Specification for Thrust Boring

REVISION HISTORICAL SHEET Rev No

Date

Page

Description

TABLE OF CONTENTS REVISION HISTORICAL SHEET.................................................................................... 1 TABLE OF CONTENTS................................................................................................... 2 1.

SCOPE..................................................................................................................... 4

2.

DEFINITIONS........................................................................................................... 4

3.

REFERENCE DOCUMENTS.................................................................................... 4 3.1

Codes and Standards...................................................................................... 4

3.2

Contractor Project Specifications..................................................................... 5

3.3

THRUST BORING SUBCONTRACTOR’S SCOPE OF WORK....................... 5

3.4

Thrust Boring Subcontractor’s Scope of Work................................................. 5

3.5

Thrust Boring Works to be Subcontracted....................................................... 6

4.

GENERAL REQUIREMENT..................................................................................... 7

5.

THRUST BORING PLANNING AND PROGRAMMING........................................... 7

6.

THRUST BORING DESIGN REQUIREMENTS........................................................ 8

7.

8.

6.1

Thrust Boring Pre-Design Survey Requirement............................................... 8

6.2

6.1.1 Topographic and Bathymetric Survey...................................................... 8 Profile Design.................................................................................................. 8

THRUST BORING MATERIAL PROCUREMENT REQUIREMENTS....................... 9 7.1

Pipe Material.................................................................................................... 9

7.2

Field Joint Coating........................................................................................... 9

7.3

End Seal and Spacer....................................................................................... 9

THRUST BORING CONSTRUCTION REQUIREMENTS......................................... 9 8.1

General Requirement...................................................................................... 9

8.2

Thrust Boring Survey Requirement.................................................................. 9

8.3

Thrust Boring Equipment Requirement............................................................ 9

8.4

Site Preparation............................................................................................. 10 8.4.1 General.................................................................................................. 10 8.4.2 Starting Pit Area..................................................................................... 10

9.

8.5

8.4.3 Arrival Pit Area....................................................................................... 10 Pre Construction Meeting.............................................................................. 10

8.6

Rig Up of Thrust Boring Equipment................................................................ 11

8.7

Thrust Boring................................................................................................. 11

8.8

Pull Back of 24” Pipeline into 30” Casing Pipe............................................... 12

8.9

Contractor's Taking Over............................................................................... 12

THRUST BORING QUALITY MANAGEMENT REQUIREMENT............................ 12 9.1

Inspection and Test Plan (ITP) Requirement.................................................. 12

9.2

Acceptable Tolerances................................................................................... 12

9.3

Thrust Boring Records Drawings................................................................... 12

10. THRUST BORING HEALTH AND SAFETY MANAGEMENT REQUIREMENTS.. .13 11. THRUST BORING ENVIRONMENTAL MANAGEMENT REQUIREMENTS..........13 12. COMPLETION........................................................................................................ 13 12.1

Pulling Head Removal.................................................................................. 13

12.2

Thrust Boring and Supporting Equipment..................................................... 13

1.

SCOPE 1. This specification defines the minimum requirements for Thrust Boring to be planned, designed, supplied and implemented by the Subcontractor. 2. This specification shall be read in conjunction with General Requirement for Subcontracted Work and the relevant Specifications, Drawings and Procedures referenced herein. 3. When the contents of this specification are in conflict with the contents of the General Requirement for Subcontracted Work, then the requirements of this specification shall prevail in respect to the subject matter dealt with herein.

2.

DEFINITIONS For the definition of terms appearing within this specification that are not specifically given herein, reference should be made to General Requirement for Subcontracted Work In addition to the definitions given in the “General Requirement for Subcontracted Work”, the following definitions shall apply: 1. “Thrust Boring” or “Boring” means a technique for the trenchless installation of pipelines and casings. 2. “Thrust Boring Subcontractor” means any person named in the Subcontract for Thrust Boring Work as a subcontractor or any person appointed as a subcontractor by the Contractor, and the legal successors in title to each of these persons. 3. “General Requirements for Subcontracted Work” means a documented general requirements 4.

“Auger Boring” means a boring technique for forming a bore from a starting pit to an arrival pit by means of a rotating cutter head.

