tender146vol-II.pdf

VOLUME – II

PIPELINE ENGINEERING

SPUR LINES OF CHAINSA – JHAJJAR PIPE LINE

0

10.11.2008 DESIGN BASIS/JOB SPECIFICATION/ STANDARD SPECIFICATION/STANDARDS/ DRAWINGS/DATASHEET

REV.

DATE

INDEX Volume – II PIPELINE ENGINEERING (BIDDING DOCUMENT NO. - 8000000682)

S. NO.

TITLE

REV.

SPEC.

No. of Pages

JOB SPECIFICATION 1 2 3 4 5 6 7

Engineering Design Basis Piping Material Specification Welding Specification for Mainline for Transportation of Gas Welding Specification Chart Welding Specification Chart Specification for Geo Textile bags for Anti-Buoyancy Technical Specification for PreCommissioning and Commissioning

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0001-01-04-03-001 0001-01-05-02-001

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STANDARD SPECIFICATION – PIPELINES Specification for Longitudinal 1 0 Seam Submerged Arc Welded Linepipe (Onshore) Specification for Helical (Spiral) 2 Seam Submerged Arc Welded 0 Linepipe (Onshore) 3 Specification for Seamless Pipe 0 4 Specification of ERW pipe 0 Specification of External coating 0 5 – 3L PE Coating Specification of Internal Epoxy 6 0 coating 7 Specification of Ball Valve 0 8 Specification of Plug Valve 0 Specification of Gas Powered 0 9 Valve Actuators Specification for Seamless 10 fittings & Flanges, Size up to DN 0 400 mm (16”)

Page 1 of 7

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Specification for flanges & Welded Fittings (Size DN 450 mm (18") and above Specification for Long Radius Bends for Onshore Pipelines Specification for Flow Tee (Bar Tees) for Onshore Pipeline Specification for Scraper Traps for Onshore Pipelines Specification for Pig Signaler for Onshore Pipelines Specification for Insulating Joints for Onshore Pipelines Specification for Casing Insulator and End Seals Specification for Field Joint Coating (Onshore Pipeline) Specification for Concrete Weight Coating of Onshore Pipelines Specification for Repair of Polyethylene Coating Specification for Quick Opening End Closure Specification for Pipeline River Crossings using HDD Construction of pipelines crossing Roads, Rail Roads and Minor Water Crossings Major Water Crossing Conventional Trenching Specification for Pipeline Construction (Onshore) Specification for Hydrostatic Testing of Onshore Pipelines Specification for Pipeline Markers Specification for Documentation for Pipeline Construction Specification for Blasting Specification for Detailed Pipeline Route Survey (Onshore) Welding Specification for Fabrication of Piping Spec. for Instructions to Vendor for Quality Data Requirement

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Spec. for Issue and Reconciliation of Material Spec. for Pipeline Information Management system

STANDARD SPECIFICATION – PIPING 1 Technical Notes for Pipes 2 Technical Notes for Valves Technical Notes for 3 Butt Welded, Socket Welded and Screwed Fittings Technical Notes for Flanges, 4 Spectacle Blinds and Drip legs Technical Notes for Bolts and 5 Nuts Technical Notes for 6 Gaskets Inspection and Test Plan for 7 Gaskets Standard Specification for 8 Fabrication and Erection of Piping Standard Specification of "Non9 Destructive Examination of Piping" Specification for Inspection, 10 Flushing and Testing of Piping System Specification for Shop and Field 11 Painting Standard specification of PMI at 12 Vendor's works. STANDARD DRAWING – PIPELINES Typical Right of Way for 1 Pipelines Typical Trench Dimensions for 2 Pipelines 3 Pipeline Symbols 4 Topographical Symbols Existing pipeline on sleeper 5 crossing Pipeline Road/ Highway 6 Uncased Crossing 7 Details of casing vent and drain 8 Casing pipe details

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Existing Under Ground Pipe Crossing (Type-I) Existing Under Ground Pipe Crossing (Type-II) Under Ground Cable Crossing Over Head Power Line Crossing Typical trench dimension for two or more pipelines in common trench K.M. Post Typical ROU boundary marker Aerial marker Direction marker Pipeline Warning Sign Navigable Waterway Pipeline Crossing Warning Sign Pipeline Road/Highway Cased Crossing Typical Stream Crossings Typical Slope Breakers Details Bank Protection Details for water crossings Typical details of railway crossings Select Backfill for Station Approach Slope stabilization in ghat/ hill areas Soil stabilization in hilly areas Typical lined canal cased crossing detail Typical lined canal crossings (Uncased) Typical Cross section for ROU preparation in Hilly areas

STANDARD DRAWING – PIPING 1 Jack Screw for Spectacle Blind 2 Jack Screw for Spacer & Blind Vents & Drains on Lines 1-1/2” 3 & Below Vents & Drains on Lines 2” & 4 Above Wells Installations 1-1/2” 5 Diameter Traps 6 Pressure Tapings – PG, PT, PI,

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PA, PC etc Handle Projections for Spacers and Blinds T-Strainer Type-1 2"-4" (150# RF, 300# RF and RTJ, 600# RF and RTJ) T-Strainer Type-1 6"-24" (150# RF, 300# RF and RTJ, 600# RF and RTJ) Orientation of Orifice Traps Stub-in Standard Welding of pipe with different thickness Fillet weld details Welding details for branch connections Method of cutting and dimensions of field manufactured concentric reducers Tolerances for fabrication Pipe shoe for hot insulated C.S. pipe, size 2" thru 8", Type-S1 (for temp. up to 343°C) Pipe shoe for hot insulated C.S. pipe, size 10" thru 30", Type-S2. (for temp. up to 343°C) Pipe saddle for bare pipe size 14” thru 48” type- S6A Pipe shoe for slope line pipe size 2" thru 6" type-S9A/9B/9C Low support sliding for bare and insulated pipe size 2" thru 36" type-L1 & L1A Low support fixed for bare & insulated pipe size 2" thru 36" type-L3 & L3A. Low support sliding for bare pipe size 3/4" thru’ 36" type-L5 & L5A. Low support sliding for bare and insulated pipe size 2” thru 36” Type-L6 Low support Fixed/Restrained for bare and insulated pipe size 2" thru 36", type-L7 & L7A

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Restrained Low support for bare and insulated pipe size 2" thru 36", type-L8 & L8A Adjustable low support sliding for pipe size 2" thru 6" typeL10 & L10A Low support sliding & fixed for pipe size 3/4" thru 11/2"typeL15. Low support stanchion for bare & insulated CS/AS/SS pipe type – L16 and L16A Adjustable low support with 4 bolts for pipe size 8" thru 24" type-L17 & L17A. Adjustable low support for bare and insulated pipe size 2" thru 24". type-L18 & L18A Adjustable low support with guide & cross guide for bare and insulated pipe size 2" thru 24" type-L19 & L19A. Pipe clamp for bare pipe size 1/2" thru 24” Type C-1 U-bolt for bare pipe size 1/2" thru 24" type-C4 Dummy pipe support for bare pipe size 2" thru 24" type B-39 Dummy pipe support for insulated pipe size 2" thru 24" type-B40 Pipe support brackets type-B42 Guide support for bare size 1/2" thru 24" type-G1 Guide support for bare size 1/2" thru 24" type-G2 & G2A Cross guide for bare pipe size 2" thru 24" type-G3 Cross guide for bare pipe size 2" thru 24" type-G4. Anchor for bare pipe size 2" thru 24" type-G5. Supporting arrangement for angle & relief valves type-SP2. Typical anti vibration support for control valve-SP3.

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LAYOUT DRAWING & PORTACABIN PLAN Layout Sultanpur Dispatch 1 0 Terminal Layout SV-1 (Sultanpur 2 0 Neemrana) 3 Dharuhera CGS & TOP 0 Layout Bhiwadi / Chopanki TOP 4 0 Station 5 Layout Bhiwadi CGS 0 6 Layout SV-2 & Khushkhera CGS 0 Layout SV-3, Sultanpur 7 0 Neemrana 8 Layout Neemrana CGS & RT 0 Layout Hayatpur TOP (for 9 0 Manesar) 10 Layout Manesar CGS 0 11 Layout Hayatpur PRS 0 12 Layout SV-1 (Gurgaon Line) 0 13 Layout Gurgaon Terminal 0 14 Porta-Cabin Layout 0 DATASHEETS – LINEPIPE / PIPING 1 Datasheet of Ball Valve 2 Datasheet of Ball Valve 3 Datasheet of Ball Valve Datasheet of Scraper Launcher / 4 Receiver 5 Datasheet of Pig Signaler 6 Datasheet of IJ Datasheet of Flow Tee (Barred 7 Tee) - 18" X 18" , 600# Datasheet of Flow Tee (Barred 8 Tee) - 18" X 12" , 600# Datasheet of Flow Tee (Barred 9 Tee) - 18" X 8" , 600# Datasheet of Quick Opening End 10 Closure Datasheet of Gas Powered Valve 11 Actuator 12 Datasheet of Plug Valve 13 Datasheet of Plug Valve Data Sheets of Gate Valves of 14 Size below 2”

0001-00-10-01-6002

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ENGINEERING DESIGN BASIS (PIPELINE ENGINEERIG) SPUR LINES OF CHAINSA – JHAJJAR PIPELINE

GAIL (INDIA) LTD NEW DELHI

ENGINEERING DESIGN BASIS

SPECIFICATION


0001-01-04-03-001

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Copyright GAIL – All rights reserved

TABLE OF CONTENTS

1.0

INTRODUCTION

2.0

SCOPE

3.0

DESIGN CODES AND STANDARDS

4.0

DESCRIPTION OF FACILITIES

5.0

PIPELINE ROUTE

6.0

DESIGN DATA

7.0

PIPELINE AND ASSOCIATED FACILITIES DESIGN

8.0

OTHER TECHNICAL REQUIREMENTS

ANNEXURE-A

LIST OF CODES AND STANDARDS

ENCLOSURES: 1. Schematic Arrangement for Pipeline Facilities Drawing no. 0001-00-03-01-5003.



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1.0

INTRODUCTION M/s GAIL (India) Ltd., proposes to lay following Natural Gas spur Pipelines (from Chainsa- Jhajjar pipeline):Sl.

Pipeline

Tap-off Point

Size(Inch) X Length (Km)

1

Sultanpur Haryana) to Neemrana (Rajasthan)

Tap-off point at Chainage – 70.05 Km in Chainsa-Jhajjar line

18” X 85.28

2

Spur Line to Bhiwadi

Tap-off point at Chainage – 12” X 9 31.6 Km in Sultanpur – Neemrana Line

3

Hayatpur to Manesar


4

Hayatpur to Gurgaon

Tap-off point at Chainage – 10” X 11 61.14 Km in Chainsa-Jhajjar line

10” X 5.4

These pipelines are to cater the natural gas requirement of consumers at Dharuhera, Bhiwadi, Khushkhera, Neemrana, Manesar and Khandsa/Gurgaon. The Sultanpur-Neemrana pipeline is proposed to pass through Dharuhera and Khushikhera. The above proposed pipeline shall have laying length as given above and 4 nos. of Sectionalising Valve (SV) stations. The pipeline shall be designed to handle Natural Gas & RLNG. 2.0

SCOPE This document establishes minimum design parameters and basis for design and detailed engineering of the Pipeline and Associated facilities covered under this project as defined briefly herein below.

3.0

DESIGN CODES AND STANDARDS Pipelines and terminal facilities envisaged shall be designed and engineered GAIL (INDIA) LTD NEW DELHI


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primarily in accordance with the provisions of the latest edition of Code ASME B 31.8: Gas Transmission and Distribution Piping Systems and OISD 141: Design and Construction Requirements for Cross Country Hydrocarbon Pipelines. In addition, requirements, as applicable to gas service of following codes/standards shall be complied with: OISD Std. 138

Inspection of Cross Country Pipelines-Onshore

ASME B 31.3

Chemical Plant & Petroleum Refinery Piping

API Std. 1102

Steel Pipeline Crossing Railways & Highways

API Std. 1104

Standard for Welding Pipelines and Related Facilities

ISO 13623

Petroleum & natural gas industries – Pipeline transportation systems

In addition to above, codes and standards listed in Annexure-A of this document shall also be referred. In case of conflict between the requirements of ASME B31.8/OISD 141 and other codes/Standards referred above, requirement of ASME B 31.8/OISD 141 shall govern. In case of conflict between requirements of B31.8/OISD 141 and this document, requirements of this document shall govern. 4.0

DESCRIPTION OF FACILITIES Details of facilities shall be as per P&ID’s, process design basis, data sheets, line schedule etc covered in the process package. The pipeline facilities envisaged as a part of Spur Line of Chainsa-Jhajjar Pipeline are described briefly herein below.

