Installation of RCC route marker as per the AGP drawing enclosed with
technical scope at interval of 100 mtr distance along the route of laid pipeline and at both
sides of crossing or as per the direction of the EIC/Owner’s representative. And same
should be incorporated in as built drawings. Network should be provided with route
markers along the roads parallel as well as at beginning of branch pipeline for route
identifications.
Supply & Installation of pole marker as per the AGP drawing enclosed with technical
scope at both sides of a critical crossings as per the direction of the EIC/Owner’s
representative. And same should be incorporated in as built drawings. The artwork is
typical for all the markers with Owner’s logo on it. The contractor must take prior approval
for the artwork from EIC before installation of Markers. The lot wise approval shall be
attached with bills.
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37 | P a g e
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PURGING
01.SCOPE
Content of in this procedure is to establish guidelines and requirements for Purging
inspection to be carried out during executing the PE Pipeline Construction by the contractor.
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 ASME B31.8
 OISD

shall govern.
03.REQUIREMENT
 Nitrogen
 Insulated Hand Tools
 Calibrated LEL Indicator
 Calibrated Pressure Gauge
04.MANPOWER
 Site Engineer
 Supervisor
 Approved Technicians
 Labors
 Helper
05.PROCEDURE
Purging shall be carried out in accordance with the principles defined in the American Gas
Association publication “Purging Principles and Practice”.
The Contractor shall also provide nitrogen required for purging as per the direction of EIC.
Nitrogen shall be supplied in labelled, tested and certified cylinders and completed with all
necessary regulators, hoses and connections, which shall be in good and working condition.
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No separate payment shall be paid for supplying Nitrogen cylinders for purging and is
included in the laying rates.
Prior to use of nitrogen cylinder, Contractor shall ensure industrial nitrogen purity by
checking oxygen % in the cylinder as per AGP guidelines
In addition, the Contractor shall submit purging plan and get approval from Owner / Owner
representative before commencing any purging work. The Plan shall include, but not limited
to the provision of the following materials and equipment: Personal Safety Equipment, Fire
Extinguisher, Purging Adaptor, Purge stack with flame trap and gas sampling point, Gas
sampling equipment (may be gas leak detector), squeeze -off tool, etc.
The Plan shall also include the purging process along with detail on the sequence of events.
The process is to also specifically mention the need to lay a wet cloth over the PE main and
in contact with the ground, to disperse static electricity during the purging work.
A purge stack with flame trap shall be used when purging services. Care shall be taken to
ensure that the purge outlet is so located that vent gas cannot drift into buildings.
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41 | P a g e
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COMMISSIONING
01.SCOPE
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Rev. No.00

Commissioning and its related works to be carried out during executing the PE Pipeline
Construction by the contractor
 ASME B31.8
 OISD
 Specification (AGP)
shall govern.
03.REQUIREMENT
 Calibrated Gas Detector
 Calibrated LEL Indicator
 Proper Hand Tools
 Fire Extinguisher
 First Aid Box
04.MANPOWER
 Site Engineer
 Supervisor
 Approved Technicians
 Labors
 Helper
05.PROCEDURE
Contractor shall provide the required personnel, Vehicles, labour, supervision, tools,
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equipment, instruments and technical assistance for performance tests, Pre commissioning
and commissioning activities as per requirement / satisfaction of Owner /Owner’s
representative in-line with AGP procedure / guideline
Major activities to be ensured during commissioning are given below;
Commissioning activity shall be commenced only after receiving valid work permit from
EIC at site. AGP EIC of PE work shall check the same before starting of PE network.
Overall schematic drawing of section / AS BUILT drawing shall be prepared with clearly
marked Venting, Elevation, PE Valves Location, End caps by the contractor and get
approval from Owner/Owner representative prior to the start of commissioning of PE
network.
Prior to the start of commissioning of PE networks, the following shall be ensured.
Proper flushing, Hydro testing / Pneumatic testing record of proposed section for
commissioning of PE network
Proper venting location / point
Proper barricading and warning sign board at venting / PE valve location
Availability & Installation of Calibrated pressure gauge
Availability of calibrated EF jointing machine, DG Set etc. with RCCB of max 30 mA
rating
Ensure availability of calibrated methane detector
Ensure availability of additional Squeeze tools for emergency
Ensure the traffic controlled by man and diversion at the time of Gas In
It shall be checked and ensured that the positive pressure in the PE network is equal to
the pressure maintained/locked after testing of PE network.
It shall be ensured that venting is minimum 3 meters above the ground level by crack
opening of valve during commissioning of PE network until two successive readings
confirm same concentration of gas by methane detector.
Monitor surrounding areas for checking Natural Gas LEL to avoid fire / accident in
vicinityduring commissioning of PE network.
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RESTORATION
01.SCOPE
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Restoration and its related works to be carried out during executing the PE Pipeline
Construction by the contractor
 OISD

