HCC Management System

Procedure for
THERMIT WELDING
Project: Kalol Mehsana Gas Pipeline Project
(Job No: GSPL/113)

PROCEDURE FOR THERMIT WELDING

(Temporary & Permanent Cathodic Protection System)

HCC NOVA P 46 17 46
Date: 02nd April 2006
DOCUMENT RELEASE AUTHORIZATION

Rev.
No

02.04.06

Date:

For Approval

Description

Prepared By
( Raychem PRG
Ltd )

Checked By
(Manager QA
HCC-NOVA JV)

Approved By
(Dorsch
Reviewed By ABS
Consult (I) Pvt.
(TPI)
Ltd / GSPL)

Project

Kalol Mehsana Gas Pipeline Project (Job No: GSPL/113)

Owner

Gujarat State Petronet Ltd.

Consultant

Dorsch Consult (India) Pvt. Ltd.

TPIA

ABS Industrial Verification Ltd

Contractor

HCC-NOVA JV.

CP Contractor

Raychem RPG Ltd

This document is the property of HCC and is copyright protected. Unauthorized photocopy either
partly or fully is prohibited. Authorized controlled copy of this document can be had from Doc.
Controller.

Doc No: HCC NOVA 46 17 46 Rev No: 0, Dt: 02/04/06, Page 1 of 8

Issued for
constrn. By
GSPL
(KMPL
Project)

HCC Management System

Procedure for
THERMIT WELDING
Project: Kalol Mehsana Gas Pipeline Project
(Job No: GSPL/113)

INDEX
S.No.

Description

Page No.

1.

Scope

03

2.

Reference

03

3.

Materials Required

03

4.

Method

03

5.

Pre-cautions

05

6.

Health, Safety & Environment

05

7.

Quality Assurance / Quality Control

05

8.

Appendix / Formats

05

9.

Inspection & Test Plan

06

10.

Inspection Report

07

11.

Drawing

08

Doc No: HCC NOVA 46 17 46 Rev No: 0, Dt: 02/04/06, Page 2 of 8

HCC Management System

Procedure for
THERMIT WELDING
Project: Kalol Mehsana Gas Pipeline Project
(Job No: GSPL/113)
1.0 Scope
This procedure covers the Thermit Weld of various types of cables with the
pipeline and provide adequate quality assurance/control of workmanship and
inspection at site.
2.0 Reference:
GSPL Specification: 1013-113-410
3.0 Materials Required:
Equipment

Crimping

Tool,

Thermit

(or)

CAD

Mould,

chissel

and

hammer, Gun or spark ignitor

Materials

Cable Lugs, cad weld powder, Disc, Epoxy Dobefil-60

and hardner-758, PVC Funnel and M Seal

4.0 Method:
1. Excavate a pit over the pipeline to expose the pipeline top surface at
location of thermit weld location where cable to pipe connection is to be
done. Care should be taken not to damage the coating of buried pipeline.
2. Mark where connection is to be carried out. If there is more than one
connection as per design document, consecutive marking shall be minimum
300 mm apart. The location for cable to pipe connection shall be selected
such that the pipe joints and field coated areas are avoided. Care shall be
taken that cable to pipe joint is not made upon the long seam or
circumferential weld.

Doc No: HCC NOVA 46 17 46 Rev No: 0, Dt: 02/04/06, Page 3 of 8

HCC Management System

Procedure for
THERMIT WELDING
Project: Kalol Mehsana Gas Pipeline Project
(Job No: GSPL/113)
3. Cut and open the coating on the pipeline with care and without damaging
the pipe for a size of approximately 50 mm x 50 mm.
4. Clean the surface of the pipeline to white metal finish using sand
paper/wire brush
5. Depending on the size of cable, select the model of cad weld material i.e.
CA-15 or CA-32 and mould.
6. Place the mould on the exposed area and pour the cad weld material.
Before pouring the cad weld material, put the disc inside mould for holding
the cadweld material. Ignite using the gun and wait for a minute as cool
down period. The Thermit weld shall be checked by hitting the weld with a
small hammer.
7. Place a plastic funnel / PVC pipe 75mm ID (approx.) around the exposed
area such that about 5mm wide coating remains in side the plastic
funnel/PVC Cap. Place M-seal around the plastic funnel to prevent leakage
of encapsulation materials.
8. Fill up the conical mould from the top by pouring mix of Epoxy Dobefil
60 and hardener 758 at 10:1 ratio. 3/4th of the PVC Cap to be filled with
mix .
9. Allow the epoxy-hardener to set and test the insulation by a holiday
detector at 15 - 20 KV.