5. “Micro Tunnelling” means a boring technique which utilises a non-man entry remote control boring head and thrust jacks. 3.

REFERENCE DOCUMENTS The following publications form a part of this document. Unless otherwise specified herein, the latest edition is to be used.

3.1

CODES AND STANDARDS ASME B31.8 – 2007

Gas Transmission and Distribution Piping System

API Spec. 5L

Specification for Line Pipe

PP 11/1979

Peraturan Pemerintan Republik Indonesia tentang Keselamatan Kerja pada Pemurnian dan Pengolahan Minyak Pedoman dan Tata Cara Pemeriksaan Keselamatan Kerja Atas Instalasi, Peralatan dan Teknik yang Dipergunakan Dalam Usaha Pertambangan Minyak dan Gas Bumi dan Pengusahaan Sumber Daya Panas Bumi Keselamatan Kerja Pipa Penyalur Minyak dan Gas Bumi

Keputusan Dirjen MIGAS No. 84.K/38/DJM/1998

KEPMENTAMBEN NO. 300.K/38/M.PE/1997

3.2

CONTRACTOR PROJECT SPECIFICATIONS General Requirements for Subcontracted Work Inspection and Test Plan (ITP) Basic Engineering Design Data Pre-Construction Survey Procedure Specification for Pipe Specification for Heat Shrinkable Sheet and Coating Repair Material Data Sheet for Piping Data Sheet for End Seal and Spacer Main Line & Tie-in Welding Procedure Thrust Boring Procedure Procedure for Excavation of Starting & Arrival Pits Reinstatement and Restoration 3.3

3.4

THRUST BORING SUBCONTRACTOR’S SCOPE OF WORK

3.5

THRUST BORING SUBCONTRACTOR’S SCOPE OF WORK

No 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Description Provide alignment drawings, maps, illustrations, specifications and data sufficient for the Thrust Boring Subcontractor to carry out Detailed Design and execution of the Thrust Boring Works Location and identification of any existing underground utilities or sub-structures that are present, adjacent or in proximity of the crossing location. Provide temporary or permanent protection to existing roads, underground utilities and structures, if required. Detailed Design and submit the crossing long section drawing to the Contractor for approval. Provide a Construction Schedule to carry out the work. Provide procedures required to carry out the Thrust Boring work Provide all work permits, licences and other permissions, as required, for the duration of the Thrust Boring works. Provide Thrust Boring equipment and mobilize to the Job Site. Provide manpower, supervision and management of the Thrust Boring Subcontractors activities. Provision of access at Starting and Arrival Pit locations suitable for truck & crane access including temporary land if required. Survey, setting out of Starting and Arrival pit positions to confirm the crossing alignment. Excavate and Shore Starting and Arrival pits, set-up and rig up the Thrust Boring Equipment in readiness for boring. Execute installation of the 30-inch diameter casing pipe in the crossing. Provide the 30-inch casing pipe string required for the crossing,

Thrust Boring Subcontractor

Contractor X X X

X X X X X X X X X X X

No

15 16 17 18 19 20

3.6

Thrust Boring Subcontractor

Description including welding, fitting spacers/centralizers. Execution of hauling, stringing, welding, NDE, field joint coating, handling of the 24” pipeline Pulling- back into the 30” casing of the 24” diameter pipeline. Restoration and reinstatement Starting and Arrival Pits, existing services, structures and work areas on completion of Thrust Boring Work. Supply and install Cathodic Protection System for casing pipe. Supply and install End Seal and Spacer materials. Hand over the Thrust Boring Works result to the Employer.

X X X

X X X

THRUST BORING WORKS TO BE SUBCONTRACTED TABLE-1 LIST OF THRUST BORING LOCATION Crossing Details

Reference Drawing

Area/Terrain

No.

