SOP-9 - Tie in Joints

हिन्दुस्तान पेट्रोलियम कार्पोरेशन लिमिटेड Doc No.
SP – 09
Hindustan Petroleum Corporation Limited
Issue No.
परियोजना एवं पाइपलाइन 01 Issue Date
Projects & Pipelines
Page 1 of
Safety Procedure for Tie-in Joints Rev No. 0
18
Issue By Approved By
Management Representative DGM-Projects
Revision and Amendment sheet
Page Clause Revisi Revision

Amendment Details
No. No. on No. Date
Note: - As per the procedure for control of document procedure

can be revised up to maximum 5 revisions and after 5 th
revision, new issue of the document with new issue number
shall be issued to all the controlled copy -holders.
हिन्दुस्तान पेट्रोलियम कार्पोरेशन लिमिटेड Doc No. SP – 09
Issue No.
Page 2 of
18
SAFETY PROCEDURE FOR TIE-IN JOINTS
1.0 Purpose
To encourage and educate personnel on the HPCL sites to

regard Safety First as its prime objective and to be aware of
their commitment, responsibility and statutory obligation.
This procedure will provide information and guidance while
Tie-In Joints . To identity tendency of unsafe activities and
condition and provide safe work environment.
2.0 Scope
Applicable to all Pipeline Project locations and greenfield

project sites.
3.0 Reference
OISD GDN -192

OISD-141
OISD-105
HSE procedures in practice
4.0 Responsibility
4.1 ROU In-charge / Officer In-charge / Project consultant’s

Safety Officer
4.2 Officer In-Charge / Project consultant’s Safety Officer shall

ensure that all the work is done with proper work permit &
use of proper PPEs.
5.1 Procedure
5.2 Prerequisite before starting work

Issue No.
Page 3 of
18
1. All stakeholders should be informed in advance and take

prior approval as advised and required.
2. Do Job Safety Analysis (JSA) with stakeholders involved in
activities and make JSA as mentioned in OISD-105 and get
signatures of designated person of Client, EPMC, Contractor
and Stackholders for mentioned activities.
3. Job to be supervised by a competent person. Designated
safety person should be present always at site.
4. All person should wear required PPEs.
5. Conduct Tool Box Talk daily and maintain record. Approved
format of Tool Box Talk by Client/EPMC should be used.
6. Sufficient Number of dry chemical type/CO2 type fire
extinguisher, Sand Buckets, DCP Powder etc. shall be made
available by contractor before starting work. Hose-Pipe
connected to Hydrant line, Fire Tender etc. may be made
available while working in the vicinity of existing HPCL
installation.
7. First Aid Box should always be available at site. Regular
inspection should be done by EPMC/Client to ensure that all
medicines are available and expired medicine should be
replaced before expiry date.
8. Only trained personnel to be deployed for this activity.
9. All Measuring & Test Equipment’s used must be well
maintained.
10. All lifting devices & Tools used shall be well maintained
and approved by a competent authority.
11. All heavy equipment shall be equipped with an
operational back up alarm.
12. Proper Warning Boards and Safety Boards should be
provided at working site.
5.3 PPEs
Issue No.
Page 4 of
18
Persons working at site shall always wear the appropriate

personal protective equipment which can include the following;
1. Safety Helmets
2. Safety footwear
3. Leather glovers
4. Goggles
5. Face and eye protection with correct grade of shield;
Above mentioned PPEs are minimum required which may include

more PPEs as per work and site conditions.
5.4 Detail of activities
1. All material like OFC cable , HDPE Conduit and other

associated works shall be unbder contractor scope for
completion of OFC Installation.
2. Contractor shall obtain all statutory approvals,
crossings approval and taking cognizance of the site
conditions.
3. The Cable shall be laid on the same side of the pipeline
across the entire length and crossing of the pipeline
shall be avoided
4. Manual laying of OFC-
I. Place the jack stand along the sides of the trench
II. Observe the correct drum positions – that is OFC
should be uncoiled from the bottom and not from
the top.
III. Unroll the OFC to the length spacing the workers
after every 20 minutes
IV. OFC can be placed into open trench either directly
from a decoiler or in special case temporarily laid
along the side of the trench and placed later on.
V. Minimum bending radius of the fiber optical radius
and duct to be taken into account
Issue No.
Page 5 of
18
Moving Trailer Method –