shall govern
03.REQUIREMENT
 Proper Hand tools
 Barricades
04.MANPOWER
 Site Engineer
 Supervisor
 Labors
05.PROCEDURE
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 Wherever the restoration is required, the roads, footpaths (including roads

and footpaths inside colonies) shall be restored to original condition, and the
same shall be done as per concerned local authority norms and to the
satisfaction of the concerned local authority.
 To retard curing of the installed concrete, wet sack cloth is to be placed on
the finished surface and kept damp for a period of 36 hours.
 Where slabs and blocks are to be restored, the level of the compacted
subbase is to be adjusted according to the slab/block thickness.
 The slabs or blocks should be laid on moist bedding material, which should
be graded sand, mortar or mortar mix. The slabs or blocks should be tapped
into position to ensure they do not rock after laying.
 The restored slabs or blocks should match the surrounding surface levels.
Joint widths should match the existing conditions, and be filled with a dry or
wet mix of mortar.
 The restoration shall be done in accordance with the norms of concerned
land-owning agencies.
 Turf shall be replaced in highly developed grassed area. In lesser-developed
grassed areas topsoil should be replaced during the restoration process.
 Where permanent surface restorations cannot be completed immediately,
the Contractor shall provide and maintain a suitable temporary running
surface for vehicular traffic and pedestrians.
 The Contractor is to ensure the restoration work is properly supervised, and
that the material used is suitable for the purpose and properly compacted.
 Where the required standards are not achieved the Contractor will be
required to replace the defective restoration work.
 That Payment for pipe laying will only be authorized on initial satisfactory
restoration, and where the sites has been cleared of all surplus materials, etc.
 Contractor has to obtain the clearance certificate from the concerned local
authorities after completion of the restoration work. Restoration
specification specified in the tender is only a typical specification and the
contractor has to carry out restoration as per latest version of the Concerned
authorities specification to its original condition and also to the entire
satisfaction of land owner (Private/Public).
Contractor has to restore the area wherever he has carried out drilling, clamping etc. to its
original condition to the satisfaction of the consumer and to ensure no passage to the
premises and seepage.
Wherever any items of the consumer is damaged/broken during working, the same will be
rectified or replaced to the total satisfaction of the consumer.
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The contractor will be responsible for the maintenance of all restoration carried out, for the
duration of the contract guarantee period.
The contractor is to ensure the restoration work is properly supervised, and that the
material
used is suitable for the purpose. Wherever the required standards are not achieved the
contractor will be required to replace the defective reinstatement work.
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RECORDS
01.SCOPE
The Scope of this document is to do Recordings and its related works in proper
manner with quality and to avoid lack of information.
02.REFERENCE DOCUMENT
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If the contractor finds any discrepancy, ambiguity or conflict in between any of the
Standards and the contract documents, then this should be promptly referred to the
Engineer -in-Charge (EIC) for his decision, which shall be considered binding on the
contractor
03.REQUIREMENT
 Work activity documents
04.MANPOWER REQUIREMENT
 Site Engineer
05.PROCEDURE
 Follow the Specifications and required to submit computerized As-built
drawings duly certified by EIC in A0/ A1 sheet form at 1:200 scale with six sets
of prints plus soft copy.
 The as-built drawing shall be submitted on area wise as specified. The bill of
materials used for the particular area shall be specified on the drawings.
 The Contractor shall use the area and crossing survey drawings prepared by
them as reference.
 On-site sketches, picking up key reference points, shall be made during the
installation of services. The lengths, depths of installed pipe work, changes in
direction, major fittings, etc, shall be recorded together with appropriate
references to other services crossed and in the proximity of the gas pipe.
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HEALTH SAFETY ENVIRONMENT
01.SCOPE
This establishes the Health, safety and Environment (HSE) aspects to be

complied with by LIL during construction at site.
02.REFERENCES
This document should be read in conjunction with following,