4.1

SULTANPUR – NEEMRANA LINE

4.1.1 Despatch cum Receipt Station at Sultanpur and Neemrana Facilities at Despatch cum Receipt Station at Sultanpur & Neemrana terminals shall consist of Pig launcher cum receiver complete with associated piping including hook-up with existing Chainsa-Jhajjar Pipeline at Chainage 70.50 Km in Sultanpur. Additionally Neemrana terminal shall have filtering, metering and let down skid (CGS). 4.1.2 SV & TOP at SV-1 (Ch. 16.02 Km), SV-3 (Ch. 62.2) Tap-off with flow tee and valve. Provision for Insulating Joint at the buried/above ground transition in the above ground section of pipeline. Sectionalizing Valve in Main line. 4.1.3 TOP & CGS at Dharuhera, Bhiwadi Tap-off with flow tee and valve. Provision for Insulating Joint at the buried/above ground transition in the above ground section of pipeline. Filtering, metering and let down skid with associated piping and Instruments. GAIL (INDIA) LTD NEW DELHI


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4.1.4 SV-2 , TOP and CGS at Khushkhera Tap-off with flow tee and valve. Provision for Insulating Joint at the buried/above ground transition in the above ground section of pipeline. Sectionalizing Valve in Main line. Filtering, metering and let down skid with associated piping and Instruments. 4.1.5 Bhiwadi/ Chopanki TOP for Bhiwadi Tap-off with flow tee and valve all underground. 4.2

HAYATPUR – MANESAR LINE

4.2.1 TOP Hayatpur for Manesar Line Extending the existing Tap-off off with valve. Provision for Insulating Joint at the buried/above ground transition in the above ground section of pipeline 4.2.2 TOP & CGS at Manesar Tap-off with flow tee and valve. Provision for Insulating Joint at the buried/above ground transition in the above ground section of pipeline. Filtering, metering and let down skid with associated piping and Instruments. 4.3

HAYATPUR – GURGAON LINE

4.3.1 PRS at Hayatpur Extending the existing Tap-off off with PRS/ valve. Provision for Insulating Joint at the buried/above ground transition in the above ground section of pipeline 4.3.2 SV-1 – Gurgaon Line (Ch. 6.4 Km) Sectionalizing Valve (underground) at Chainage 6.4 Km. 4.3.2 Gurgaon Terminal Station Provision for Insulating Joint at the buried/ above ground transition in the above ground section of pipeline. Tap-off with Valve and Blind as per P&ID. 4.2

Main Pipeline Pipeline facilities are schematically indicated in drawing no. 0001-00-03-01-5003.

5.0 5.1

PIPELINE ROUTE Pipeline Route Salient features of the surveyed pipeline route as per pipeline route map no. MAS/ GAIL/ CGJHPL/08/ RM-01/02/03/04, GAIL/ SKP/ GURGAON/ 2008/ R.M./01 (Rev.0), and survey report are tabulated herein below:



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SALIENT FEATURES OF RESPECTIVE PIPELINE ROUTE Sultanpur – Spur Line Hayatpur Hayatpur Neemrana to Bhiwadi Manesar Gurgaon Size, OD ( Inch) 18 12 10 10 Length (Km) 85.28 9 5.4 11 Highest elevation Refer Survey Refer Refer Survey Refer Survey Report Survey Report Report above MSL (m) Report Lowest elevation above Refer Survey Refer Refer Survey Refer Survey Report Survey Report Report MSL (m) Report No. of River Crossing , 0 0 0 0 Width > 100 m No. of Road Crossing 3/2 0/2 0/0 1/0 (NH/SH) No. of Railway 3 0 0 0 Crossing No. of Canal Crossing 6 0 0 0 5.2

Terrain Details For Terrain details and Land use pattern refer survey reports prepared by M/s MASCON MSC PVT. Ltd and M/s SKP Projects P. Ltd. attached elsewhere in the bid document.

6.0 6.1

DESIGN DATA Main pipeline shall be designed for conditions as follows: PIPELINE DESIGN PARAMETER Description Value Sultanpur – Neemrana Line 457.2 mm OD Bhiwadi/ Chopanki Tap-off – Bhiwadi Line 323.9 mm OD Hayatpur to Manesar 273.1 mm OD Hayatpur to Gurgaon PRODUCT – Natural Gas/ RLNG Design Pressure (Kg/ Cm2g) 99.93 2 Operating Pressure (Kg/ Cm g) 60-99 0 Maximum Design Temperature, C i. Above Ground Section -29 to 65.0 ii. Under Ground Section -29 to 45.0 Operating Temperature, 0 C 13 - 25 Economic Design Life, Years 35 Corrosion Allowance 0 Hayatpur to Gurgaon – Design Pressure shall be 49 273.1 mm OD 2 Kg/cm g and Design Temp AG/UG (-) 29 to 65 / (-) 29 to 45. Rest other parameter shall be as above.



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All terminal facilities (equipment and associated piping) shall be designed for design and operating conditions given in the process package. 7.0

PIPELINE AND ASSOCIATED FACILITIES DESIGN

7.1

General Pipeline and pipeline stations to be installed as a part of this project shall be designed and engineered in accordance with the standards/codes referred in section 3.0 of this document.

7.2

Pipeline

7.2.1 Pipeline shall be designed in accordance with requirements of ASME B 31.8 and OISD 141. The pipeline shall withstand all installation, testing and operating condition/ loads. All necessary calculations shall be carried out to verify structural integrity and stability of the pipeline for the combined effect of pressure, temperature, bending (elastic), soil/pipe interaction, external loads and other environmental parameters as applicable during all phases of work from installation to operation. Allowable stress limit shall be as per ASME B 31.8. Such calculations shall include, but are not limited to following: -

Buoyancy control and stability analysis for pipeline section to be installed in areas subjected to flooding/submergence. Unless specified, specific gravity of installation in such area shall be at least 1.2.

-

Stress analysis at crossing of major rivers, rail and highway etc.

-

Crossing analysis of rivers by HDD if applicable.

-

Pipeline expansion and its effect on station piping (above ground/below ground).

7.2.2 Pipeline shall also be checked for adequacy against anticipated earthquake loading and any special measures such as increase in wall thickness/ grade/ select backfill etc. as required to ensure safety and integrity of the pipeline system shall be implemented. 7.2.3 Mainline shall be provided with bi-directional pigging facilities suitable for handling all types of pigs including intelligent pigs. 7.2.4 Pipeline and its associated facilities shall be designed using the applicable design code and as modified below. The pipeline shall be designed to meet the Location Class as defined in ASME B31.8, except as modified below.



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Location Class

Design Factor

All

Station Piping

Class – 1

River / Stream Crossings  Drilled / Bored/ Inaccessible / Open Cut  Others  HDD Cased/Uncased Crossings or Parallel Encroachments on ROW of Hard Surfaced Roads, Public Streets and Highways Railway Crossing

Class – 2

7.3

Type of Facility

0.5

River / Stream Crossings  Drilled / Bored/ Inaccessible / Open Cut  Others  HDD Cased/Uncased Crossings or Parallel Encroachments on ROW of Hard Surfaced Roads, Public Streets and Highways Railway Crossing

0.6 0.72 0.5 0.6 0.5 0.5 0.6 0.5 0.5 0.5

Class – 3

All

0.5

Class – 4

All

0.4

Station Piping

7.3.1 Station piping to be provided at terminals, intermediate stations, SV stations shall be designed in accordance with OISD 141/ASME B 31.8 and utility piping to be provided at these locations shall be designed in accordance with the provisions of ASME B 31.3. 7.3.2 All piping shall be designed for combined effects of pressure, weight and temperature during operating conditions without over stressing the piping, valves or equipment. All piping shall be adequately supported, guided or anchored so as to prevent undue vibration, deflection or loads on connected equipment such as filters, meters etc. 7.4

Materials Pipeline and its appurtenances shall be provided with carbon steel materials suitable for the intended service, as detailed in subsequent paragraphs

7.4.1 Line pipe for main line Line pipe shall conform to API 5L and Company specifications. Type of line pipe to be used shall be SEAMLESS/LSAW/ HSAW/EW. GAIL (INDIA) LTD NEW DELHI


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Sr. No.

LINE SIZE

GRADE

Class - I Class - II

Class - III

Class IV

1

18”(457.2 mm)

6.5

7.9

9.3

11.7

2

12” (323.9 mm)

6.4

6.4

7.9

9.5

3

10” (273.1 mm)

X-70, PSL-2 X-60, PSL-2 X-60, PSL-2

6.4

6.4

6.4

7.8

-

7.4.2 Other Materials All other materials and equipments including scraper traps, flow tees, insulating joints, ball valves, plug valves, globe valves, check valves, pig signallers, flanges and fittings shall be carbon steel suitable for the service conditions and shall be compatible with the line pipe material. 7.5

External/ Internal corrosion coating

7.5.1 Pipeline to be installed below ground shall be protected against external corrosion by a combination of high integrity externally applied coatings and permanent impressed cathodic protection system. Externally applied coating shall be three layer side extruded polyethylene coating. 7.5.2 In addition, pipeline shall be provided with minimum 80 micron thick liquid epoxy internal coating conforming to ISO 15741/API RP 5L2. Extremities of pipe shall be free from coating over a length of 20± 5 mm. 7.5.3 All above ground piping and structures shall be painted to prevent atmospheric corrosion. Painting of above ground piping and structures shall be as per specifications. Painting shall be suitable for normal corrosive environment/corrosive environment, as applicable, as defined in Painting Specification No. S-05-02-014 for all stations and terminals. 7.6

Insulating joints Insulating joints shall be provided to electrically isolate the buried pipeline from above ground pipeline. Insulating joints shall be monolithic type and shall allow smooth passage of pigs. Insulating joints shall be installed in above ground portion of the pipeline, immediately after the buried/aboveground transition at the scraper stations. Wherever pressure/ temperature transmitters are used on cathodically protective pipeline the same shall be electrically isolated by providing insulating joints/ flanges.

7.7

Pipeline Burial The pipeline shall be buried normally at a depth of 1.0 meter below natural ground level except river/ rail/ road/ canal/waterways crossing where minimum cover shall be as GAIL (INDIA) LTD NEW DELHI


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given below or as per the requirements of statutory/local authorities whichever is more stringent. Increased cover shall be provided at critical locations and crossings. Sl.

Location

Minimum Cover (m)

1.0

Industrial, commercial and residential area

1.0

2.0

Rocky terrain

1.0

3.0

Minor water crossing/ canal/ drain/ nala/ waterways

1.5

4.0

HDD crossing of canals (below bed)

2.5

5.0

River crossings for which scour depth is defined (below scour)

1.5

6.0

Other River crossings (Bank width > 50m) (Below Bed)

2.5 (For normal soil) 1.5 (For rocky strata)

7.0

Other River crossings (Bank width < 50m) (Below Bed)

1.5

8.0

Cased/uncased road crossing

1.2

9.0

Cased railway crossing

1.7

10.0

Drainage, ditches at roads/railway crossings

1.2

11.0 Marshy land/Creek area

1.5

Additional soil cover other than specified above shall be provided at locations indicated by statutory/ local authorities or in areas likely to have an increased risk of impact damage or third party interference as per agreements between COMPANY and authorities. In case, any private dwelling, industrial building or place of public assembly falls within 15 m of pipeline, additional cover of minimum 300 mm shall be provided over and above the cover indicated in the above table. 7.8

Marshy Areas / Areas Prone to Flooding Wherever marshy areas/areas prone to flooding are encountered along the pipeline route, pipeline shall be provided with anti buoyancy measures viz. continuous concrete coating/ Geotextile gravel filled bags. Unless specified otherwise in AFC drawings, specific gravity of installation in such areas shall be at least 1.2.