This method should be used when section/
route does not contain any road/ railway bores or
utility crossings
5. Backfilling- 250 mm soft soil padding shall be done on
the top of HDPE duct/OFC . Warning mat shall be laid as
per directions of EPMC/Client
6. For Pipeline crossings executed by boring- OFC shall be
laid in permanently lubricated HDPE conduit which shall
be sub ducted in a separate casing conduit .
7. Easy to use OFC sealing plugs shall be used to seal the
ends of the conduit to prevent the engress of water,
dirt.
8. The two ends of the conduit shall be sealed
immediately after installation and resealed when the
OFC has been installed in the conduit.
9. Welding
10. Field joint coating
11. Radiography
12. Lowering
13. Backfilling
5.5 Hazards involved
1. Crew safety
i. Injury/Accident due to collapsing of trench/Machinery
failure
ii. Noise, eye hazards
iii. Electrical hazards
iv. Radiation Hazard
2. Electrical safety
Issue No.
Page 6 of
18
i. Electric Shock due to open joint/cut wire

ii. Fire due to electric short circuit
iii. Touching of Hydra/Excavator to overhead electric
line
3. Trenching
i. Falling of person in trench
ii. Damage of underground utilities
iii. Snake Bite
4. Handling of pipes
i. Falling of Pipe due to breaking sling belt
ii. Failure of Hydra/Crane etc. may cause accident at
site
iii. Damage of lifting equipment due to overload
iv. Poor slinging methodology
v. Overhead electric lines
vi. Soft ground condition
vii. Unbalancing may lead to Tilting of equipment
5. Welding
i. Fire Hazard
ii. Burn
iii. Gas / Fumes
iv. Dehydration
v. During welding operation, the eye may be penetrated
by sparks, spatter, slag, infra-red light, ultraviolet light,
foreign bodies

i. Fire
ii. Injury while blasting pipe surface
iii. Environment damage due to blasting material
iv. Explosion in Hopper/Compressor
Issue No.
Page 7 of
18
v. Eye Injuries from blasting materials

vi. Electric shock while holiday testing
7. Radiography
i. Radiation exposure
ii. Un-authorized operation/entry
iii. Health Hazards
iv. Electrical Hazards
v. Hit due to fall of radiography camera while setting.
vi. Fall/slip in trench
vii. Snake/Insect bite
8. Lowering
i. Accident
ii. Falling in trench
iii. Collapsing of trench
iv. moving equipment
v. overhead power lines
vi. open excavations
9. Backfilling
i. Injury
ii. Run over by vehicle
iii. Hit due to movement of vehicle while loading/unloading
iv. Soft ground condition
v. Un-authorized operation.
vi. Respiratory problem from dust
5.6 Precaution
Issue No.
Page 8 of
18
1. Crew safety
i. All working person should be healthy and mentally sound.
ii. All the testing equipment shall have valid calibration test
certificates.
iii. All the joint coating material to be used shall be within the
valid expiry dates as given by the manufacturer
iv. Crew should wear proper PPEs asper job and site
requirement.
v. Use Ear buds and Goggles while blasting is in progress.
vi. Don’t touch any open/cut electric wire which may cause
electric shock.
vii. Person having respiratory disease should use proper mask
while working
near blasting area.
2. Electrical safety
i. Joints between the cable section should be made with

properly constructed insulated cable coupling, adequately
shrouded so that live metal is not exposed if the parts of the
connector are separated.
ii. Use one socket for one appliance.
iii. Ensure usage of only fully insulated wires or cables.
iv. Don't place bare wire ends in a socket.
v. Ensure earthing of machineries and equipment.
vi. Do not use damaged cords and avoid temporary
connections.
vii. Use spark-proof/ flame proof type field distribution boxes
where are chances of Flammable type fluid or gas leakges.
viii. Do not allow open/bare connections.
ix. Provide all connections through 30mA ELCB.
x. Protect electrical cables/equipments from waterand naked
flames.
xi. Check all connections before energizing.
Issue No.
Page 9 of
18
xii. Display voltage and current ratings prominently with

'Danger' signs.
xiii. Ensure approved cable size, voltage grade and type.
xiv. Switch off the electrical utilities when not in use.
xv. Do not allow unauthorized connections.
xvi. Ensure proper grid wise distribution of Power.
xvii. All cables, including welding and ground cables, shall be
checked for any worn out or cracked insulationbefore
starting the job. Ground cable should be separate without
any loose joints.
xviii. Cable coiling shall be maintained at minimum level, if not
avoidable.
xix. Before using hydra/excavator where overhead electrical
cable are passing, ensure that proper clearance should be
available between electrical line and hydra boom.
xx. Donot do excavation near electrical line pole as pole may fall
down and may cause electrical hazards.
3. Trenching
i. Ensure Temporary fencing on either side of the ROU