 Specification – AGP
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 Relevant IS codes
 Reporting Formats
03.RESPONSIBILITY & ORGANISATION

Safety activities at site shall be under control of LIL. He shall be responsible for
implementation of HSE provisions. The nominated or designated safety engineer/ officer
shall assist and perform day to day HSE work as per his advice.
04.GENERAL REQUIREMENT
1) The LIL should follow HSE policy of IOCL/ VCS as applicable to construction site.
2) The LIL shall deploy a full time HSE engineer / officer to coordinate
the site. The HSE officer shall be duly qualified in Industrial Health &
Safety management with an experience of 4 -5 years.
3) The LIL shall ensure that HSE requirements are clearly understood &
faithfully implemented at all level, at each site.
4) The LIL shall organize safety awareness programs regularly.
5) The LIL shall ensure his participation in the every HSE meeting called by AGP or AGP’s
representative.
6) The LIL shall conduct daily tool box talk.
7) The LIL shall submit Monthly HSE reports (Form attached in ANNEXURES).
8) The LIL shall provide all help and support to the injured person got injury at site
during construction work and arrange compensation as per insurance policy/act.
9) The LIL shall adhere consistently to all provisions of HSE. In case of non-compliance
or continuous failure the AGP or AGP’s representative may impose stoppage of work
without any cost time implication to AGP. A penalty amount of Rs 1000/-shall be
imposed on the LIL for the serious HSE violation. Three times of this penalty may
count as a serious violation of LIL in line with HSE. This may affect to new work
assignment/award of LIL.
05.ACCIDENT, INCIDENT AND NEAR-MISS REPORTING
Accident
Unintended occurrence arising out of and in the course of employment
of a person, which results in to injury with or without damage to
plant/equipment/materials.
Incident
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Unplanned and uncontrolled event which results in damage to plant or equipment or

loss of material without causing any injury to persons, like fire, spill, leak, property damage
etc.
Near-miss
An unexpected, unwanted event not causing loss, injury or illness but which under
slightly altered conditions can lead to an accident can be defined as “Any event which under
slightly unfavourable circumstances, may have resulted in any of the following: -
-Injury, fatal or otherwise or ill health to people
- Loss of property, damage to plant or materials
- Damage to the environment
- A business interruption
-Accident, Incident and Near miss reporting form listed in ANNEXURES
06.HSE REQUIREMENTS AT SITE

Personnel Protective Equipment
The LILs shall provide sufficient numbers of following personal protective equipment
(PPE) to workmen and supervisors/engineers to use them properly at work site.
Following five numbers of Personnel protective equipment are identified as
MANDATORY for all.
 Safety Helmet
 Coverall
 Safety shoes/footwear
 Safety Glasses
 Hand Gloves
07.METHODOLOGY
Use of Power Tools and Cables
 All electrical equipment and tools used by the LILs and their
employees shall be properly checked by LIL’s supervisor before
use.
 All power tools must have proper guard at all time.
 Leads /cables must be placed so that they do not create a tripping hazard.
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Material Handling and Storage

The LIL will only use crane/Hydra and lifting equipment that has been
tested and certified as fit for purpose by 3rd Party. All crane operators and
riggers will be adequately trained and certified. The LIL will keep records of
tests and certification of all lifting equipment crane employed on the Works.
Maintenance records shall be routinely inspected by the LIL and made
available for Safety audits.
LIFTING GEAR: Lifting machine, chains, ropes and lifting tackles used at site shall conform to
the following:
 All parts shall be good construction, sound material and adequate strength
and free from defects.
 Shall be properly maintained, thoroughly examined, load tested by
competent person.
 No lifting machine and no chain, rope or lifting tackle shall
except for purpose of test be loaded beyond safe working
load and this safe working load must be plainly marked on
the gear concerned.
 All material must be properly stacked and secured to prevent sliding, falling
or collapse.
 Stairs and passage ways must be kept clear at all time.
Trenches and Excavation

