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Representative for each procedure in accordance with requirements of API (the American Petroleum
Institute) Standard1104.

The Contractor shall obtain radiography of the welds as required by the Employers Representative
and shall radiograph not less than2% of the welding carried out on the pipelines. Only a procedure
approved in writing by the Employers Representative shall be adopted for welding on the pipelines,
and change from one procedure to another will not be permitted without submitting the new
procedure for retesting.

2.9.11. Painting of Piping Systems

Buried and exposed portions of ductile iron, steel and galvanized iron piping systems shall be
protected by a coating system as described in the individual pipe Subsections of this specification.

Damaged coating surfaces shall be repaired in the field by cleaning and re-priming and re-coating
with the same primer and a compatible surface coating at least the thickness of the factory applied
coating, plus an overlapping of at least 50 mm onto the adjacent pipe surfaces.

After the completion of pipe assembly in the field, damaged areas of the factory applied coating shall
be fully repaired and the whole surface shall be cleaned of foreign matter. The field applied finished
coats shall then be applied.

The approval of the Employers Representativeshall be obtained as to all details of the field coating
system applications, including surface preparation, working environment, application techniques,
intermediate drying times and repair of coatings.

Coatings shall not be applied to wet surfaces or during rain. The Contractor shall be deemed to have
made full allowance in his Tender for the effects of weather.

2.9.12. Sampling Points

Wherever directed by the Employers Representative the Contractor shall install 50 mm BSP taps
and blanking plugs into pipe work for the purpose of sampling, pressure monitoring and metering.

2.10. Hydraulic Testing

2.10.1. Pipeline Testing Sectional Test

All pipelines shall be hydraulically tested in the presence of Employers Representative in lengths
between valve stations or in such shorter lengths as the Employers Representative may direct or
permit. Fittings required for temporarily closing the openings in pipelines to be tested shall be
properly designed for this purpose and shall be adequately strutted to withstand the test pressure
specified.

Each pipeline shall be tested after completion of installation with the exception of any back filling in
case reinstallation of segments will be required after testing. Permanent valves shall be tested along
with the pipelines.

The protocol for testing a pipeline shall include provision for the purging of air from the pipeline prior
to a water test. Testing shall be with water only and air testing shall not be allowed.

The Contractor shall keep a record of all tests and their results, which shall be available for
inspection at any time and shall be submitted to the Employers Representative periodically.

The water required for testing shall be arranged by the contractor himself. The Contractor shall fill the
pipe and compensate the leakage during testing. The Contractor shall provide and maintain all
requisite facilities, instruments, reciprocating pumps, pressure gauges, water tankers etc. for the field

Part 3 Particular Specifications

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testing of the pipelines. The testing of the pipelines generally consists in three phases: preparation,
pre-test/saturation and test, immediately following the pre-test. Generally, the following steps are
required which shall be monitored and recorded in a test protocol:
i. Complete setting of the thrust blocks.
ii. Partial backfilling and compaction to hold the pipes in position while leaving the joints
exposed for leakage control
iii. Opening of all intermediate valves (if any)
iv. Fixing the end pieces for tests and after temporarily anchoring them against the soil
(not against the preceding pipe stretch)
v. at the lower end with a precision pressure gauge and the connection to the
reciprocating pump for establishing the test pressure
vi. at the higher end with a valve for air outlet
vii. If the pressure gauge cannot be installed at the lowest point of the pipeline, an
allowance in the test pressure to be read at the position of the gauge has to be made
accordingly
viii. Slowly filling the pipe from the lowest point(s).
ix. The water for this purpose shall be reasonably clear and free of solids and
suspended matter
x. Complete removal of air through air valves along the line.
xi. Closing all air valves and scour valves.
xii. Slowly raising the pressure to the test pressure while inspecting the thrust blocks and
the temporary anchoring.
xiii. Keeping the pipeline under pressure for the duration of the pre-test by adding make-
up water to maintain the pressure at the desired test level. Make up water to be
arranged by Contractor himself at his own cost.
xiv. Start the test by maintaining the test pressure at the desired level by adding more
make-up water; record the water added carefully and the pressure in intervals of 15
minutes at the beginning and 30 minutes at the end of the test period.
xv. Water used for testing shall not be carelessly disposed of on land which would
ultimately find its way to trenches.
xvi. The testing conditions for the pipelines shall be as per the test pressures and
condition laid out in IS 8329 for DI pipes.
The pipeline stretch will pass the test if the water added during the test period is not exceeding the
admissible limits. No section of the pipe work shall be accepted by the Employers Representative
until all requirements of the test have been obtained.

The pipeline stretches shall be tested to the pressures equal to 1.5 times the maximum operating
pressure in the pipeline stretch under test, subject to a maximum of 200 m of water head or 20
2
kg/cm . Operating pressure shall be equal to static pressure on the pipeline invert level with respect to
zonal supply reservoir full tank level.

2.10.2. Test Requirements for MS Pipelines

The quantity of water added in order to re-establish the test pressure should not exceed 0.1 liter per
mm of pipe diameter per km of pipeline per day for each 30 m head of pressure applied.

All pressure testing at site should be carried out hydraulically. The pipes shall be accepted to have
passed the pressure test satisfactorily, if the quantity of water required to restore the test pressure
does not exceed the amount calculated as above.

2.10.3. Test Requirements for DI Pipelines

Part 3 Particular Specifications