wherever it is considered essential to ensure safety and
Noninterference.
ii. No temporary or permanent deposit of any kind of material
resulting from clearing and grading be stacked in the ROU
and any other position which may hinder the passage and /
or natural water drainage
iii. Contractor shall carry out grading, bridge & detouring at
road, water & other crossing and other location for the
passage of its men & equipment.
iv. Ensure prominent display / availability of emergency contact
no for immediate rescue, response
Issue No.
Page 10 of
18
v. In case of rivers/water bodies, which are prone to scour and

erosion, the safety cover shall be provided below the
predicted scour level.
vi. Provide suitable size of shoring and strutting, if required.
vii. Keep soil heaps away from the edge equivalent to 1.5m or
depth of pit whichever is more.
viii. Don't allow vehicles to operate too close to excavated areas.
Maintain atleast 2m distance from edge of cut.
ix. Maintain sufficient angle of repose. Provide slope not less
than 1:1 and suitable bench of 0.5m width at every 1.5m
depth of excavation in all
soils except hard rock.
x. Battering/benching the sides.
xi. Provide atleast 2 No’s ladder to enter/exit in trench for doing
trench examination.
4. Handling of pipes
i. A Tie-In pit or bell hole of suitable length, depth and
width shall be cut to enable to work freely inside the
trench.
ii. Proper care shall be taken so as not to allow pit to
collapse or pit wall caving in.
iii. Necessary supports shall be used wherever required
iv. Check crane/sling/chain pulley certification for their
Safe Working Load and testing date.
v. Safe Working Load must be mentioned on each lifting
device.
vi. Better communication between crane operator and
foreman.
vii. Use only tested lifting tools & tackles certified by TPI.
viii. Use of PPE’s like safety shoe, hard hat, hand gloves etc.
ix. Only trained and experienced operator shall operate
lifting equipment.
Issue No.
Page 11 of
18
x. Work to be supervised by experienced and responsible

persons.
xi. Only tested & good conditioned lifting gears shall be
used.
xii. Check lifting gears every day before starting work.
xiii. No overloading to lifting gears.
xiv. Place the crane properly on the leveled and firm
ground.
xv. Check the crane capacity/radius & load to be lifted.
Check the limit switches functionality everyday before
starting work.
xvi. Cordon off the lifting zone & Provide signal man. Use
tag lines to the load. Don’t stand or rest on the way of
moving vehicles.
xvii. Hoisting and swinging shall be done smoothly. Use tag
lines to guide the load to be lifted.
xviii. Keep proper clearance from overhead electric lines.
xix. Use the plates or wooden sleepers while placing crane
in soft gound condition.
xx. No overloading of crane.
xxi. Engage experienced person with valid license for lifting
work.
xxii. Don’t apply hand directly in between the stack. Use
appropriate hand gloves.
xxiii. Use experienced personnel for rigging works.
xxiv. Clear the loose objects from the load to be lifted.
xxv. Ensure full time supervision.
xxvi. Cordon off the lifting zone.
5.Welding
i. The tie-in should be done in such a way as to leave no

strain in the pipe. If necessary, redressing of the trench
shall be done to eliminate force or strain in the pipe.
Issue No.
Page 12 of
18
ii. As and when a Tie-in joint is planned during the lowering

of pipeline, the same shall be recorded in Tie-in record
book maintained by the respective Welding Engineer.
iii. Use specified shielding devices and other PPE of correct
specifications.
iv. An electrode holder should be fully insulated so that the
live portions can not be touched accidentally.
v. Flammable material should be kept out of any area where
welding is taking place.
vi. Where such a course of action is not practicable, fire
retardant cloth should be used to protect the surroundings
from the flame and from spatter.
vii. At-least one fire extinguisher should always be
immediately available in the area of any welding
operation.
viii. To protect skin from burn injury the hands, arms legs, and
feet should be protected by gloves or gauntlets, spats and
jackets made from chrome leather.
ix. The footwear should be made of leather.
x. During gas welding to protect eyes from infra red light,
box goggles with a housing made to BS 1542 and filter
made to BS EN 169 and 171.
xi. During arc welding the welder must use welding helmet or
hand screen with housing complying with BS 1542 and
fitted with appropriate filter to BS EN 169 &170.
xii. During welding the fumes generated mainly consists of
iron oxide, carbon monoxide, nitrous, ozone. These fumes
are mostly causing respiratory disease.So,The welding
operation should be carried out in a well ventilated
location.
xiii. If a number of welding operation is carried out in a same
location or the work being carried out in a confined space
Issue No.
Page 13 of
18
the most effective form of fume control equipment is

suction type ventilation.
xiv. Workers should be encouraged to drink saline / electrolyte
solution/ORS
xv. Don’t see welding by naked eyes which may result in
Flash burn. Always use welding helmets or welding
goggles.
xvi. Use leather glover and leather apron while doing welding
to avoid burning.
xvii. Welding area should be barricade to avoid entry of
unauthorized person.
xviii. All quality records generated during the welding of Tie-In
joints shall be reviewed and approved by HPCL/EPMC.