7.9

Pipeline in common ROW The location of new underground pipeline, when running parallel to an existing underground pipeline in same ROU/ROW shall be laid at minimum clear distance of 5.0 m from the existing underground pipeline. This distance may be reduced to 3.0 m after GAIL (INDIA) LTD NEW DELHI


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assessment of construction methodology which do not result in unsafe conditions during construction. 7.10 Backfilling In normal cross-country areas, the pipeline trench shall be backfilled with excavated soil. Select rockfill/ slope breakers shall be provided in the trench in steep areas (slope generally 10% and more) to prevent erosion. In case of rivers/water bodies prone to scour and erosion, the safety cover shall be provided below the predicted scour level. In addition to the cover, anti buoyancy measures (concrete coating) shall be provided at river crossings. Contractor shall keep top 150 mm of excavated top soft soil (free of gravels) aside, which shall be back filled in the end as top layer. Select backfill shall be provided at approaches to terminal up to transition point (below ground/above ground) inside terminal. Select back fill shall also be provided as applicable for areas prone to seismic activity. Recommendation of Seismic Analysis Report should be considered for such special backfill. Pipeline route shall be examined to establish any drainage requirement in hilly terrain. In case required, the drainage shall be designed to prevent trench flooding during construction and protect the integrity of the installed pipeline following completion of all construction activities. In rocky areas, the trench bottom shall have sand/soft soil padding of 150 mm. After laying of pipeline, sand/soft soil padding shall be placed around and on top of the pipe so that thickness of compacted padding on top of pipe corrosion coating shall be at least 150 mm. Disposal of debris and surplus material to designated disposal areas or designated place(s), as the case may be and as directed by Engineer-in-charge shall be carried out. 8.0


8.1

Scraper Stations Scraper traps shall be provided at the Despatch terminals (Sultanpur) and Receiver Terminal at Neemrana. The scraper traps shall be bi-directional capable of handling intelligent pigs and other cleaning pigs. The launching and receiving barrels shall be designed in accordance with the requirements of ASME B 31.8 and its end closure shall be designed and fabricated according to ASME Section VIII, Div.1. Adequate arrangements for launching, retraction, handling and lifting of cleaning and instrumented pigs shall be provided at the scraper stations. Traps shall be accessible by walkway/road for movement of equipment, pigs etc. These stations shall be provided with access road from the nearest metalled road. GAIL (INDIA) LTD NEW DELHI


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Corrosion resistant coating shall be provided on the pipeline up to a minimum length of 500 mm after it comes aboveground / before it gets buried underground at terminals and scraper stations. The diameter of barrel of the launcher cum receiver shall be three nominal sizes larger than the pipeline nominal size. Center line elevation of scraper trap shall be at suitable height from grade level. Suitable arrangements shall be provided for handling & lifting of pigs. The piping system at the terminals and intermediate stations shall be designed to have sufficient flexibility to prevent pressure and thermal expansion or contraction from causing excessive stresses on the connected equipment. The piping shall be designed/fabricated as defined in clause 8.3. As far as possible, pipeline expansion shall be absorbed by allowing the scraper traps to move on supports. Installation of anchor block in the under ground pipeline is not permitted. If required adequate length of trench in approaches to stations shall be provided with a select backfill to ensure flexibility. 8.2

Sectionalising Valve Stations Sectionalising valve station shall be provided along pipeline route for isolating sections of pipeline as per ASME B 31.8 for: -

Limiting the hazard and damage from accidental discharge from pipeline system.

-

Facilitating maintenance of pipeline system and

-

Complying with the requirements of applicable codes.

The location of sectionalizing valves are indicated in PFD. The requirements of applicable codes taking consideration of terrain features, requirement of safety and operation etc. to be taken in to account while providing Sectionalizing Valves. Sectionalizing valve on the main pipeline shall be ball valves of full bore type, to allow smooth passage of cleaning and intelligent pigs. All valves installed at Intermediate facilities, block valve stations, scraper stations and pipeline sectionalizing valve stations shall be gas actuated/ hand operated and with butt welding ends. Sectionalizing and Station block valves shall be installed buried and provided with a stem extension in such a way that the center line of rim of the hand wheel on a horizontal shaft or center of actuator is at approximately 1.0 m above the finished ground level. Valve surface shall be provided with corrosion protection coating. Valve body vent and drain lines shall be extended and terminated above ground. The valve stations shall be located at a readily accessible location such as near road and shall be provided with an access road from the nearest all weather metalled road. The facilities within valve station shall be secured by a chain link fence enclosure with gate. The location of valve station shall be clear of overhead power lines. The provisions of remote operated feature shall be as per the operation and control GAIL (INDIA) LTD NEW DELHI


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philosophy to be adopted for the project. At locations, where valve stations are combined with CP/Repeater stations, the safe distance and statutory clearance as per standard shall be followed. 8.3

Piping

8.3.1 General This section describes the design requirements of piping applicable for Despatch station, intermediate pigging stations, sectionalizing valve stations and receiving station. All piping and equipment shall be designed as per ASME B 31.8. All piping materials shall be as per Piping Material Specification (PMS). Utility piping to be provided shall be designed in accordance with the provisions of ASME B 31.3. Design shall provide consideration for all loadings like weight, temperature etc., significantly affecting the pipe material stresses in addition to fluid pressure. 8.3.2 Piping flexibility/stress analysis All piping shall be designed for thermal expansion under start up, operating and shut down conditions without over stressing the piping, valves or equipment. Provisions for expansion shall normally be made with bends and offsets. All piping shall be adequately supported, guided or anchored so as to prevent undue vibration, deflection or loads on connected equipments. Equipments/ valves requiring periodical maintenance shall be supported in such a way that the valves and equipment can be removed with minimum temporary pipe supports. 8.3.3 Piping layout         8.4

Piping will be located above-ground wherever possible within the terminals. Piping shall be designed considering skin temperature of piping material under empty conditions as 65ºC or design temperature of pipeline whichever is higher. Piping stress analysis shall be carried out to determine allowable pipe movement and support requirements wherever felt necessary. Buried piping inside the terminal area will have a minimum depth of cover of 1.2 m. Where buried pipes come out of the ground, the underground coating on the pipe will continue for a distance of 500 mm above ground. Platforms, crossovers shall be provided for ease of operation and maintenance. Platform for filters shall be provided for maintenance/ operational access. Painting above ground piping and structures shall be as per specifications enclosed in the Bid package. Welding



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Welding shall be carried out in accordance with API 1104, specification for welding and welding charts. Butt welds shall be 100 % radio graphed / automatic UT for automatic welding, as applicable for all pipelines. For gas service all butt welds for process piping shall be 100% radiographed and for utility piping NDT requirements shall be as per specification no. S-05-02-12. 8.5

Hydrostatic Testing After installation, the entire pipeline system shall be hydrotested with inhibited water. The water shall tested, as applicable prior to using for hydrotesting. The minimum hydrostatic pressure in any section shall be as per ASME B 31.8 for gaseous hydrocarbon pipelines. The maximum hydrostatic test pressure at any location of the pipeline shall not exceed the pressure required to produce a hoop stress equal to 95% of SMYS of the pipe material based on minimum wall thickness in the test section. The test duration shall be minimum 24 hours. Hydrostatic testing of terminals shall be carried out separately. Terminals as well as other intermediate facilities shall be tested at 1.4 times the design pressure. The test duration shall be 6 hours. Mainline valves shall be installed after successful completion of hydrotesting.

8.6

Dewatering and swabbing Dewatering, swabbing and pre-commissioning operations shall be carried out after hydrotesting and prior to commissioning of the pipeline as per Project specifications. For gaseous hydrocarbon pipeline the line shall be dried. Swabbing shall be carried out prior to installation of Sectionalizing valves. After swabbing operation the pipeline sections shall be dried as per relevant specification enclosed with the tender.

8.7

Crossings

8.7.1 Water Crossings All water crossing shall be installed by open cut. The requirement of HDD at any water crossing shall be finalized during detailed engineering. Wherever there is an evidence of bank erosion, the banks shall be protected by using gravel and boulders filled embankment mattresses of galvanized iron wire to be laid over the backfilled, compacted and graded banks. 8.7.2 Rail Crossing Pipeline at rail crossings shall be provided with casing pipe. The size of Casing pipe shall be – 609.6 mm O.D. (24”), 6.5 mm WT, API 5 L Gr. X70, LSAW/ HSAW (unless advised otherwise by concerned authorities) and shall be installed by boring/ jacking/ HDD/ ramming. The rail crossing shall comply with the requirements of API 1102 and Indian Railway Authorities. The crossing angle shall be as close to 90º as possible. It should be noted that the extent of casing pipe generally specified by Railways is 14.0 m beyond centerline of the outermost tracks on either side or 0.6 meter beyond the ROU limits of Railways on either side, whichever is more. Carrier pipe shall be electrically insulated from the casing pipe and casing ends shall be sealed using durable, GAIL (INDIA) LTD NEW DELHI


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electrically non-conducting materials. The crossing drawing shall be subject to approval of concerned Railway Authorities prior to implementation. 8.7.3 Road Crossing Road crossings shall comply with the requirements of API 1102 and the requirements of the concerned road authorities. Unless otherwise required by concerned Authorities, casing pipe shall not be used. However at national highway road crossings pipeline shall be provided with casing pipe, which shall extend min. 600 mm beyond Road ROW on either side. The casing pipe shall be installed by trenchless method like ramming/ boring/ jacking/ HDD /Micro Tunelling. Provision of casing at locations other than national highways shall be decided based on type of road crossing and as per requirements of local authorities if necessary. The casing pipe shall be 609.6 mm O.D. (24”), 6.5 mm WT, API 5 L Gr. X70, LSAW/ HSAW. The crossing angle shall be as close to 90º as possible. Casing insulators and end seals shall be provided to ensure electrical isolation of carrier pipe and casing pipe. 8.7.4 Existing Pipeline Crossing The specific requirements of Owner/operator of existing pipeline shall generally be followed. The minimum clearance between the lines shall be 300 mm unless specified otherwise. 8.8

Valves

8.8.1 Application of various types of valves shall be as follows: Valve type

Typical application

Globe

Throttling

Ball

On/off, Isolation (on main line)

Plug

On/off, Isolation (in the terminals)

Check

Uni-directional flow

All pipeline valves shall comply with the requirements of API 6D/ relevant PMS. Ball valves shall have primary metal seated design. In order to minimise potential leak sources, valves used in mainline shall be with butt-weld ends. Valve installed within the terminal to isolate the mainline/ pipeline shall also be provided with butt welding ends. However terminal valves shall be flanged ends. Flanges may be used where frequent access or removal of equipment is required. Wherever underground valves are provided, valves shall be provided with a stem extension in such a way that the centreline of the rim of the hand wheel on a horizontal shaft or centre of power actuator as approximately 1.0 m above the finished ground level. Minimum size of any tapping from the underground pipeline shall be 2" NB and shall be GAIL (INDIA) LTD NEW DELHI


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provided with an isolation ball valve located at a minimum distance from the pipeline. 8.9

Branch Connections All branch connections or side tap on the piggable lines wherever the branch line diameter is approx. 40% or more of the main line size, shall be provided with flow tees to enable smooth passage of all types of pigs. Flow tees for this purpose shall have an internal pipe housed in a tee.

8.10 Pipeline Bends In order to accommodate changes in vertical and horizontal alignment in piggable section of pipeline, elastic bends/cold field bends/hot formed long radius bends shall be used. Miter bends shall not be used for change in direction. Necessary design/ calculation for arriving Minimum Elastic Bend Radius shall be worked out by Contractor and shall be ratified by GAIL. Minimum bend radius shall be as follows: Minimum Bend Radius Pipeline Details 18”, X-70, PSL-2 (thk. 6.5/7.9/9.3 mm) 12”, X-60, (thk. 6.4/7.9/9.5 mm) 10”, X-60, (thk. 6.4/ 7.8 mm)

Hot Formed Cold Field LR Bend Bend Radius Radius R=27 D

R=6D

R=18 D

R=6D

R=18 D

R=6D

8.11 Pig Signallers 8.11.1 Pig signallers shall be installed as a minimum at the following locations at each Launcher/ Receiver: -

On Pig launcher cum receiver

-

One location on the line

8.11.2 Pig signaller shall be bi-directional type with trigger mechanism, suitable for maintenance with pipeline under operating pressure. 8.12 Specifications All procurement of materials shall be as per Piping Material Specification (PMS) and specifications indicated in PMS. ANNEXURE - A LIST OF CODES AND STANDARDS In addition to the codes/standards mentioned in para 3.0, the latest edition of the below listed equivalent codes and standards shall also be used for design of proposed pipeline. The listing includes, but is not limited to, the following: GAIL (INDIA) LTD NEW DELHI


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1. Line Pipes API 5L API 5L1 API 5LW 2. Valves API 6D API 602 ASTM A694 MSS-SP-6 MSS-SP-25 BS 5351

Specification for Line pipe Recommended Practice for Railroad Transportation of Line pipe Recommended Practice for Transportation of Line pipe on Barges & Marine Vessels Specification for pipeline valves (Steel Gate, Plug, Ball and Check Valves) Compact Steel Gate Valves-Flanged, Threaded, Welding & Extended Body ends. Forgings, Carbon & Alloy steel for Pipe Flanges, Fittings, Valves & parts for High Pressure Transmission Service. Finishes for Contact Faces of connecting End Flanges of Ferrous Valves and Fittings. Standard Marking System for Valves, Fittings & Unions Steel Ball Valves for the Petroleum, Petrochemical and Allied Industries

3. Flanges & Fittings MSS-SP-44

Steel Pipeline Flanges

ANSI B16.5

Pipe Flanges and Flanged Fittings Ring-joint Gaskets & Grooves for Steel Pipe Flanges Forgings, Carbon Steel for Piping Components

ANSI 16.20 ASTM A105 ASTM A193 API 601

Carbon & Alloy Steel Bolts & Studs for High Temperature Service Standard for Metallic Gaskets for Raised-Face Pipe Flanges & Flanged Connections