KP

1

KP 02+920

RWC

TB

26

Field

2

KP 07+688

RC-RIC

TB

12

Rice Field

3

KP 12+950

RC

TB

7

Rice Field



4

KP 13+210

RWC

TB

32

Rice Field



5

KP 15+010

RC

TB

20

Grass

6

KP 15+810

RC

TB

16

Residential



7

KP 16+650

Overpass

TB

43

Rice Field



8

KP 17+930

HRC

TB

77

Field



9

KP 18+140

Overpass

TB

40

Rice Field



10

KP 18+480

HRC

TB

46

Rice Field



11

KP 20+069

Overpass

TB

45

Rice Field



12

KP 21+318

Overpass

TB

54

Rice Field



13

KP 23+450

Overpass

TB

57

Rice Field



14

KP 24+910

Overpass

TB

48

Rice Field



15

KP 26+840

Overpass

TB

41

Field



Type

Length Method (m)

Rice Field / Residential Rice Field / Residential







16

KP 27+840

Overpass

TB

45

17

KP 29+280

RIC

TB

40

18

KP 29+580

HRC

TB

40

Grass



19

KP 29+680

HRC

TB

45

Grass



20

KP 30+540

HRC

TB

113

Field



Legends:  RWC

: Rail Way Crossing

 RIC

: River Crossing

 RC

: Road Crossing

Contractor

 

 HRC

4.

: Highway Road Crossing

GENERAL REQUIREMENT 1. The Thrust Boring Subcontractor shall be responsible for undertaking all the requirements given in the General Requirement for Subcontracted Work 2. The Thrust Boring Subcontractor shall furnish all labour, materials and equipment necessary for undertaking a complete crossing installation at the location shown in the Preliminary Design Drawings in the Table 1. 3. The Thrust Boring Subcontractor shall be responsible for reviewing all Contractorfurnished Project Specifications, Drawings and Procedures as listed in Sub-Sections 3.2 and 3.3 of this specification. 4. Thrust Boring shall be performed by an experienced Thrust Boring Subcontractor employing experienced personnel. The CVs’ of Subcontractor personnel shall be submitted to the Contractor for review, not later than thirty (30) days before commencing the Thrust Boring work. 5. The Thrust Boring Subcontractor shall be responsible for co-operating with the Contractor, the Employers’ Personnel and other parties for implementing and completing the Thrust Boring Work in accordance with the requirements of the Thrust Boring Subcontract.

5.

THRUST BORING PLANNING AND PROGRAMMING 1. The Thrust Boring Subcontractor shall submit a documented Thrust Boring Construction Plan in accordance with the requirements given in the General Requirement for Subcontracted Work and the particular requirements given herein. 2. The Thrust Boring Subcontractor shall submit the Construction Plan for the Contractors’ review not later than 30 days before commencement of the Thrust Boring Work. 3. The Thrust Boring Construction Plan shall, as a minimum requirement, include the following: a) Layout drawings of starting, arrival and staging areas. b) Thrust Boring procedure. c) Prepare the bore plan for the crossing. d) Prepare a drilling fluid plan which includes details of the drilling fluids to be used, estimated flow rates, methods to be implemented for minimizing drilling fluid escape or loss, if using “Iseki type” slurry shield machine. e) Method of final treatment / disposal of waste drilling fluid and cuttings. f)

A list of Thrust Boring Subcontractors Personnel and CV.

g) A list of the Thrust Boring Subcontractors’ equipment and its specifications. 1. The Thrust Boring Subcontractor shall submit a detailed Working Programme for the Contractors’ review, not later than 15 days after commencement of the Thrust Boring Subcontract. The Programme shall be in accordance with the Contractors’ work

schedule. The Subcontractors’ Working Programme shall show the following minimum requirement: a) Detail Design of the Crossing including Starting and Arrival pits.

as

b) Mobilization of Thrust Boring equipment to the Site. c) Mobilization of Thrust Boring Subcontractors’ personnel to the Site. d) Rig-up of Thrust Boring equipment. e) Thrust Boring f)

Pipe Pulling

g) Rig Down of Thrust Boring Equipment h) Thrust Boring As Built Survey i)

Thrust Boring As Built Documentation.

j)

Demobilization of Thrust Boring Equipment

k) Demobilization of Thrust Boring Subcontractors’ Personnel 6.