i. Surface Preparation
a. Ensure dead man switch is working
b. Air pressure machine on the sandblasting shall be
checked on daily basis to ensure it is safe to use
c. Connected hoses shall be provided with steel strap
d. Use respirator, standard fresh air supply- hood
e. All workers in the vicinity of sandblasting works shall
wear dust masks
f. Cover blasting area with sheet or cloth to avoid flowing
of Blasting material in surrounding area. Vacate the
area before carrying out the operation
g. Only qualified operator/blaster should perform the task
h. Wear hearing protection.
i. Use Copper Slag only. Donot use sand
j. Face guard and white goggles should be provided to
blaster.
k. Fire Extinguisher should be kept near working area.
Issue No.
Page 14 of
18
ii. Application of Coating by Heating

a. Wear leather gloves and leather appron while
heating coating material
b. Keep fire extinguisher near working area.
c. Before preheating pipe, check that hoses are
connected properly to cylinder, area is free from any
flammable material, valid permit has taken and area
is corned off by caution tape and proper Warning
board has been provided.
d. Check trench is stable before going near trench.
Special care to be taken during Monsoon.
iii. Inspection including Holiday Test

a. Wear leather gloves.
b. Check electrical cable is free from any open cut.
c. Proper insulation should be provided for the holiday
machine
d. Ensure proper earthing
7. Radiography
i. Safety in NDT method is first priority, hence all technicians

must work as per BARC radiation safety guide and all local
rules and regulations. All radiography jobs shall be carried
out as per BARC Safety Regulations. All technicians should
use TDL / dosemeter while carrying out Radiography
Testing.
ii. During field radiography, nearby area around the radiation
source should be cordoned off. Radiation warning signals
should be pasted all along the cordoned off area.
iii. Entry into the restricted area by unauthorised persons

should be strictly prohibited during exposure.
Issue No.
Page 15 of
18
iv. All personnel working with radiography sources should wear

appropriate protective equipment and film badges issued
by BARC.
v. Protection facilities such as manipulator rod, remote
handling tongs, lead pots, radiation hazard placards and
means of cordon off shall be available at each site.
vi. The radiography source shall never be touched or handled
directly with hands.
vii. The package containing radiography cameras and sources
should never be carried by public transport like bus, train
etc.
viii. Radiography sources and cameras, when not in use, should
be stored inside a source pit with lock and key arrangement
as approved by BARC. The storage room should preferably
be located in an isolated area of minimum occupancy and
radiation level outside the storage room should not exceed
0.25 mR/hr as per BARC Regulations.
ix. In case of an accident (due to loss or of damage to
radiography source), action should be taken in line with
BARC Safety Rules/Guidelines.
x. Technologically advance methods should be preferred for
reduced radiation effect wherever safety so warrants.
xi. The minimum qualification of NDT personnel to carry out
Radiography testing should be Level-1 in Radiography
Testing in accordance with documents ASNT SNT TC-1A.
However person carrying out Radiographic interpretation
should be qualified as Level –II in Radiography Testing as
per ASNT SNT TC-IA.
xii. On-arrival at site, radiographer must obtain permit-to-work

from authorized person of work site and inform him of
following:
a) Type and strength of radiographic sources.
b) Model and serial number of radiographic equipment.
c) Name of radiographer.
Issue No.
Page 16 of
18
d) Type of safety equipment to be used.