ANSI B16.9

Factory Made Wrought Steel Butt Welding Fittings

ANSI B16.11

Forged Fittings, Socket Welded & Threaded

ANSI B16.26 ASTM A234

Butt Welding Ends

ASTM A694 MSS-SP-75 GAIL (INDIA) LTD NEW DELHI

Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures Forgings, Carbon & Alloy Steel for Pipe Flanges, Fittings, Valves & Parts for High Pressure Transmission Service. Specification for High Test Wrought Butt Welding Fittings ENGINEERING DESIGN BASIS

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MSS-SP-97

Integrally Reinforced Forced Branch Outley Fittings – Socket Welding, Threaded and Butt Welding Ends. Pipe Bending Methods, Tolerances, Processes & Material Requirements

PFI-ES-24 4. Testing & Welding ANSI/AWS D1.1 API 1104 AWS A3.0

Structural Steel Welding Standard for Welding Pipelines and Related Facilities Welding Terms and Definitions

AWS A5.1 AWS A5.5

Welding Electrodes Specification for Low Alloy Steel Covered Arc Welding Electrodes

ASTM E165 ASTM A370

Liquid Dye Penetrant Inspection of Pipeline Welds

ASTM E18

Standard Methods and Definitions for Mechanical Testing of Steel Products. Standard Hardness Test for Metals

ASTM E23

Standard for Impact Test for Metals

ASTM E84 ASTM E92

Standard Test Method for Micro-hardness of Metals Standard Test Method for Vickers Hardness of Metallic Materials Standard Test Method Indentation Hardness for Metallic Materials by Portable Hardness Testers

ASTM E110 ASTM E709 MSS-SP-53 MSS-SP-54 MSS-SP-55

Standard Guides for Magnetic Particle Examination Quality Standard for Steel Casting & ForgingMagnetic Particle Method Quality Standard for Steel Casting & ForgingRadiographic Examination Quality Standard for Steel Castings & ForgingsVisual Method.

5. Surface Preparation, Painting and Coating SIS-05-59 SSPC-SP-01

Pictorial Surface Preparation Standards for Painting Steel Surfaces Solvent Cleaning

SSPC-SP-03

Power Tool Cleaning



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SSPC-SP-05

Joint Surface Preparation Standard: White Metal Blast Cleaning

SSPC-SP10

Structural Steel Painting Council – Joint Surface

NACE No.2

Preparation Standard - Near-White Metal Blast Cleaning

SSPC-PA-02

Measurement of Dry Paint Thickness and Magnetic Gauges

ASTM E12 ASTM-G6

Measurement of Pipeline Dry Film Coating Thickness Abrasion Resistance of Pipeline Coating

ASTM G8

Cathodic Disbonding of Pipeline Coatings

NACE-RP-0274

High Voltage Electrical Inspection of Pipeline Coatings Prior to Installation

IEC 454 – 2

Specification for Pressure-Sensitive Electrical Purposes

Adhesive

Tapes

for

CSA Z245.20-02 External Fusion Bond Epoxy Coating for Steel Pipe 6. Safety Systems IP Model Code of Safe Practice in the Petroleum Industry parts 3, 6 and 9.



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PIPING MATERIAL SPECIFICATION

SPUR LINES OF CHAINSA – JHAJJAR PIPELINE

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

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CONTENTS SL NO.

DESCRIPTION

1.0

SCOPE

2.0

CODES AND STANDARDS

3.0

MATERIAL SPECIFICATIONS

4.0

CLASS DESIGNATION CODES

5.0

PIPELINE

6.0

PIPING

7.0

FITTINGS

8.0

BENDS

9.0

FLANGES

10.0

GASKETS

11.0

BOLTING

12.0

THREAD SERALANT

13.0

VALVES

14.0

QUICK OPENING END CLOSURE

15.0

HYDROTESTING VENT AND DRAINS

16.0

PIPELINE SPECIALITY ITEMS

TABLE - 1

PIPE WALL THICKNESS DETAILS FOR MAINLINE SPUR LINE

TABLE - 2

PRESSURE/TEMP & OTHERS DESIGN CONDITIONS FOR VARIOUS PIPING CLASSES

ANNEXUREMATERIAL SPECIFICATIONS FOR PIPING CLASSES A,B,C,D,E,F,G,H,I ANNEXURE-1 LIST OF ATTACHMENTS



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1.0

SCOPE

1.1

It is propose to install a Natural gas pipe lines from Sultanpur – Neemrana, Bhiwadi / Chopanki TOP to Bhiwadi, Hayatpur – Manesar and Hayatpur - Gurgaon in Haryana / Rajasthan states to initially cater the demand of consumers in Dharuhera, Bhiwadi, Khushkhera, Neemrana, Manesar, Khandsa and Gurgaon regions. The proposed Natural gas pipeline shall be of 457 mm (18”) OD, approximately 85.28 km long; 323.9 mm (12”) OD, approximately 9 km long and 273.1 mm (10”) OD, approximately 16.40 km. The scope shall include piping and tap-off points at various locations of Chainsa–Jhajjar spur pipeline, that is for Bhiwadi, Gurgaon, Manesar, dispatch terminals, Sectionalising Valve stations, Tap-off terminals, receiving terminals, Spur line and various CGS’s. This document covers minimum requirements for various piping materials necessary for the design of the piping/ pipeline and metering skid facilities coming under the project. This specification shall be read in conjunction with various Codes and Standards of latest edition, as applicable.

2.0

CODES AND STANDARDS

2.1

Pipeline and pipeline terminal facilities envisaged as part of this project shall be designed and engineered primarily in accordance with the provisions of the latest edition of the following codes: (i)

ASME B31.8

-

Gas Transmissions and Distribution for pressure Piping System

(ii)

ASME B31.3

-

Chemical Plant and Petroleum Refinery Piping

(iii)

OISD Standard 141

-

Design and Construction Requirements for Cross Country Hydrocarbon Pipelines.

2.2

All codes, standards and specifications referred herein shall be the latest edition of such documents.

2.3

For sake of brevity the initials of the society to which the codes are referred may be omitted in the specifications, for example, B16.5 is a code referring to ASME; A106 is a code referring to ASTM.

2.4

In addition, GAIL specifications and standards for various piping and pipeline materials shall also be applicable.

3.0

MATERIAL SPECIFICATIONS Individual piping class has been generally designed to cover a set of service operating within pressure-temperature consideration as per ASME B16.5/ B16.34 or part of it. Deviations of material from class specifications may occur due to specific design conditions and/ or availability. These deviations are permissible if they equal or better the individual class requirements and shall be subjected to approval on case-to-case basis. All materials shall conform to detailed specifications / data sheets for items as applicable.

4.0

CLASS DESIGNATION CODE The piping class designation shall generally consist of three digits made up of a letter, number, letter e.g. A1A, A3A, A4A, B1A, D1A, E1A, etc. as follows: First letter indicates ASME Class rating e.g. PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI


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A – Class 150 B – Class 300 D – Class 600 E – Class 900 The middle number indicates differences in the specifications within the same class rating and material.

The last letter indicates type of material. E.g. A – Carbon steel. 5.0

PIPELINE

5.1

Line pipe material grade and wall thickness details are indicated in Table-I.

6.0

PIPES

6.1

Carbon steel pipe shall be made by open hearth, electric furnace or basic oxygen process only. The steel used shall be fully killed and made with fine grain structure. The grade and wall thickness of various sizes of pipes shall be as per piping material specification for the applicable class.

6.2

Pipe dimensions shall be in accordance with ASME B 36.10 for carbon steel ASTM standard pipes; & API 5L for carbon steel API 5L grade pipes.

6.3

All pipe threads shall conform to American Standard taper as per ASME B1.20.1 NPT, unless otherwise specified.

6.4

For butt weld end, bevel shall be in accordance with API specification 5L or ASME B 16.25 as applicable.

7.0

FITTINGS

7.1

Fully killed carbon steel shall be used in the manufacture of fittings. The fitting shall have carbon equivalent not exceeding 0.45, based on check analysis.

7.2

Threaded joints, if used, shall conform to American Standard taper as per ASME B1.20.1 NPT.

7.3

Dimensions of socket welded/ screwed fittings shall conform to ASME B 16.11. Swage shall be as per BS 3799.

7.4

Dimensions of steel butt welded fittings shall be as per ASME B 16.9.

7.5

Bore of socket welded fittings shall suit outside diameter (OD) of pipe and its thickness.

7.6

Butt welding ends shall conform to API specification 5L or ASME B 16.25 as applicable. In case of difference in thickness of matching ends, requirements of ASME B 31.8 shall apply.

7.7

Integrally reinforced forged branch fittings such as Sockolet, Weldolet etc. shall be as per MSS-SP97. Fittings not covered in ASME B16.9 and MSS-SP-97 shall conform to manufacturer’s standard.

7.8

Fittings thickness tolerances shall match pipe thickness tolerance.

8.0

BENDS PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI


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8.1

Unless otherwise specified for process piping, elbow of radius R Minimum Bend Radius D = Specified Outside Diameter

8.2

In order to accommodate changes in vertical and horizontal alignment in piggable section of pipeline, Elastic bends/ Cold field bends/ Hot formed long radius bends shall be used. Long Radius Bend shall be used only when indicated in the drawing.

8.3

Miters shall not be used.

9.0

FLANGES

9.1

Pressure Temperature rating of flanges shall conform to B16.5/ MSS-SP44/ B16.47 Series A, as applicable.

9.2

Dimensions of flanges shall be in accordance with B16.5/ MSS-5P44/ B16.47 Series A, as applicable.

9.3

Neck of weld neck (WN) flanges shall suit pipe bore and thickness.

9.4

Bore of socket welded (SW) flanges shall suit pipe O.D. and its thickness.

9.5

Threads for screwed flanges, if used, shall conform to American Standard taper as per ASME B 1.20.1 NPT.

9.6

Sizes for blind flanges shall be indicated by nominal pipe size.

9.7

Unless specified otherwise in Piping Material Specification the flange face finish shall be as per ASME B16.5.

9.8

Butt welding ends of WN flanges shall conform to ASME B 16.25.

9.9

Spectacle blind/ spacer & blinds shall be in accordance with ASME B16.48/ manufacturer’s standard.

9.10

Two jack screws, 1800 apart shall be provided in spectacle blind or spacer & blind assemblies as per GAIL standards.

10.0

GASKETS

10.1

Spiral wound metallic gasket with compressed asbestos filler shall conform to ASME B16.20/ API 601. All spiral wound gaskets shall be provided with stainless steel centering ring.

10.2

Spiral wound gasket shall be self-aligning type.

11.0

BOLTING & THREADS

11.1

Nuts for stud bolts shall be American Standard Hexagon Heavy Series and double chamfered.

11.2

Dimension and tolerances for stud bolts and nuts shall be as per ASME B18.2.1 and 18.2.2 with full threading to ASME B 1.1 Class 2A thread for bolts and Class 2B for nuts. Diameter and length of stud bolts shall be as per ASME B 16.5/ ASME B16.47 with full threading.

11.3

Threads for nuts shall be as per ASME B 1.1 Nuts for stud bolts dia ¼“ to 1”

:

1.5 D shall only be used.

UNC-2B


=


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Nuts for stud bolts dia 1⅛ %” to 3¼ 11.4

:

8UN-2B

Threads for stud bolts shall be as per ASME B 1.1, as follows: Stud bolts dia ¼“ to 1”

:

UNC-2A

Stud bolts dia 1⅛ %” to 3¼

:

8UN-2A

11.5

Threads for threaded pipe, fitting, flanges and valve shall be in accordance with B1.20.1 taper threads, unless specified otherwise.

11.6

Heads of jack screws shall be heavy hexagonal type. Jack screw end shall be rounded. Stud bolts shall be fully threaded with two hexagonal nuts.

12.0

THREAD SEALANT

12.1

Threaded joints shall be made with 1” wide PTFE jointing tape.

13.0

VALVES

13.1

Valve ends shall be as per valve data sheets for various piping class.

13.2

Sectionalizing valves, Block valves and other isolation valves installed on the main pipeline shall be ball valves with butt welding ends. All inline isolation valves on the mainline (pipeline) shall be full bore valves to allow smooth passage of cleaning as well as intelligent pigs.

13.3

All buried valves shall be provided with stem extension, sealant, vent/drain and shall have butt welded ends as per relevant specification/ data sheet.

13.4

Flange dimensions and face finish of flanged end valves shall conform to clause 9.0 of this specification.

13.5

Butt welding ends of Butt Welded valves shall conform to ASME B 16.25.

13.6

Face to face and end to end dimensions shall conform to applicable standards.

