Client:

CONTRACTOR:

CLIENT: M/S.GAIL (INDIA) LTD.

(GAIL)

CONTRACTOR: ACE ENERGY INFRASTRUCTURE PVT LTD. (ACE) PROJECT: INTELLIGENT PIGGING OF PIPELINESIN AGRA REGION FOA NO. GAIL/AG/10/C622/5300015885/JBS/C&P DATED 05-APRIL-2011 PROJECT NO. ILI-A11-001

WORK INSTRUCTIONS FOR IN-LINE INSPECTION OPERATIONS CLEANING & GAUGING

ACE DOCUMENT NUMBER : ILI-WI-07

Rev.

Date

Revision Details

Ace Originator

Ace Approve

TPIs / Clients Approval

00

March 28, 2011

For Approval

Franklin

Vijay

Client Contractor Project Document Doc No.

: GAIL (India) Ltd : Ace Energy Infrastructure Pvt.Ltd. : Intelligent Pigging Of Pipelines In Agra Region : Cleaning & Gauging : ILI-WI-07 Rev A

Revision Control Rev. A 0 Date March 15, 2011 March 28, 2011 Revision Details For Internal review For Approval Revised By Franklin Franklin

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Client Contractor Project Document Doc No.

: GAIL (India) Ltd : Ace Energy Infrastructure Pvt.Ltd. : Intelligent Pigging Of Pipelines In Agra Region : Cleaning & Gauging : ILI-WI-07 Rev A

TABLE OF CONTENTS

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Client Contractor Project Document Doc No.

: GAIL (India) Ltd : Ace Energy Infrastructure Pvt.Ltd. : Intelligent Pigging Of Pipelines In Agra Region : Cleaning & Gauging : ILI-WI-07 Rev A

1. DOCUMENT SCOPE This work instruction is intended to serve as a guideline for carrying out a Cleaning & Gauging as a part of a pipeline inspection Contract. 2. LIST OF REFERNCE DOCUMENTS The various associated documents that shall be read in consonance with this document are as follows: Reference WI-01 WI-02 WI-03 WI-04 WI-05 WI-06 WI-08 WI-09 WI-10 WI-11 Title Project Method Statement Work Instruction for Site Survey Work Instruction for Deployment of Magnetic Markers Work Instruction for Deployment of MAG Loggers Work Instruction for Launch & Receive Operations Work Instruction for Valve Operations during Launch & Receive Work Instruction for Caliper Pigging Work Instruction for MFL Pigging Work Instruction for Location & Recovery of Pigs Work Instruction for Dig Verification

3. ESSENTIAL INFORMATION This work instruction is intended to serve as a guideline for carrying out a Cleaning & Gauging as a part of a pipeline inspection Contract. The purpose of the Cleaning & Gauging is to: Pipeline proving is necessary to establish if the pipeline is suitable for the safe passage of the inspection tool. The contract may omit the proving phase if the customer has confirmed the minimum bore and minimum bend radii, and is prepared to accept the possibility of an impaired inspection due to debris or restrictions. If cleaning is required, the type of cleaning and number of runs will depend on the type and estimated quantity of debris to be removed from the pipeline. A gauge pig will normally be used to establish the minimum bore of the pipeline and/or the presence of any bends that may impede passage of the inspection tool.

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Client Contractor Project Document Doc No.

: GAIL (India) Ltd : Ace Energy Infrastructure Pvt.Ltd. : Intelligent Pigging Of Pipelines In Agra Region : Cleaning & Gauging : ILI-WI-07 Rev A

4. HEALTH SAFETY & ENVIRONMENT During Cleaning & Gauging, especially during launching and receiving of Cleaning and Gauging Pig in the pipeline facilities, personal protection equipment must be worn by the persons conducting the Cleaning & Gauging at all times. In addition to the above, specific restrictions and directions related to Health, Safety and Environment issued by the Pipeline Operator / Client must be complied with.