THRUST BORING DESIGN REQUIREMENTS 1. Prior to commencement of Thrust Boring work at the Site, the Thrust Boring Subcontractor shall obtain the Contractors’ approval of the Subcontractors detail design drawings. 2. The Thrust Boring Subcontractor shall develop its’ own Design Submission Schedule (DSS) in accordance with the Contractors’ DSS, which is included in the Thrust Boring Subcontract. The Thrust Boring Subcontractors’ DSS shall be submitted to the Contractor for its review, not later than 15 days after commencement of the Thrust Boring Subcontract.

6.1

THRUST BORING PRE-DESIGN SURVEY REQUIREMENT

6.1.1

Topographic and Bathymetric Survey 1. The Contractor shall carry out a topographic of the crossing area. 1. The Thrust Boring Subcontractor shall perform survey as necessary to complete his Detail Design.

6.2

PROFILE DESIGN 1. The Thrust Boring Subcontractor shall design the crossing profile in accordance with the project specifications within the constraints of the information collected during the survey. 1. The planned crossing profile and bend radius shall make allowance for cover requirements for areas such as drains or other utilities which lie outside of the road area but form part of the crossing alignment.

7.

THRUST BORING MATERIAL PROCUREMENT REQUIREMENTS

7.1

PIPE MATERIAL 1. The Contractor will haul the Employer’s Free-issue Materials (24” diameter Line Pipe) to the site for its own installation work including, stringing, welding, NDT and field joint coating. 2. Steel casing pipe to be used for the crossing will be supplied by the Contractor. The casing pipe size will be 30” nominal diameter.

7.2

FIELD JOINT COATING 1. The Contractor will supply an apply field joint coating after passing NDT of each joint for the 24” diameter pipeline.

7.3

END SEAL AND SPACER 1. End Seal and Spacer shall use materials in accordance with Data Sheet for End Seal and Spacer. 2. The Spacer and End Seal materials shall be manufactured from non conductive material to prevent electric contact between main line pipe and casing pipe.

8.

THRUST BORING CONSTRUCTION REQUIREMENTS

8.1

GENERAL REQUIREMENT The Thrust Boring Subcontractor shall be responsible for construction the crossing installation in accordance with the General Requirements for Subcontracted Work, this specification and accepted industry practices.

8.2

THRUST BORING SURVEY REQUIREMENT In addition to the general survey of the crossing location, as described elsewhere in this specification, the Thrust Boring Subcontractor shall be responsible for any construction survey which may be required to align the thrust boring machine and establish control points that the Thrust Boring Subcontractor may require to enable him to carry out the Work.

8.3

THRUST BORING EQUIPMENT REQUIREMENT 1. The Thrust Boring Subcontractor shall submit specifications of the thrust boring equipment to be used. It is the Thrust Boring Subcontractors’ responsibility to ensure that the equipment proposed is adequate to complete the project. 2. All equipment shall be in good, safe operating condition with sufficient supplies, materials and spare parts on hand to maintain the system in good working order for the duration of this project. 3. The bore head shall be steerable. 4. The Guidance System shall be of a proven type such as a visible laser striking a target inside the shield or by use of a Total Station measuring shield mounted prisms, or use of a pilot bore system. All of which shall be setup and operated by personnel trained and experienced with the system which is being used.

8.4

SITE PREPARATION

8.4.1

General 1. Prior to any alterations to work-site, Thrust Boring Subcontractor shall photograph or video tape entire work area, including starting pit and arrival pit. One copy of which shall be given to the Contractor and one copy to remain with Thrust Boring Subcontractor. 1. The Thrust Boring Subcontractor shall physically identify the exact location of the utilities by hand excavation, when possible, in order to determine the actual location and path of any underground utilities which might be within 20 feet of the bore path. 2. Thrust Boring Subcontractor shall not commence boring operations until the location of all underground utilities within the work area have been verified.