13.7

Valves shall conform to following standards unless specified otherwise in piping material specification for various piping class. Flanged/ Socket Welded end valves (1½” and below) Design STD. for Process lines Gate Valves Globe Valves Ball Valves Plug Valves

: : : :

API 602 BS 5352 BS 5351 BS 5353

Flanged/ Butt Welded end valves (2” and above) Design STD. for Process Lines Gate Valves Globe Valves Check Valves

: : :

API 6D BS 1873 API 6D



REV-0 Page 6 of 68

Ball Valves Plug Valves 13.8

: :

API 6D API 6D

All manual operated valves shall be provided with wrench I hand wheel or gear operator as specified here in below.

13.8.1 Gate Valves For ANSI class 150 and 300

:

Hand wheel operated for size ≤12” NB. Gear operated for size ≥14” NB.

For ANSI class 600

:

Hand wheel operated for size ≤ 10” NB. Gear operated for size ≥ 12” NB

13.8.2 Globe Valves For ANSI class 150, 300, 600 and 900 - Hand Wheel operated for all size 13.8.3 Ball valves & Plug Valves For all ANSI class

:

Wrench operated for size ≤ 4” NB. Gear operated for size ≥ 6” NB.

13.8.4 Gas Actuated Valves Gas actuated valves shall be as per P & IDs. The actuator shall have provision for remote operation as per P & IDs. All gas actuated valves shall have additional provision of hand wheel operation. 14.0

QUICK OPENING END CLOSURE Quick opening end closure to be installed on scraper traps shall be designed in accordance with Section VIII of ASME Boiler and Pressure Vessel Code and equipped with safety locking devices in compliance with Section VIII, division 1. UG-35.2 of ASME Boiler and Pressure Vessel Code.

15.0

HYDROTESTING VENTS AND DRAINS In terminal piping, high point vents and low point drains required for the purpose of hydrotesting shall be of size 0.75”. These vents & drains shall consist of gate valves with blind flange assembly.

16.0

PIPELINE SPECIATLITY ITEMS Pipeline specialty items viz, scraper traps, Barred tees, insulating joints, LR bends etc. shall be as per specifications attached elsewhere.



REV-0 Page 7 of 68


12 10 10

Bhiwadi/Chopanki TOP – Bhiwadi Spur Line

Spur line Hayatpur - Manesar

Spur Line Hayatpur - Gurgaon

3.

3.

18

X – 60, PSL-2

X – 60, PSL-2

X – 60, PSL-2

X – 70, PSL-2

SEAMLESS ,EW

SEAMLESS ,EW

SEAMLESS ,EW

LSAW, HSAW, SEAMLESS, EW

6.4

6.4

6.4

6.5

METHOD OF MANUFACTURE

Sultanpur – Nimrana Pipe line

MATERIAL (API 5L) Class –I

TPIPE DIA (INCH)

LINE PIPE

SECTION

2.

1.

Sl. No.

6.4

6.4

6.4

7.9

Class – II

6.4

6.4

7.9

9.3

Class – III

W.T. (mm)

6.4

7.8

9.5

11.7

Class IV

TABLE -1

PIPING MATERIAL SPECIFICATION

SPECIFICATION

0001-01-05-02-001

REV-0 Page 8 of 68

TABLE – 2 Design Condition Pressure Temp. (Kg/cm2 ) (0 C) 99.93 65

Class

Service

D1A

Hydrocarbon Gas

B1A

Hydrocarbon Gas

49.0

65

1.5

A1A

Hydrocarbon Gas

19

65

1.5

A3A

Utilities

10.5

65

1.5

J2A

Potable Water

10.5

65

0

A93A

Fire Water

18.9

65

1.5

C.A. (mm)

Pipe Material

Design Code

1.5

API 5L X – 52/ ASTM A 106 GRB / Gr.B (Charpy) / Gr. B PSL2 as applicable ASTM A 106 GR- B / Gr.B (Charpy) / Gr. B PSL2 as applicable ASTM A 106 GR- B / Gr.B (Charpy) / Gr. B PSL2 as applicable IS-1239 (BLACK) IS-1239 (Galv) IS-1239 (Black)/ IS-3589 GR 410 as applicable

ASME B 31.8 / OISD – 141

ASME B 31.8 / OISD – 141/ 226

ASME B 31.8 / OISD – 141 / 226

ASME B 31.3 ASME B 31.3 ASME B 31.3

CORROSION ALLOWANCE : Above mentioned corrosion allowance is only for station piping. No corrosion allowance is considered in linepipe.



REV-0 Page 9 of 68

ANNEXURE A PIPING MATERIAL SPECIFICATION (A1A - CLASS 150#)



REV-0 Page 10 of 68

PIPING CLASS

:

A1A, 150 #

BASE MATERIAL

:

CARBON STEEL

CORROSION ALLOWANCE

:

1.5 MM

SPECIAL REQUIREMENT

:

NON IBR

TEMPERATURE (Deg. C) AND PRESSURE ( Kg/Sq. cm g ) RATINGS

SERVICE : NON CORROSIVE PROCESS - FLAMMABLE / NON FLAMMABLE, NON LETHALHYDROCARBONS, AMMONIA, STEAM & GAS CONDENSATE (NON- IBR), UTILITIES (WATER, INST, AIR, NITROGEN, CARBON DIOXIDE) AND LUBE OIL BEFORE THE FILTER. NOTES 1.

ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID.

2.

NDT OF WELDS SHALL BE AS FOLLOWS: RADIOGRAPHY

:

ALL BUTT WELDS

-

100%

MPI

:

SOCKET WELDS

-

100%

3.

PIPING DESIGN AS PER ASME B 31.8 & OISD 226.

4.

CHARPY V-NOTCH TEST & HARDNESS TEST SHALL BE CONDUCTED FOR PIPE, FITTINGS AND FLANGES.

5. 6. 7.

ALL BRANCH CONNECTIONS INCLUDING VENT, DRAIN, PRESSURE AND TEMPERATURE CONNECTION SHALL BE AS PER BRANCH CONNECTION TABLE GIVEN ON NEXT PAGE. THE BRANCH DETAILS INDICATED IN APPLICABLE STANDARD SHALL BE IGNORED. FOR VALVES, REFER RESPECTIVE VALVE DATA SHEETS. FOR HANDLE PROJECTION REFER STD. DRG-S-05-01-007. SPECIAL NOTES ITEM MAINTENANCE JOINTS PIPE JOINTS

SIZE ALL

DESCRIPTION FLANGED TO BE KEPT MINIMUM

1.5” & BELOW

SW COUPLING

2.0” & ABOVE

BUTT WELDED

ON LINES ≤1.5”

REFER GAIL STD.S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75” REFER STD.S-05-01-004

ON LINES ≤1.5”

REFER GAIL STD – S-05-01-003

ON LINES ≥2.0”


TEMP. CONN

1.5”

PRESS. CONN

0.75”

FLANGED, INSTALLATION AS PER GAIL STD – S-05-01-005. SW NIPPLE WITH GATE VALVE TO SPEC AS PER

DRAINS

VENTS

STD.S-05-01-006



REV-0 Page 11 of 68

T

T

T

W

W

W S

W S

T T T

S S S

S S S

S S S

S S S

S S S

S S S

5.000

W S

4.000

T S

3.500

T S

3.000

T T

72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8.0 6.0 5.0 4.0 3.5 3.0 2.5 2.0 1.5 1.25 1.0 0.75 0.5

BRANCH PIPE (SIZE IN INCHES)

T

10.00

T

8.000

T

6.000

T

T

2.500

1.000

T T T

2.000

0.750

T

T T

1.500

T T T 1.250

T

T T

0.500


72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8.0 6.0 5.0 4.0 3.5 3.0 2.5 2.0 1.5 1.25 1.0 0.75 0.5

RUN PIPE (SIZES IN INCH) – A1A



REV-0 Page 12 of 68

CODE

DESCRIPTION

F H P R S

SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS

T W I X L

TEES WELDOLETS INSTRUMENT TEE REFER NOTES SWEEPOLET

Lower Size (Inch)

Upper Size (Inch)

Sch./ Thk

Dim. STD

Material

Description

PIPE

00.500

00.750

S160

B 36.10

ASTMA 106 GR.B

PE, SEAMLESS

PIPE

01.000

01.500

XS

B 36.10

ASTMA 106 GR.B

PE, SEAMLESS

PIPE

02.000

02.000

XS

B 36.10

ASTMA106 GR.B (CHARPY)

BE, SEAMLESS

PIPE

03.000

03.000

STD

B 36.10


BE, SEAMLESS

PIPE

04.000

04.000

STD

B 36.10


BE, SEAMLESS

PIPE

06.000

06.000

STD

B 36.10


BE, SEAMLESS

PIPE

8.000

14.000

6.4

API 5L

API 5L GR.B PSL2

BE, SEAMLESS

PIPE

16.000

18.000

6.4

API 5L

API 5L GR.B PSL2

BE, SAW

PIPE

20.000

20.000

7.1

API 5L

API 5L GR.B PSL2

BE, SAW

NIPPLE

00.500

00.750

M

B 36.10

ASTMA 106 GR.B

PBE, SEAMLESS

NIPPLE

01.000

01.500

M

B 36.10

ASTMA 106 GR.B

PBE, SEAMLESS

FLNG.WN

00.500

01.500

M

B-16.5

ASTM A 105

150, RF/125AARH

FLNG.WN

02.000

24.000

M

B-16.5

ASTM A 105 (CHARPY)

150, RF/125AARH

FLNG.BLIND

00.500

01.500

B-16.5

ASTM A 105

150, RF/125AARH

PLNG.BLIND

02.000

24.000

B-16.5

ASTM A105 (CHARPY}

150, RF/125AARH

FLNG.FIG8

00.500

01.500

B-16.48

ASTM A 105

150, RF/125AARH

Item Type

Pipe Group (A1A)

Flange Group (A1A)



REV-0 Page 13 of 68

FLNG.FIG8

02.000

08.000

B-16.48

ASTM A105 (CHARPY)

150, RF/125AARH

SPCR &BLIND

10.000

24.000

B-16.48

ASTM A105 (CHARPY)

150, RF/125AARH

ELBOW.90

00.500

0..750

B-16.11

ASTM A 105

SW, 6000

ELBOW.90

01.000

1.500

B-16.11

ASTM A 105

SW, 3000

ELBOW.90

02.000

24.000

B-16.9

ASTM A 234,GR. WPB (CHARPY)

BW, 1.5D

ELBOW.45

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

ELBOW.45

01.000

01.500

B-16.11

ASTMA 105

SW, 3000

ELBOW.45

02.000

24.000

B-16.9

ASTM A234,GR. WPB (CHARPY)

BW, 1.5D

T.EQUAL

00.500

00.750

B 16.11

ASTM A 105

SW, 6000

T.EQUAL

01.000

01.500

B 16.11

ASTM A 105

SW, 3000

T.EQUAL

02.000

24.000

B-16.9

ASTM A234,GR.WPB (CHARPY)

BW

T.RED

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

T.RED

01.000

01.500

B-16.11

ASTMA 105

SW, 3000

T.RED

02.000

24.000

M, M

B-16.9


BW

REDUC.CONC

02.000

24.000

M,M

B-16.9


BW

REDUC.ECC

02.000

24.000

M,M

B-16.9


BW

SWAGE.CONC

00.500

03.000

M,M

BS-3799

ASTM A 105 (CHARPY)

PBE

SWAGE.ECC

00.500

03.000

M,M

BS-3799

ASTM A 105 (CHARPY)

PBE

CAP

00.500

00.750

B-16.11

ASTMA 105

SCRF, 6000

CAP

01.000

01.500

B-16.11

ASTMA 105

SCRF, 3000

CAP

02.000

24.000

B-16.9


BW

CPLNG.FULL

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.FULL

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

CPLNG-HALF

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.HALF

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

Fitting Group (A1A)

M

M

M



REV-0 Page 14 of 68

CPLNG.LH

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.LH

01.000

01.500

B-16.11

ASTM A 105

SW,3000

CPLNG.RED

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.RED

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

SOCKOLET

00.500

0.750

MSSSP97

ASTM A 105

SW, 6000

SOCKOLET

01.000

01.500

MSSSP97

ASTM A 105

SW, 3000

WELDOLET

02.000

10.000

MSSSP97

ASTMA 105 (CHARPY)

BW

VLV.GATE

00.500

01.500

API-602

BODY-ASTM A 105, TRIM-STELLITED, STEM13%CR. STEEL

SW,800, 3000,B16.11

VLV.GLOBE

00.500

01.500

BS-5352

BODY-ASTM A 105,TRIM-STELLITED, STEM13%CR STEEL

SW,800, 3000,B16.11

VLV.CHECK

00.500

01.500

BS-5352

BODY-ASTMA 105,TRIM-STELLITED

SW,800, 3000, B16.11

00.500

24.000

B18.2

BOLT: 193 GR.B7,NUT: A194 GR. 2H

24.000

B16.20ANSI B 16.5

SP,WND, SS316+CAF

O’let Group (A1A)

M, XXS

Valves Group (A1A)

Bolt Group (A1A) BOLT.STUD

Gasket Group (A1A) GASKET

00.500


SPIRAL, 150


REV-0 Page 15 of 68

ANNEXURE B PIPING MATERIAL SPECIFICATION (A3A - CLASS 150#)



REV-0 Page 16 of 68

PIPING CLASS

:

A3A, 150 #

BASE MATERIAL

:

CARBON STEEL

CORROSION ALLOWANCE

:

1.5 MM

SPECIAL REQUIREMENT

:

NON IBR


SERVICE : NON CORROSIVE UTILITIES (ABOVE GROUND) – COOLING WATER, INERT GAS, INSTRUMENT AIR, CONDENSATE NOTES 1.