Doc No: HCC NOVA 46 17 46 Rev No: 0, Dt: 02/04/06, Page 4 of 8

HCC Management System

Procedure for
THERMIT WELDING
Project: Kalol Mehsana Gas Pipeline Project
(Job No: GSPL/113)
5.0

PRECAUTIONS:

Excavation to be done without damaging the coating.

Check hardness of encapsulation before holiday test by applying Pressure with

thumb.

6.0

Coating repair and holiday test should be completed before backfilling.

HEALTH, SAFETY & ENVIRONMENT
Hazard Identification and risk assessment will be carried out and Operational
Control measures shall be adopted for Anode Installation Activities.
1. Necessary PPE to be utilized
2. Only trained personnel to be deployed for this activity.
3. Care to be taken while doing thermit welding / Holiday Detector usage

7.0

QUALITY ASSURANCE & QUALITY CONTROL

Quality Assurance shall be maintained by ensuring the systematic
implementation of this Procedure and ensure that necessary quality records are
generated as per ITP.

8.0

APPENDIX / FORMATS

Inspection Test Plan

:HCC NOVA T 46 17 46

Thermit Welding Inspection Report

:HCC NOVA F 46 17 46 01

Doc No: HCC NOVA 46 17 46 Rev No: 0, Dt: 02/04/06, Page 5 of 8

INSPECTION & TEST PLAN

THERMIT WELDING
Owner

Gujarat State Petronet ltd

Format: HCC -NOVA T 46 17 46

Consultant

Dorsch Consult India Pvt.Ltd.

Revision : 0

TPIA

ABS industrial Verification Ltd.,

Date:

Contractor

HCC NOVA joint Venture

CP Contractor

Raychem RPG Ltd

Project

Kalol Mehsana Gas Pipeline Project

Controlling
Specification

Acceptance
Criteria

Submission & Obtaining

approval of Procedure

Contract
Specification
-1013-113-401

Contract
Specification
-1013-113-401

Location

Appd. Design
Document

Appd. Design
Document

Check The Cable Size

Drawing /
Appd. Deisgn
Document

Drawing /
Appd. Deisgn
Document

Check the Thermit Weld

Drawing

Hammer Test

Sr.
No

Activity Description

Verifying
Document

Frequency
of Inspe/
Testing

Inspection Category
RRL

HCC
NOVA
JV

TPIA

Dorsch/
GSPL

At the
Beginning

Every
Location

RI

RI

HCC-NOVA
P 46 17 4601

Every
Location

RI

RI

Drawing

HCC-NOVA
P 46 17 4601

Every
Location

RI

RI

HCC-NOVA
P 46 17 4601

Every
Location

RI

RI

Check the
Encapsulation Hardness

HCC-NOVA
P 46 17 4601

Every
Location

RI

RI

Check the Continuity

HCC-NOVA
P 46 17 4601

Every
Location

RI

Holiday Check

HCC-NOVA
P 46 17 4601

Every
Location

RI

Approved
Procedure
HCC-NOVA
P 46 17 46
HCC-NOVA
P 46 17 4601

Remarks

Legend
W : Witness
I

RI

: Implementation

A : Acceptance / Approval

: Review of Record

For Raychem RPG LTD

: Random Inspection

P : Perform
For HCC NOVA JV

For ABS (TPIA)

For Dorsch / GSPL

Name:

Name:

Name:

Name:

Sign:

Sign:

Sign:

Sign:

Date:

Date:

Date:

Date:
Page 6 of 8

INSPECTION REPORT
THERMIT WELDING
Owner

Gujarat State Petronet ltd

Format: HCC -NOVA F 46 17 46 01

Consultant

Dorsch Consult India Pvt.Ltd.

Revision : 0

TPIA

ABS industrial Verification Ltd.,

Date:

Contractor

HCC NOVA joint Venture

Report No.

CP Contractor

Raychem RPG Ltd.

Project

Kalol Mehsana Gas Pipeline Project

Sr.
No

Description

Location Chainage

Test Station Type

Type and Size of Cables

Observation
K.M

1.
2.
3.

Thermit Weld

OK / NOT OK

Hammer Test

OK / NOT OK

Cable Continuity with Pipeline

OK / NOT OK

Hardness of Encapsulation

OK / NOT OK

Holiday Check

For Raychem RPG LTD

Mtrs

For HCC NOVA JV

For ABS (TPIA)

For Dorsch / GSPL

Name:

Name:

Name:

Name:

Sign:

Sign:

Sign:

Sign:

Date:

Date:

Date:

Date:

Page 7 of 8