Before commencing any excavation work the Sit-in-charge will
ensure that the proposed works have been adequately assessed and
planned to ensure that they are executed safely and without risks to Health
and safety.
The factors to be assessed and planned will include: -
 The nature and stability of the material being excavated and the need for any
support of walls.
 The effect of excavation on nearby area.
 The foreseeable presence of hazardous contaminants.
 The proximity of mobile plant.
 The provision of edge protection (fall prevention of people and materials).
 Access and egress.

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Pipe Transportation and Lowering

 All drivers shall hold a valid driving license for the class of vehicle.
 Securing of the load shall be according to established and approved methods.
 All overhangs shall be made clearly visible and restricted to acceptable limits.
 Load shall be checked before moving off and after traveling a suitable
distance.
 All vehicles used by LILs shall be in worthy condition and in conformance to
the Land Transport requirement.
 Effective communication should be done among all involved personals.
 Signaling shall be done by authorized foreman only.
 Ensure appropriate measures are taken for overhead hazards.
 Persons are not allowed towards trench side / under the boom at the time of
lowering.
 Co-ordination of lowering in by a single man only.
 Inspection of equipment before use.
 All personnel should stay clear of moving equipment.

 Use of certified lifting tools and tackles.
Pressure / Leak Testing.
Hydraulic and Pneumatic Test Access to the test area shall be limited to
essential personnel only before the test commences compliance is required
with the following points:
 Persons supervising pressure or leak tests must have sufficient

knowledge and experience of testing to fully understand the
hazards of the activity and the precaution, which must be
taken.
 Effective communication, including formal procedures, must
be established between sites whenever the test envelope
extends beyond one site, for example, pipelines.
 The area shall be cordoned off (using tape, shields or barriers,

etc) at an adequate distance from the equipment to be
56 | P a g e
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tested, as specified on the Permit to Work
 Warning signs shall be posted at access ways, at other strategic

positions, and on the equipment to be tested (including the
doors of test workshops or other designated areas
 Pressuring equipment shall be provided with suitably calibrated pressure

control / regulator devices.
 Pressuring equipment shall not be left unattended at any time during the
test.
 Pressuring equipment shall be isolated from the

equipment under test and where practicable
disconnected, when the test pressure has been
reached.
 Care must be taken to ensure that materials of

construction have the required ductility at the test
temperature to prevent brittle fracture.
 A safety valve should be fitted to the equipment/system being

tested, set to relieve at a pressure that will prevent over
pressurization.
 Sufficient venting / draining points shall be provided in

order to prevent trapping of pressurizing medium behind
non-return valves, check valves, between isolation valves,
or within dead legs of the pressure envelope.
 The gas supply must be isolated when test pressure has been achieved
 The pressure envelope must contain sufficient vents, to a safe location.
 De-pressurization after pneumatic testing must be gradual.
Work Permit Procedure
 For working at more than 10’ height the permission must be obtained from
site in-charge.
 For doing any Hot work in the fire risk areas the permission
must be obtained from site in charge or safety officer.
 For any Excavation work it must be ensured that there are no

underground utilities like cables, Water pipeline etc.
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 For any work inside confined space, entry permit must be obtained from site
engineer.
Barricades and Warning Signs
 Area where work is being carried out above man height or below 1’ ground
depth must be barricaded.