2.

NDT REQUIREMENT AS PER GAIL STANDARD S-05-02-012

3. FOR VALVES REFER VALVE DATA SHEET SPECIAL NOTES ITEM MAINTENANCE JOINTS PIPE JOINTS

SIZE ALL

DESCRIPTION FLANGED TO BE KEPT MINIMUM

1.5” & BELOW

SW COUPLING 3000 #

2.0” & ABOVE

BUTT WELDED

ON LINES ≤1.5”


ON LINES ≥2.0”

AS PER P&ID OR 0.75” S-05-01-004

ON LINES ≤1.5”

REFER GAIL STD S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75”, S-05-01-004

TEMP. CONN

1.5”

FLANGED, INSTALLATION AS PER GAIL STD. S-05-01-005

PRESS. CONN

0.75

SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD.

DRAINS

VENTS

S-05-01-006



REV-0 Page 17 of 68

P

T

P

P

H H H

H H H

H H H

H H H


72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8.0 6.0 5.0 4.0 3.5 3.0 2.5 2.0 1.5 1.25 1.0 0.75 0.5

6.000

T T T

5.000

P H

4.000

P H

3.500

P H

3.000

T T

2.500

T

2.000

1.000

T

1.500

T T T 1.250

T

T T 0.750

T

0.500


72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8.0 6.0 5.0 4.0 3.5 3.0 2.5 2.0 1.5 1.25 1.0 0.75 0.5

(A3A)



REV-0 Page 18 of 68

CODE

DESCRIPTION

F H P R S


T W I X L

Lower Size (Inch)

Upper Size (Inch)

Sch./ Thk

Dim. STD

PIPE

00.500

1.50

HVY

PIPE

02.000

06.000

NIPPLE

00.500

Item Type


Material

Description

IS-1239I

IS-1239 (BLACK)

PE, C. WELDED

HVY

IS-1239I

IS-1239 (BLACK)

PE, C. WELDED

01.50

HVY

IS-1239I

IS-1239 (BLACK)

PE, C. WELDED

M

B-16.5

ASTM A 105

150, RF/125AARH

Pipe Group (A3A)

Flange Group (A3A) FLNG.SW

00.500

01.500

FLNG.SO

02.000

06.000

B-16.5

ASTM A 105 (CHARPY)

150, RF/125AARH

FLNG.BLIND

00.500

01.500

B-16.5

ASTM A 105

150, RF/125AARH

FLNG.BLIND

2.00

6.00

B-16.5

ASTM A105 (CHARPY}

FLNG.FIG8

00.500

01.500

B-16.48

ASTM A 105

150, RF/125AARH 150, RF/125AARH

FLNG.FIG8

02.000

06.000

B-16.5

ASTM A105 (CHARPY)

150, RF/125AARH

B-16.11

ASTM A 105

SW,3000

B-16.9

ASTM A 234 GR. WPB (CHARPY)

BW, 1.5D

B-16.11

ASTM A 105

SW, 3000

B-16.9


BW, 1.5D

B 16.11

ASTM A 105

SW, 3000

Fitting Group (A3A) ELBOW.90

00.500

01.500

ELBOW.90

02.00

06.00

ELBOW.45

00.500

01.50

ELBOW.45

02.000

06.000

T.EQUAL

00.500

01.50

STD

STD



REV-0 Page 19 of 68

T.EQUAL

02.00

06.00

T.RED

00.500

01.500

T.RED

02.000

06.00

REDUC.CONC

02.000

REDUC.ECC

STD

B 16.11


BW

B-16.11

ASTM A 105

SW, 3000

STD

B-16.9


BW

06.000

STD,STD

B-16.9


BW

02.000

06.000

STD,STD

B-16.9


BW

SWAGE.CONC

00.500

03.000

STD,STD

BS-3799

ASTM A 105 (CHARPY)

PBE

SWAGE.ECC

00.500

03.000

STD,STD

BS-3799

ASTM A 105 (CHARPY)

PBE

CAP

00.500

01.50

B-16.11

ASTMA 105

SCRF, 3000

CAP

02.000

06.00

B-16.9


BW

CPLNG.FULL

00.500

01.50

B-16.11

ASTM A 105

SW, 3000

CPLNG-HALF

00.500

01.50

B-16.11

ASTM A 105

SW, 3000

CPLNG.LH

00.500

01.50

B-16.11

ASTM A 105

SW, 3000

CPLNG.RED

00.500

01.50

B-16.11

ASTM A 105

SW, 3000

UNION

0.50

01.500

BS-3799

ASTM A 105

SW, 3000

STD

Valves Group (A3A) VLV.GATE

00.250

01.500

API-602

BODY-ASTM A 105, TRIM-STELLITED, STEM13%CR. STEEL

SW,800, 3000,B16.11

VLV.GATE

02.00

24.00

API-600

BODY-ASTM A 216, WCB, TRIMSTELLITED, STEM13%CR. STEEL

FLGD, 150, B 16.5, RF/125AARH

VLV.GLOBE

00.25

01.500

BS-5352

BODY-ASTM A 105,TRIM-STELLITED, STEM13%CR STEEL

SW,800, 3000,B16.11

VLV.GLOBE

02.00

16.00

BS-1873

BODY-ASTM A 216, WCB, TRIMSTELLITED, STEM13%CR. STEEL

FLGD, 150, B 16.5, RF/125AARH

VLV.CHECK

00.250

01.500

BS-5352


SW,800, 3000, B16.11

VLV.CHECK

02.00

24.00

BS 1868

BODY-ASTM A 216, GR. WCB, TRIM 13% CR. SREEEL

FLGD, 150, B 16.5, RF/125AARH



REV-0 Page 20 of 68

VLV.BALL

00.500

16.00

BS-5351

BODY-ASTM A 105,A 216 GR. WCB TRIMBODY SEAT - RPTFE

FLGD, 150, , B 16.5, RF/125AARH

VLV.BTRFLY

03.500

24.00

BS-5155

BODY-ASTM A 216 GR., WCB, TRIM- 13% CR. STEEL

WAFL, 150, B16.5 WAF/125AARH

00.500

6.000

B18.2

BOLT: A 307, GR. B, NUT: A 563 GR.B

6.000

B16.21ANSI B 16.5

IS-2712- GR.-W/3

RING, 150, 2 MM



00.500

TRAP/ STRAINER GROUP (A3A) TRP

00.500

1.50

MANF’S STD

B:A105, T:13%CR, S:SS304

FLGD, THRMDNMC, 150, RF/125AARH

TRP

01.500

6.000

MANUF STD

B:A285GR.C; INT: SS304

CONETYPE, 150, FF/125 AARH

TRP

00.500

1.500

MANUF STD

B:A105; INT: SS304

SW, Y-TYPE, 800

TRP

02.00

6.000

MANUF STD

B:A234GR. WPB; INT: SS304

BW, T - TYPE

M



REV-0 Page 21 of 68

ANNEXURE C PIPING MATERIAL SPECIFICATION (B1A - CLASS 300#)



REV-0 Page 22 of 68

PIPING CLASS

:

(B1A), 300 #

BASE MATERIAL

:

CARBON STEEL

CORROSION ALLOWANCE

:

1.5 MM

SPECIAL REQUIREMENT

:

NON IBR


SERVICE NON CORROSIVE PROCESS- FLAMMABLE / NON FLAMMABLE, NON LETHALHYDROCARBONS, AROMATICS, AMMONIA, SWEET GAS, FLUSHING OIL AND OTHER UTILITIES -MP CONDENSATE, INSTRUMENT AIR, PLANT AIR, NITROGEN, AMMONIA GAS ETC. NOTES 1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID. 2. NDT OF WELDS SHALL BE AS FOLLOWS: RADIOGRAPHY

:

ALL BUTT WELDS

-

100%

MPI

:

SOCKET WELDS

-

100%

3.

PIPING DESIGN AS PER ASME B 31.8 & OISD 141 & 226

4.

FLANGES OF SIZE 22” SHALL BE AS PER MSS-SP-44.

5.

CHARPY V-NOTCH TEST & HARDNESS TEST SHALL BE CONDUCTED FOR PIPE, FITTINGS AND FLANGES.

6.

ALL BRANCH CONNECTIONS INCLUDING VENT, DRAIN, PRESSURE AND TEMPERATURE CONNECTION SHALL BE AS PER BRANCH CONNECTION TABLE GIVEN ON NEXT PAGE. THE BRANCH DETAILS INDICATED IN APPLICABLE STANDARD SHALL BE IGNORED.

7.

FOR VALVES REFER RESPECTIVE VALVE DATA SHEET.

SPECIAL NOTES ITEM

SIZE

DESCRIPTION

MAINTENANCE JOINTS

ALL

FLANGED, TO BE KEPT MINIMUM

PIPE JOINTS

1.5” & BELOW

SW COUPLING

2.0” & ABOVE

BUTT WELDED

ON LINES ≤1.5”


ON LINES ≥2.0”

AS PER P&ID OR 0.75”; GAIL STD. S-05-01-004

ON LINES ≤1.5”

REFER GAIL STD. S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75”. S-05-01-004

TEMP. CONN

1.5”


PRESS. CONN

0.75”

SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD. S05-01-006

DRAINS VENTS



REV-0 Page 23 of 68

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52

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50

48

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40

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36

36

34

34

32

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30

30

28

28

26

26

24

24

22

22

20

T

20

T

T

18

T

T

T

16

T

T

T

T

14

T

T

T

T

T

12

18 16 14 12 10 8.0 6.0

T

T

T

T

T

T

T

10

T

T

T

T

T

T

T

8.0

T

T

T

T

T

W

W

5.0 T

T

T

T

W

W

W

W

W

3.5

4.0 3.5

3.0

T

T

T

W

W

W

W

W

W

W

2.5

3.0 2.5

2.0 1.5

T

T

T

T

W

W

W

W

W

W

W

W

T

S

S

S

S

S

S

S

S

S

S

2.0 1.5

S

S

S

S

S

S

S

S

S

S

S

S

S

0.75

T T

T

T

S

S

S

S

S

S

S

S

S

S

S

0.5

6.000

8.000

10.000

12.000

14.000

16.000

18.000

20.000

5.000

S

S

4.000

S

S

3.500

S

S

3.000

S

S

2.500

S

T

2.000

T

T

1.500

1.0

1.250

T T

1.000

1.25

0.500 0.750

1.25

0.5

6.0 5.0

4.0

0.75



72

1.0

(B1A)



REV-0 Page 24 of 68

CODE

DESCRIPTION

F H P R S


T W I X L


Lower Size (Inch)

Upper Size (Inch)

Sch./ Thk

Dim. STD

Material

Description

PIPE

00.500

00.750

S160

B 36.10

ASTMA 106 GR.B

PE, SEAMLESS

PIPE

01.000

01.500

XS

B 36.10

ASTMA 106 GR.B

PE, SEAMLESS

PIPE

02.000

02.000

XS

B 36.10


BE, SEAMLESS

PIPE

03.000

03.000

STD

B 36.10


BE, SEAMLESS

PIPE

04.000

06.000

STD

B 36.10


BE, SEAMLESS

PIPE

08.000

08.000

7.9

API 5L

API 5L GR.B PSL2

BE, SEAMLESS

PIPE

10.000

10.000

9.3

API 5L

API 5L GR.B PSL2

BE, SEAMLESS

PIPE

12.000

12.000

10.3

API 5L

API 5L GR.B PSL2

BE, SEAMLESS

PIPE

14.000

14.000

11.1

API 5L

API 5L GR.B PSL2

BE, SEAMLESS

PIPE

16.000

16.000

12.7

API 5L

API 5L GR.B PSL2

BE, SAW

PIPE

18.000

18.000

14.3

API 5L

API 5L GR.B PSL2

BE, SAW

PIPE

20.000

20.000

15.9

API 5L

API 5L GR.B PSL2

BE, SAW

NIPPLE

00.500

00.750

M

B 36.10

ASTM A 106 GR.B

PBE, SEAMLESS

NIPPLE

01.000

01.500

M

B 36.10

ASTM A 106 GR.B

PBE, SEAMLESS

Flange Group (B1A) FLNG.SW 00.500

01.500

M

B-16.5

ASTM A 105

300, RF/125AARH

FLNG.WN

02.000

16.000

M

B-16.5

ASTM A 105 (CHARPY)