5. METHODOLOGY The methodology to be followed during the Cleaning & Gauging is as follows: 5.1. Cleaning & Gauging The launching and receiving trap dimensions have been assessed and are capable of accommodating the pig (s) in question. Refer to the Technical Data Sheet for information on pig dimensions. All associated permits and safety measures are to be in place before any work activity can commence. Toolbox talks must be completed before any work activity can commence. Ensure communication system between launching station, SV station, receiving station and Central Control Room are established and functioning. Ensure that the launch trap is drained / purged with inert gas pre-favorably with Nitrogen before opening the pig trap. Check for the earth strap to the launch trap is in place before opening the door of launching trap. Arrange for lifting the launching system and position it on from Ground close to the trap. After the trap door is opened, lift the launch system into position so that the nosepiece is inserted into the trap. While the crane supports the load, adjust the support legs to level up the launch system. Remove the four-leg lifting chain. Earth the reaction chains to the launcher using the earthing wand and fit the reaction chains between the launcher and trap. Lift the cleaning pig with the crane and lifting beam and earth it to the launcher using the earthing wand. Position the cleaning pig (First: Foam Pig A foam cleaning pig will be run to remove moisture and prove line, Second: Magnetic Cleaning Pig A single module brush magnetic bi-directional vehicle will be run to sweep the line of debris, Third - Gauging Pig) in the pusher tray.
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Client Contractor Project Document Doc No.

: GAIL (India) Ltd : Ace Energy Infrastructure Pvt.Ltd. : Intelligent Pigging Of Pipelines In Agra Region : Cleaning & Gauging : ILI-WI-07 Rev A

Operate the launcher to drive the crosshead and pusher tray forward until the pusher fingers engage with the cleaning pig. Continue to drive the cleaner into the launch trap until the last vehicle has entered the trap. Any pusher poles used during the operation must be earthed using the earthing strip. Withdraw the pusher tray from the launch trap Remove the reaction chains. Earth the four-leg lifting chain to the launcher using the earth wand and use them to lift the launcher away from the trap and place it on firm ground. Close the trap door and pressurize the trap in line with launching & receiving Trap Valve Operations.refer ILI-WI06 Work Instruction for valve Operation during Launch & Receive for Pig movement Launching the cleaning pig (confirming that it has left the trap and passed the main valve). 5.2. Launching operation at launching station (i) A typical launch trap is show below for reference purposes only.
DRAIN VALVE 'F' (UNDERSIDE)

N2 PURGE

PIG SIGNAL

PG

VALVE 'B'

VENT VALVE 'E' VALVE 'D' VALVE 'A'

BALANCE LINE KICKER LINE

VALVE 'C'

PLAN VIEW

(ii)

S.V. station In route of pipeline during pigging monitoring of pigs movement will be carried out by reading the pressure on upstream and downstream of the S.V. from the pressure gauges mounted there

5.3. Receiving operation of pigs at Receipt Station All associated permits and safety measures are to be in place before any work activity can commence.
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Client Contractor Project Document Doc No.

: GAIL (India) Ltd : Ace Energy Infrastructure Pvt.Ltd. : Intelligent Pigging Of Pipelines In Agra Region : Cleaning & Gauging : ILI-WI-07 Rev A

Toolbox talks must be completed before any work activity can commence. Ensure communication system between launching station, SV station, receiving station and Central Control Room are established and functioning. Ensure that the receive trap is drained / purged with inert gas pre-favorably with Nitrogen before opening the pig trap. Ensure the pigs have been reached into the received trap by observing the pig signaler from time to time. Wait for one hour from depressurizing the receipt trap before opening the door. Remove the pigs from receipt trap and clean the area. Transport the pigs to the appropriate workplace. A typical launch trap is show below for reference purposes only.

DRAIN VALVE 'Z' (UNDERSIDE) PG

PIG SIGNAL

N2 PURGE

VALVE 'W'

VENT VALVE 'Y' VALVE 'V' VALVE 'X'

BRIDLE LINE

PLAN VIEW

6. REPORTS TO BE GENERATED This work instruction shall lead to the generation of the following reports: Reference WI-02-F01 Title Cleaning & Gauging Report

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