e) Period of works.
f) Sketch of site plan indicating location of works and
intended safety boundary.
8. Lowering
i. Lowering of pipeline should be done after approval from
owner / consultant. The activity should be done in
presence of Authorized representative of Owner /
Consultant.
ii. During lowering-in, Contractor must ensure that the pipe
is not subjected to inadmissible stresses ; the pipeline is
supported over a sufficient surface area to prevent the
supports from penetrating the coating; a sufficient
number of machines with the required capacity will be
used for lowering-in the pipeline strings.
iii. It shall be ensured that the pipe is laid gently by using
sufficient number of side booms for holding the line in
gentle s-curve maintaining the minimum elastic bend
radius.
iv. The pipeline must be laid without interruption for the
whole or the length of section available. Lowering shall
not be left in half way.
v. Where water is present, no laying shall be permitted until
the ditch has been drained to the extent and for the time
necessary to make visual inspection possible of the bed
on which the pipe is to be laid. Following such inspection,
the presence of water will be permitted, provided that it is
not so high as to cause cave-in of wall of the trench or
floating of the pipeline before backfilling, when weighting
is not provided for the pipe.
vi. Pipe shall never be picked up or lowered while any
employees are between the tractor and the pipe, and pipe
shall never be carried over the heads of employees.
Issue No.
Page 17 of
18
vii. No one should give signals, directions, or other

instructions to an equipment operator unless he has been
trained, authorised and directed to do so.
9. Backfilling
i. The upper part of the backfill shall be carried out in

consecutive layers. Each layer must be tamped down to
avoid hollow spaces which might later lead to subsidence.
Each layer shall be put back in such a way that the original
layering of the terrain is respected.
ii. Before start of Backfilling Contractor shall ensure the
provision of negative buoyancy in marshy area
iii. The backfill material shall be soil, sand, clay or other
materials containing no hard materials, which could damage
the pipe and/or coating or leave voids in the backfilled
trench
iv. Each completed layer of Backfilling shall be carefully
deposited, watered where necessary and thoroughly
consolidated to the satisfaction of Client/EPMC.
v. The surplus material shall be neatly crowned directly over
the trench and the adjacent excavated areas on both sides
of the trench to such height, which will, provide for future
settlement of the trench backfill during the maintenance
period and thereafter.
vi. The crown shall be high enough to prevent the formation of
the depression in the soil when backfill has settled into its
permanent position.
vii. If depression occur after backfill, Contractor shall carryout
the remedial work.
Issue No.
Page 18 of
18
viii. Surplus material left from this operation shall be disposed

off to the satisfaction of landowner or authority having
jurisdiction
ix. When the trench has been dug through driveways or
roads, all Backfilling shall be executed with sand or suitable
materials (shall be approved by Client/EPMC) in suitable
layers, which will be thoroughly compacted at the end of
each day’s work.
x. Be aware of the blind spot adjacent to the boom arm.
xi. Lower the bucket when not in use and disengage the drive.
6.0 RECORDS
a. Permit as per OISD-105

b. JSA and Tool Box Talk records as per OISD-105
c. Safety Checklists
d. Accident Reports as per OISD-107
e. Safety Training Record
f. Induction Reports

SOP-9 - Tie in Joints

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हिन्दुस्तान पेट्रोलियम कार्पोरेशन लिमिटेड Doc No.

Management Representative DGM-Projects

Revision and Amendment sheet

Page Clause Revisi Revision

Note: - As per the procedure for control of document procedure

SAFETY PROCEDURE FOR TIE-IN JOINTS

To encourage and educate personnel on the HPCL sites to

Applicable to all Pipeline Project locations and greenfield

OISD GDN -192

4.1 ROU In-charge / Officer In-charge / Project consultant’s

4.2 Officer In-Charge / Project consultant’s Safety Officer shall

5.2 Prerequisite before starting work

1. All stakeholders should be informed in advance and take

Persons working at site shall always wear the appropriate

Above mentioned PPEs are minimum required which may include

5.4 Detail of activities

1. All material like OFC cable , HDPE Conduit and other

Moving Trailer Method –

5.5 Hazards involved

i. Electric Shock due to open joint/cut wire

6. Field joint coating

v. Eye Injuries from blasting materials

i. Joints between the cable section should be made with

xii. Display voltage and current ratings prominently with

i. Ensure Temporary fencing on either side of the ROU

v. In case of rivers/water bodies, which are prone to scour and

x. Work to be supervised by experienced and responsible

i. The tie-in should be done in such a way as to leave no

ii. As and when a Tie-in joint is planned during the lowering

the most effective form of fume control equipment is

6. Field joint coating

ii. Application of Coating by Heating

iii. Inspection including Holiday Test

i. Safety in NDT method is first priority, hence all technicians

iii. Entry into the restricted area by unauthorised persons

iv. All personnel working with radiography sources should wear

xii. On-arrival at site, radiographer must obtain permit-to-work

d) Type of safety equipment to be used.

vii. No one should give signals, directions, or other

i. The upper part of the backfill shall be carried out in

viii. Surplus material left from this operation shall be disposed

a. Permit as per OISD-105

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