300, RF/125AARH

FLNG.WN

18.000

20.000

M

B-16.5

ASTM A 105 (CHARPY)

300, RF/125AARH

FLNG.BLIND

00.500

01.500

B-16.5

ASTM A 105

300, RF/125AARH

FLNG.BLIND

02.000

20.000

B-16.5

ASTM A105 (CHARPY}

FLNG.FIG8

00.500

01.500

B-16.48

ASTM A 105

300, RF/125AARH 300, RF/125AARH

Item Type Pipe Group (B1A)



REV-0 Page 25 of 68

FLNG.FIG8

02.000

08.000

B-16.48

ASTM A105 (CHARPY)

SPCR &BLIND

10.000

20.000

B-16.48

ASTM A105 (CHARPY)

Fitting Group(B1A) ELBOW.90 00.500

0..750

B-16.11

ASTM A 105

SW, 6000

ELBOW.90

01.000

1.500

B-16.11

ASTM A 105

SW, 3000

ELBOW.90

02.000

16.000

M

B-16.9

ASTM A 234,GR. WPB CHARPY)

BW, 1.5D

ELBOW.90

18.000

20.000

M

B- 16.9

ASTM A 234,GR. WPB CHARPY)

BW, 1.5D

ELBOW.45

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

ELBOW.45

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

ELBOW.45

02.000

16.000

M

B-16.9

ASTM A234, GR. WPB CHARPY)

BW, 1.5D

ELBOW.45

18.000

20.000

M

B 16.9

ASTM A234, GR. WPB CHARPY)

BW, 1.5D

T.EQUAL

00.500

00.750

B 16.11

ASTM A 105

SW, 6000

T.EQUAL

01.000

01.500

B 16.11

ASTM A 105

SW, 3000

T.EQUAL

02.000

16.000

M

B-16.9


BW

T.EQUAL

18.000

20.000

M

B – 16.9


BW

T.RED

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

T.RED

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

T.RED

02.000

16.000

M, M

B-16.9

ASTM A234,GR. WPB(CHARPY)

BW

T.RED

18.000

20.000

M, M

B – 16.9


BW

REDUC.CONC

02.000

16.000

M,M

B-16.9


BW

REDUC.CONC

18.000

26.000

M,M

B-16.9


BW

REDUC.ECC

02.000

16.000

M,M

B-16.9


BW

REDUC.ECC

18.000

20.000

M,M

B – 16.9


BW

SWAGE.CONC

00.500

03.000

M,M

BS-3799

ASTM A 105 (CHARPY)

PBE

SWAGE.ECC

00.500

03.000

M,M

BS-3799

ASTM A 105 (CHARPY)

PBE


300, RF/125AARH 300, RF/125AARH


REV-0 Page 26 of 68

CAP

00.500

00.750

B-16.11

ASTM A 105

SCRF, 6000

CAP

01.000

01.500

B-16.11

ASTM A 105

SCRF, 3000

CAP

02.000

16.000

M

B-16.9


BW

CAP

18.000

20.000

M

B – 16.9


BW

PLUG

00.500

00.750

B 16.11

ASTM A 105

SCRM, 6000

PLUG

01.000

01.500

B 16.11

ASTM A 105

SCRM, 3000

CPLNG.FULL

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.FULL

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

CPLNG-HALF

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.HALF

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

CPLNG.LH

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.LH

01.000

01.500

B-16.11

ASTM A 105

SW,3000

CPLNG.RED

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.RED

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

O’ let group(B1A) SOCKOLET 00.500

0.750

MSS-SP97

ASTM A 105

SW, 6000

SOCKOLET

01.000

01.500

MSS-SP97

ASTM A 105

SW, 3000

WELDOLET

02.000

10.000

MSS-SP97

ASTMA 105 (CHARPY)

BW

M, XXS

Valves Group (B1A) VLV.GATE

00.500

01.500

API-602

BODY-ASTM A 105, TRIMSTELLITED, STEM13%CR. STEEL

SW,800, 3000,B16.11

VLV.GATE

02.000

20.000

API-6D

BODY-ASTM A 216 GR. WCB TRIM-STELLITED, STEM 13% CR. STEEL

FLGD, 300, B16.5, RF/ 125 AARH

VLV.GLOBE

00.500

01.500

BS-5352

BODY-ASTM A 105,TRIMSTELLITED, STEM13%CR STEEL

SW,800, 3000,B16.11

VLV.GLOBE

02.000

20.000

BS-1873

BODY-ASTM A 216 GR. WCB TRIM-STELLITED, STEM 13% CR. STEEL

FLGD, 300, B16.5, RF/ 125 AARH

VLV.CHECK

00.500

01.500

BS-5352


SW,800, 3000, B16.11

VLV.CHECK

2.000

20.000

API -6D

BODY-ASTM A 216 GR. WCB TRIM-STELLITED, STEM 13%

FLGD, 300, B16.5, RF/ 125



REV-0 Page 27 of 68

CR. STEEL

AARH

VLV.BALL

00.500

01.500

BS-5351

BODY-ASTM A 105,TRIMSEAT RPTFE

FLGD, 300, B16.5, RF/ 125 AARH

VLV.BALL

02.000

20.000

API-6D

BODY-ASTM A 216 GR. WCC/ A234 GR WPC, TRIM-SEAT AISI 4140+0.003” ENP/ AISI 410

FLGD, 300, B16.5, RF/ 125 AARH

VLV.BALL

02.000

02.000

API-6D


BW, 300, B16.25, RF/ 125 AARH

VLV.PLUG

00.500

01.500

BS-5353

BODY-ASTM A 105, PLUG-A 105 +0.003” ENP

SW,800 3000, B16.11

VLV.PLUG

02.000

20.000

API-6D

BODY-ASTM A 216 GR. WCB PLUG-A 216 GR. WCB+0.003” ENP

FLGD, 300, B16.5, RF/ 125 AARH

Bolt Group(B1A) BOLT.STUD 00.500

26.000

B18.2


Gasket Group (B1A) GASKET 00.500

20.000

B16.20ANSI B 16.5

SP,WND, SS316+CAF

SPIRAL, 300

GASKET

20.000

B16.20ANSIB 16.5

SP,WND, SS316+CAF

SPIRAL, 300

26.000



REV-0 Page 28 of 68

ANNEXURE D

PIPING MATERIAL SPECIFICATION (D1A - CLASS 600#)



REV-0 Page 29 of 68

PIPING CLASS

:

D1A, 600 #

BASE MATERIAL

:

CARBON STEEL

CORROSION ALLOWANCE

:

1.5 MM

SPECIAL REQUIREMENT

:

NON IBR


SERVICE - REGASIFIED LNG (R-LNG) / Natural Gas NOTES 1.


2.

WALL THICKNESS OF LINEPIPE (MAIN PIPELINE) USED SHALL BE AS PER TABLE – 1 ENCLOSED.

3.

BALL VALVE TO BE USED IN MAIN LINE SHALL HAVE BUTT WELDED ENDS.

4.

MAINLINE WELDING AND NDT REQUIREMENTS OF WELDS SHALL AS PER SPECIFICATION – 0001-01-04-02-001.

5.

BARRED TEE SHALL BE WELDED TYPE FOR USE IN MAINLINE ONLY. MATERIAL SHALL BE AS PER ATTACHED TABLE-3 FOR PIPELINE SPECIALITY ITEMS.

6.

LR BEND,IJ,L/R, PIG SIG. SHALL BE FOR USE IN MAINLINE ONLY, MATERIAL AS PER TABLE-3.

7.

NDT OF WELDS EXCLUDING MAINLINE SHALL BE AS FOLLOWS: RADIOGRAPHY MPI

: :

ALL BUTT WELDS SOCKET WELDS

-

100% 100%

ALL OTHER REQUIREMENT SHALL BE AS PER S-05-02-012 8.

PIPING DESIGN AS PER ASME B 31.8 & OISD 141

9.

FLANGES OF SIZE 22” SHALL BE AS PER MSS-SP-44.

10. CHARPY V-NOTCH TEST & HARDNESS TEST SHALL BE CONDUCTED FOR PIPE, FITTINGS AND FLANGES. 11. ALL BRANCH CONNECTIONS INCLUDING VENT, DRAIN, PRESSURE AND TEMPERATURE CONNECTION SHALL BE AS PER BRANCH CONNECTION TABLE GIVEN ON NEXT PAGE. THE BRANCH DETAILS INDICATED IN APPLICABLE STANDARD SHALL BE IGNORED. 12. CORROSION ALLOWANCE OF 1.5 MM HAS BEEN CONSIDERED FOR TERMINAL PIPING AND 0.0 MM FOR MAIN PIPELINE 13. FOR DIMENSIONS OF HANDLE PROJECTION FOR SPACER & BLIND – REFER STD. DRG.S-05-01-007



REV-0 Page 30 of 68

14. SPECIAL NOTES - D1A ITEM

SIZE

DESCRIPTION

MAINTENANCE JOINTS PIPE JOINTS

ALL 1.5” & BELOW

FLANGED, TO BE KEPT MINIMUM SW COUPLING

2.0” & ABOVE

BUTT WELDED

ON LINES ≤1.5”


ON LINES ≥2.0”


ON LINES ≤1.5”


ON LINES ≥2.0”

AS PER P&ID OR 0.75”. REFER STD. S-05-01-003

TEMP. CONN

1.5”

PRESS. CONN

0.75”

FLANGED, INSTALLATION AS PER GAIL STD. S-05-01-005 SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD. S-05-01-006

DRAINS

VENTS



REV-0 Page 31 of 68

70

68

68

66

66

64

64

62

62

60

60

58

58

56

56

54

54

52

52

50

50

48

48

46

46

44

44

42

42

40

40

38

38

36

36

34

34

32

32

30

T 30

28

28

26 24

T

22 20

T

18 16

T

14 12 10

T

T 26

T

T 24

T

T

T

T 22

T

T

T

T 20

T

T

T

T

T

T 18

T

T

T

T

T

T 16

T

T

T

T

T

T

T

T 14

T

T

T

T

T

T

T

T

T 12

T

T

T

T

T

T

T

T

W

T 10

T

T

T

T

T

T

T

W

W

W

W 8.0

T

T

T

T

T

T

W

W

W

W

W

W 6.0

T

T

T

T

W

W

W

W

W

W

W

W

W 4.0

T

T

T

W

W

W

W

W

W

W

W

W

W

W 3.0

T

T

T

W

W

W

W

W

W

W

W

W

W

W

W 2.0

T

S

S

S

S

S

S

S

S

S

S

S

S

S

S

8.0 6.0 5.0

5.0

4.0 3.5

3.5

3.0 2.5

2.5

2.0 1.5

T

1.5

S

S

S

S

S

S

S

S

S

1.0

S

S

S

S

S

S

S

S

S

S

0.75

T T

T

T

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

0.5

2.000

6.000

8.000

10.000

12.000

14.000

16.000

18.000

20.000

22.000

24.000

26.000

30.000

S

S

28.000

S

S

5.000

S

S

4.000

S

S

3.500

S

T

3.000

T

T

2.500

T

T

0.75

1.250

1.0

0.750

T T

1.500

1.25

1.000

1.25

0.5


72

70

0.500


72

RUN PIPE (SIZES IN INCH) – D1A



REV-0 Page 32 of 68

CODE

DESCRIPTION

F H P R S


T W I X L


Lower Size (Inch)

Upper Size (Inch)

Sch./ Thk

Dim. STD

Material

Description

PIPE

00.500

00.750

S160

B 36.10

ASTM A 106 GR.B

PE, SEAMLESS

PIPE

01.000

01.500

XS

B 36.10

ASTM A 106 GR.B

PE, SEAMLESS

PIPE

02.000

02.000

XS

B 36.10

ASTM A106 GR.B (CHARPY)

BE, SEAMLESS

PIPE

03.000

06.000

XS

B 36.10

ASTM A106 GR.B (CHARPY)