8.4.2

Starting Pit Area 1. The starting pit area shall be leveled, with a suitable hard stand area provided for the Thrust boring support equipment. 1. The starting pit area shall be fenced with suitable fencing to prevent entry of unauthorized persons to the work site. 2. Perimeter Lighting shall be installed and operated during the night hours. 3. The starting pit will be constructed at the location where the boring shield will first enter the ground. The pit shall be excavated to a sufficient size to allow for the placement of the thrust jacks, the boring shield and the casing pipe. The starting pit shall be shored using steel frames and wooden sheeting for the crossings of the Toll road and wooden beams and wooden sheeting on other road crossings. 4. The Thrust Boring Subcontractor shall provide for anchoring of the Thrust Jacks. This may be achieved by using a concrete anchor block. In any case the anchoring method shall be able to withstand the forces expected during jacking of the casing while installing the crossing.

8.4.3

Arrival Pit Area 1. The arrival pit area shall be leveled, with a suitable hard stand area provided for the pipe fabrication. 2. The arrival pit area shall be fenced with suitable fencing to prevent entry of unauthorized persons to the work site. 1. Perimeter Lighting shall be installed and operated during the night hours. 2. An arrival pit shall be constructed at the point where the boring shield first exits the ground. The arrival pit shall be excavated to a sufficient size to allow for the removal of the boring shield. The arrival pit shall be shored and sheeted as described in 9.4.2 above.

8.5

PRE CONSTRUCTION MEETING 1. The Contractor requires that a Pre-Construction Meeting be held with the Thrust Boring Subcontractor prior to the initiation of any Thrust Boring activity, other than material procurement order. 2. The following lists the items, as a minimum, which must be discussed at this meeting:

A. Finalized Thrust Boring construction method and procedures including Detailed Design Drawings issued for construction (IFC), B. Status of Permit to Work, C. Thrust Boring construction time line diagram and general sequence of Thrust Boring activities, D. Authority and rights of the Contractor's representative, E. The Contractor's representatives' right-of-access to all portions of Thrust Boring Work, F. Other items as required. 8.6

RIG UP OF THRUST BORING EQUIPMENT 1. The thrust boring equipment shall be set in the starting pit in a manner that will prevent it from moving when the expected jacking forces are applied. 1. The slurry mixing system, if used, shall be connected the shield by a flexible hose. The slurry mixing tank may be connected to other holding tanks, other equipment, or holding pits by hose or pipe. The pipe may be steel or HDPE or other shatter proof material. 2. Slurry transport piping will be anchored and placed so as not to create a hazard for workers. 3. The slurry pumping system shall capable of delivering the slurry at a constant pressure in accordance with the shield operation requirements to maintain correct earth pressure balance and slurry flow. 4. Connections between the pump and shield shall be leak-free and the pressure delivery hose shall be rated for the expected operating pressures.

8.7

THRUST BORING 1. The Thrust Boring Subcontractor shall provide and maintain instrumentation which can accurately locate the position of the boring head and measure drilling fluid flow and pressure at all times. 1. The Thrust Boring Subcontractor shall plot the actual horizontal and vertical alignment of the pilot hole at intervals not exceeding 9 meter. Any deviation between the designed (intended) position and the actual position shall be reported in its Daily Progress Report (DPR). 2. The 30” diameter casing shall be installed along the pre-determined and approved alignment. 3. The sections of 30” casing pipe shall be joined using manual metal arc welding (SMAW). The weld preparation shall be a single V butt weld. Electrodes to be used shall be AWS E6010 class. The 30” casing pipe welds shall free from visual defects. WPS and welders of the 30” casing pipe are not required to be qualified but the welders shall be experienced welders. 4. At the completion of every casing joint installed, the position of the boring head shall be logged and the actual position shall be plotted against the planned position. 5. On Completion of the casing installation an As Bored profile will be prepared to confirm the position of the casing.

8.8

PULL BACK OF 24” PIPELINE INTO 30” CASING PIPE 1. In preparation for pull back, a pulling head will be welded on to the leading end of the product pipe. 1. The product pipe shall be either positioned on rollers or supported in some other manner as appropriate. 2. Pull back of the 24” pipeline in the previously installed 30” casing shall be completed in one continuous operation. 3. Following demobilization of the Thrust Boring Subcontractors’ equipment and subsequent tie-in of the Thrust Boring crossing section to the main line, the Contractor shall carry out the reinstatement and clean up of the site / right of way, in accordance with Reinstatement and Restoration.