Follow the instruction of all types of warning signs like “NO SMOKING” “NO
ENTRY” “DANGER” “Work at height.
Emergency Plan and Procedures
 All LIL’s employees should be aware of site Emergency control plan.
 Periodic drill to train employees for their awareness & information should be
followed.
Labor Welfare & Legal Requirement
 All mandatory provisions with regard to safety as

prescribed under contract Labour (Abolition &
Regulation) Act 1970 and Rules made there under are
applicable.
 Workmen compensation insurance and registration under ESI should be

maintained.
 Time to time, all rules and regulations suggested by safety

committee of site must be followed and implemented.
RELEVANT IS CODES
 IS: 2925 – 1984: Industrial Safety Helmets.
 IS: 4770 – 1968: Rubber gloves for electrical purposes
 IS: 6994 – 1973 (Part – I): Industrial Safety Gloves (Leather & Cotton)
 IS: 1989 – 1986 (Part – I & III): Leather safety boots and shoes
 IS: 3738 – 1975: Rubber knee boots
 IS: 5557 – 1969: Industrial and Safety rubber knee boots
 IS: 6519 – 1971: Code of practice for selection, care and repair of Safety
footwear
 IS: 11226 – 1985: Leather Safety footwear having direct molding sole
 IS: 5983 – 1978: Eye protectors
 IS: 9167 – 1979: Ear protectors.
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 IS: 3521 – 1983: Industrial Safety belts and harness.
59 | P a g e

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WORK PROCEDURE

MDPE PIPELINE LAYING

PROJECT - LAYING OF STEEL PIPELINE & ASSOCIATED

CLIENT - M/S. AGP CITY GAS PRIVATE LIMITED

TPIA - M/S. MEENAAR GLOBAL CONSULTANTS LLP & TUV INDIA

CONTRACTOR - M/S. LIKHITHA INFRASTRUCTURE LTD.

WORK PROCEDURE FOR MDPE PIPELINE LAYING

1 Handling and Storage of Pipes 03

8 Permanent Marker Installation 29

HANDLING AND STORAGE OF PIPES

This procedure covers the method of taking over/receipt, transportation, handling

If the contractor finds any discrepancy, ambiguity or conflict in between the

 Transport the pipes directly from AGP Store.

 Store the different materials in different area with proper order.

Contractor to take necessary precautions as follows:

 If the contractor finds any discrepancy, ambiguity or conflict in between the

 curves, dimensions and instructions shown on the Drawings, Specifications or

iii) Rail/ Road Cased Crossing 1.5 meter

The Content of in this procedure is to establish guidelines and requirements for

Direction change, turning of PE piping shall be made by welding PE EF fittings. However,

Inspection Report Sample

JOINTING OF PE PIPE BY ELETROFUSION FITTINGS

Electro Fusion Jointing Method / Procedure

The Content of in this procedure is to establish guidelines and requirements for

VALVE & CHAMBER INSTALLATION

If the contractor finds any discrepancy, ambiguity or conflict in between the

Inspection Report Sample –Chamber

Schematic drawing of PE network to be tested shall be prepared with clearly marked

Contractor shall ensure following before starting of pneumatic testing.

Extinguisher, Adaptor, Polyethylene connecting pipe etc.

Inspection Report Sample

PERMANENT MARKER INSTALLATION

Content of in this procedure is to establish guidelines and requirements for

The details written on marker shall be as per AGP specification.

Inspection Report Sample

If the contractor finds any discrepancy, ambiguity or conflict in between the

Inspection Report Sample

Content of in this procedure is to establish guidelines and requirements for

Prior to the start of commissioning of PE networks, the following shall be ensured.

Inspection Report Sample

Content of in this procedure is to establish guidelines and requirements for

If the contractor finds any discrepancy, ambiguity or conflict in between the

 Wherever the restoration is required, the roads, footpaths (including roads

HEALTH SAFETY ENVIRONMENT

This establishes the Health, safety and Environment (HSE) aspects to be

This document should be read in conjunction with following,

03.RESPONSIBILITY & ORGANISATION

05.ACCIDENT, INCIDENT AND NEAR-MISS REPORTING

Unplanned and uncontrolled event which results in damage to plant or equipment or

- Damage to the environment

-Accident, Incident and Near miss reporting form listed in ANNEXURES

06.HSE REQUIREMENTS AT SITE

 All power tools must have proper guard at all time.

Material Handling and Storage

Trenches and Excavation

 The foreseeable presence of hazardous contaminants.

 The proximity of mobile plant.

 The provision of edge protection (fall prevention of people and materials).

 Access and egress.