8.9

CONTRACTOR'S TAKING OVER 1. The Contractor Shall take over the installed crossing on completion of the crossing as defined in this specification and as contained in the Thrust Boring Procedure

9.

THRUST BORING QUALITY MANAGEMENT REQUIREMENT

9.1

INSPECTION AND TEST PLAN (ITP) REQUIREMENT 1. The Thrust Boring Subcontractor shall develop its own Inspection and Test Plan in accordance with the Contractor furnished Inspection and Test Plan included in the Thrust Boring Subcontract.

9.2

ACCEPTABLE TOLERANCES 1. The 30-inch diameter casing pipe shall be installed along the path shown in the relevant Detailed Design Drawings approved by the Contractor indicating planed profile for the crossing. 1. The 30-inch diameter casing pipe shall be installed with the following acceptable tolerances: A. Micro Tunneling  Elevation: +/- 100 mm from planned elevation per boring of 100 m.  Horizontal Alignment: +/- 100 mm from the planned horizontal alignment per boring of 100 m. B. Auger Bore and Pilot Bore  Elevation: +/- 250 mm from planned elevation per boring of 50 m.  Horizontal Alignment: +/- 250 mm from the planned horizontal alignment per boring of 50 m. 2. The Thrust Boring Subcontractor shall measure the position of the 30-inch casing pipe to maintain bore path within acceptable tolerance by using instruments either transit level, laser level, laser Theodolite, Total Station or Laser Total Station.

9.3

THRUST BORING RECORDS DRAWINGS 1. The Thrust Boring Subcontractor shall develop Thrust Boring Record Drawings in accordance with the Detailed Design Drawings approved by the Contractor for recording the entire Thrust Boring operation. 1. The Thrust Boring Subcontractor shall submit the Thrust Boring Record Drawings with as-built x-y-z coordinates within 15 days after completion of Thrust Boring operation for the Contractor's review.

10.

THRUST BORING HEALTH AND SAFETY MANAGEMENT REQUIREMENTS 1. The Thrust Boring Subcontractor shall manage his HSE programme in accordance with the Contractors HSE Specification and records kept by the Thrust Boring Subcontractor shall be submitted on a weekly basis to the Contractor for inclusion in the Contractors HSE Reports. 2. The Thrust Boring Subcontractor shall carry out tool box meetings at the site on a regular basis, in accordance with the requirements of the Contractors’ HSE Manual. 1. The Thrust Boring Subcontractor shall provide any specific safety equipment required by his personnel and instruct them in the correct use of such PPE. 2. The Thrust Boring Subcontractor shall ensure that all lifting equipment used by the Thrust Boring Subcontractor complies with the relevant specifications and legal requirements.

11.

THRUST BORING ENVIRONMENTAL MANAGEMENT REQUIREMENTS 1. The Thrust Boring Subcontractor shall be fully responsible for the Thrust Boring operation with full consideration of environmental aspects. 2. The Thrust Boring Subcontractor shall take all measures necessary for protecting surrounding public and private property, structures, buildings, roads, utilities, driveways and appurtenances from damage due to the Thrust Boring Work. 1. The Thrust Boring operation shall be planned and implemented to eliminate the direct discharge of water, slurry and cuttings to nearby waterways or third-party lands, 2. The Thrust Boring Subcontractor shall provide procedures and equipment to handle the slurry, and where practical, recycle the same to minimize waste. 3. The cuttings and slurry shall be dewatered and dried to the extent necessary for legal disposal in off-site landfills. 4. Any water from any dewatering processes shall be treated to meet any permit requirements and disposed of locally or hauled off-site for legal disposal. 5. The Contractor shall provide access to the Starting an arrival pit areas, including the provision of extra land for crane and vehicle access if required.

12.

COMPLETION

12.1

PULLING HEAD REMOVAL 1. After the product pipe has been installed into the casing, the pulling head will be removed and the pipe prepared for tie-in to existing facilities or pipeline.

12.2

THRUST BORING AND SUPPORTING EQUIPMENT 1. The thrust boring and supporting equipment shall be demobilized from the site to allow for completion of the pipe line work on either side of the crossing 2. The completed crossing will be handed over to the Employer as an integral part of the pipeline.