BE, SEAMLESS

PIPE

08.000

08.000

14.3

API 5L

API 5L GR.B PSL2

BE, SEAMLESS

PIPE

10.000

10.000

12.7

API 5L

API 5L X-52 PSL2

BE, SEAMLESS

PIPE

12.000

12.000

14.3

API 5L

API 5L X-52 PSL2

BE, SEAMLESS

PIPE

14.000

14.000

14.3

API 5L

API 5L X - 52 PSL2

BE, SEAMLESS

PIPE

16.000

16.000

17.5

API 5L

API 5L GR.X-52 PSL2

BE, SAW

PIPE

18.000

18.000

19.1

API 5L

API 5L GR.X-52 PSL2

BE, SAW

PIPE

20.000

20.000

20.6

API 5L

API 5L GR.X-52 PSL2

BE, SAW

PIPE

24.000

24.000

19.1

API 5L

API 5L GR.X-52 PSL2

BE, SAW

PIPE

28.00

28.00

22.2

API 5L

API 5L GR.X-52 PSL2

BE, SAW

PIPE

30.00

30.00

2

API 5L

API 5L GR.X-52 PSL2

BE, SAW

NIPPLE

00.500

00.750

M

B 36.10

ASTM A 106 GR.B

PBE,SEAMLESS

NIPPLE

01.000

01.500

M

B 36.10

ASTM A 106 GR.B

PBE, SEAMLESS

Item Type Pipe Group (D1A)

Flange Group (D1A) FLNG.SW

00.500

01.500

M

B-16.5

ASTM A 105

600, RF/125AARH

FLNG.WN

02.000

8.000

M

B-16.5

ASTM A 105 (CHARPY)

600, RF/125AARH

FLNG.WN

10.000

24.000

M

B- 16.5

ASTM A 694 GR. F-52 (CHARPY)

600, RF/125AARH

FLNG.WN

28.000

30.000

M

B-16.47-A

ASTM A 694 GR. F-52 (CHARPY)

600, RF/125AARH



REV-0 Page 33 of 68

FLNG.BLIND

00.500

01.500

B-16.5

ASTM A 105

600, RF/125AARH

FLNG.BLIND

02.000

24.000

B-16.5

ASTM A105 (CHARPY}

FLNG.BLIND

26.000

30.000

B16.47A

ASTM A105 (CHARPY}

FLNG.FIG8

00.500

01.500

B-16.48

ASTM A 105

600, RF/125AARH 600, RF/125AARH 600, RF/125AARH

FLNG.FIG8

02.000

08.000

B-16.48

ASTM A105 (CHARPY)

SPCR &BLIND

10.000

24.000

B-16.48

ASTM A105 (CHARPY)

SPCR &BLIND

26.000

30.000

MNF’S STD

ASTM A516 GR.70 (CHARPY)

600, RF/125AARH 600, RF/125AARH 600, RF/125AARH

Fitting Group (D1A) ELBOW.90

00.500

0..750

B-16.11

ASTM A 105

SW, 6000

ELBOW.90

01.000

1.500

B-16.11

ASTM A 105

SW, 3000

ELBOW.90

02.000

8.000

M

B-16.9

ASTM A 234,GR. WPB (CHARPY)

BW, 1.5D

ELBOW.90

10.000

30.000

M

MSS-SP75

MSS-SP75 GR.WPHY-52

BW, 1.5D

ELBOW.45

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

ELBOW.45

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

ELBOW.45

02.000

8.000

M

B-16.9

ASTM A234, GR. WPB (CHARPY)

BW, 1.5D

ELBOW.45

10.000

30.000

M

MSS-SP75

MSS-SP75 GR.WPHY-52

BW, 1.5D

PIPE BEND

18.000

30.000

M

MSS-SP75

MSS-SP75 GR.WPHY-52

BW, 1.5D

T.EQUAL

00.500

00.750

B 16.11

ASTM A 105

SW, 6000

T.EQUAL

01.000

01.500

B 16.11

ASTM A 105

SW, 3000

T.EQUAL

02.000

8.000

M

B-16.9


BW

T.EQUAL

10.000

30.000

M

MSS-SP75

MSS-SP75 GR.WPHY-52

BW

T.RED

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

T.RED

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

T.RED

02.000

8.000

M, M

B-16.9


BW

T.RED

10.000

30.000

M, M

MSS-SP75

MSS-SP75 GR.WPHY-52

BW

REDUC.CONC

02.000

8.000

M,M

B-16.9


BW

REDUC.CONC

10.000

30.000

M,M

MSS-SP75

MSS-SP75 GR.WPHY-52

BW

REDUC.ECC

02.000

8.000

M,M

B-16.9


BW

REDUC.ECC

10.000

30.000

M,M

MSS-SP75

MSS-SP75 GR.WPHY-52

BW



REV-0 Page 34 of 68

SWAGE.CONC

00.500

03.000

M,M

BS-3799

ASTM A 105 (CHARPY)

PBE

SWAGE.ECC

00.500

03.000

M,M

BS-3799

ASTM A 105 (CHARPY)

PBE

CAP

00.500

00.750

B-16.11

ASTM A 105

SCRF, 6000

CAP

01.000

01.500

B-16.11

ASTM A 105

SCRF, 3000

CAP

02.000

8.000

M

B-16.9


BW

CAP

10.000

30.000

M

MSS-SP75

MSS-SP75 GR.WPHY-52

BW

PLUG

00.500

00.750

B 16.11

ASTM A 105

SCRM, 6000

PLUG

01.000

01.500

B 16.11

ASTM A 105

SCRM, 3000

CPLNG.FULL

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.FULL

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

CPLNG-HALF

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.HALF

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

CPLNG.LH

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.LH

01.000

01.500

B-16.11

ASTM A 105

SW,3000

CPLNG.RED

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.RED

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

SOCKOLET

00.500

0.750

MSS-SP97

ASTM A 105

SW, 6000

SOCKOLET

01.000

01.500

MSS-SP97

ASTM A 105

SW, 3000

WELDOLET

02.000

16.000

M, XXS

MSS-SP97

ASTMA 105 (CHARPY)

BW

WELDOLET

18.000

20.000

M, M

MSS-SP97

ASTMA 694 GR. F-52 (CHARPY)

BW

O’ let group (D1A)

Valves Group (D1A) VLV.GATE

00.500

01.500

API-602

BODY-ASTM A 105, TRIMSTELLITED, STEM13%CR. STEEL

SW,800, 3000,B16.11

VLV.GLOBE

00.500

01.500

BS-5352

BODY-ASTM A 105,TRIMSTELLITED, STEM13%CR STEEL

SW,800, 3000,B16.11

VLV.CHECK

00.500

01.500

BS-5352


SW,800, 3000, B16.11

VLV.BALL

00.500

01.500

BS-5351

BODY-ASTM A 105,TRIM-SEAT RPTFE

FLGD, 600, B16.5, RF/ 125 AARH



REV-0 Page 35 of 68

VLV.BALL

02.000

24.000

API-6D


FLGD, 600, B16.5, RF/ 125 AARH

VLV.BALL

26.000

30.000

API-6D


BW, 600, B16.25, RF/ 125 AARH

VLV.BALL

02.000

30.000

API-6D


BW, 600, B16.25, RF/ 125 AARH

VLV.PLUG

00.500

01.500

BS-5353

BODY-ASTM A 105, PLUG-A 105 +0.003” ENP

SW, 800 3000, B16.11

VLV.PLUG

02.000

24.000

API-6D


FLGD, 600, B16.5, RF/ 125 AARH

VLV.PLUG

02.000

24.000

API-6D


BW, 600, B-16.5, RF/ 125 AARH

00.500

30.000

B18.2


Bolt Group(D1A) BOLT.STUD

Gasket Group(D1A) GASKET

00.500

24.000

B16.20ANSI B16.5

SP,WND, SS316+CAF

SPIRAL, 600

GASKET

26.000

30.000

B16.20ANSI B16.47A

SP,WND, SS316+CAF

SPIRAL, 600



REV-0 Page 36 of 68

ANNEXURE E

PIPING MATERIAL SPECIFICATION (A4A - CLASS 150#)



REV-0 Page 37 of 68

PIPING CLASS

:

A4A, 150 #

BASE MATERIAL

:

CARBON STEEL

CORROSION ALLOWANCE

:

1.5 MM

SPECIAL REQUIREMENT

:

LOW TEMPERATURE SERVICE


SERVICE NON CORROSIVE PROCESS-FLAMMABLE / NON-FLAMMABLE, NON-LETHAL-BELOW -29DEG C AND UPTO -45 DEG C.HYDROCARBONS, XYLENE, METHANOL, NH3, GAS FLARE ETC. NOTES 1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID. 2. NDT OF WELDS SHALL BE AS FOLLOWS: RADIOGRAPHY

:

ALL BUTT WELDS

-

100%

MPI

:

SOCKET WELDS

-

100%

3.


4.

IMPACT TESTING IS REQUIRED

5.


6.


7.

FOR DIMENSIONS OF HANDLE PROJECTION FOR SPACER & BLIND, REFER Std. SPEC. S-05-01-007 SPECIAL NOTES

ITEM

SIZE

DESCRIPTION

MAINTENANCE JOINTS

ALL


PIPE JOINTS

1.5” & BELOW

SW COUPLING

2.0” & ABOVE

BUTT WELDED

ON LINES ≤1.5”

REFER GAIL STD S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75” REFER STD. S-05-01-004

ON LINES ≤1.5”


ON LINES ≥2.0”

AS PER P&ID OR 0.75”.REFER STD. S-05-01-003

TEMP. CONN

1.5”


PRESS. CONN

0.75”

SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD. S-05-01-006

DRAINS VENTS



REV-0 Page 38 of 68

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56

56

54

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52

50

50

48

48

46

46

44

44

42

42

40

40

38

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36

36

34

34

32

32

30

30

28

28

26

26

24

24

22

22

20

20

18

18

16

16

14

T

14

T

T

12

T

T

T

10

T

T

T

T

8.0

T

T

T

T

12 10 8.0 6.0

T

5.0 T

T

T

T

W

W

3.5

4.0 3.5

3.0

T

T

T

W

W

W

W

2.5

3.0 2.5

2.0 1.5

T

T

T

T

W

W

W

W

W

T

S

S

S

S

S

S

S

2.0 1.5

S

S

S

S

S

S

S

0.75

T T

T

T

S

S

S

S

S

S

S

S

0.5

8.000

10.000

12.000

14.000

5.000

S

S

4.000

S

S

3.500

S

S

3.000

S

S

2.500

S

T

2.000

T

T

1.500

1.0

1.250

T T

6.000

1.25

1.000

1.25

0.5

6.0 5.0

4.0

0.75


72

70

0.500 0.750


72

1.0

RUN PIPE (SIZES IN INCH) A4A



REV-0 Page 39 of 68

CODE

DESCRIPTION

F H P R S

SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS Upper Lower Size Size (Inch) (Inch)

Item Type

T W I X L


Sch./ Thk

Dim. STD

Material

Description

Pipe Group (A4A) PIPE

00.500

00.750

S160

B 36.10

ASTM A 333 GR.6

PE, SEAMLESS

PIPE

01.000

01.500

XS

B 36.10

ASTM A 333 GR.6

PE, SEAMLESS

PIPE

02.000

02.000

XS

B 36.10

ASTM A 333 GR.6

BE, SEAMLESS

PIPE

03.000

14.000

STD

B 36.10

ASTM A 333 GR.6

BE, SEAMLESS

NIPPLE

00.500

00.750

M

B 36.10

ASTM A 333 GR.6

PBE,SEAMLESS

NIPPLE

01.000

01.500

M

B 36.10

ASTM A 333 GR.6

PBE, SEAMLESS

Flange Group (A4A) FLNG. WN 00.500

14.000

M

B-16.5

ASTM A 350 GR. LF2

150, RF/125 AARH

FLNG.BLIND

00.500

14.000

B-16.5

ASTM A 350 GR. LF2

150, RF/125 AARH

FLNG.FIG.8

00.500

8.000

ASMEB16.48

ASTM A 350 GR. LF2

150, FF/125 AARH

SPCR &BLIND

10.000

14.000

ASMEB16.48

ASTM A 350 GR. LF2

150, FF/125 AARH

Fitting Group (A4A) ELBOW.90

00.500

0.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

ELBOW.90

01.000

1.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

ELBOW.90

02.000

14.000

B-16.9

ASTM A 420 GR.WPL6

BW, 1.5D

ELBOW.45

00.500

0.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

ELBOW.45

01.000

1.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

ELBOW.45

02.000

14.000

B-16.9

ASTM A 420 GR.WPL6

BW, 1.5D

T.EQUAL

00.500

00.750

B 16.11

ASTM A 350 GR.LF2

SW, 6000

T.EQUAL

01.000

01.500

B 16.11

ASTM A 350 GR.LF2

SW, 3000

T.EQUAL

02.000

14.000

B-16.9

ASTM A 420 GR.WPL6

BW

T.RED

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

T.RED

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

M

M

M



REV-0 Page 40 of 68

T.RED

02.000

14.000

M, M

B-16.9

ASTM A 420 GR.WPL6

BW

REDUC.CONC

02.000

14.000

M,M

B-16.9

ASTM A 420 GR.WPL6

BW

REDUC.ECC

02.000

14.000

M,M

B-16.9

ASTM A 420 GR.WPL6

BW

SWAGE.CONC

00.500

03.000

M,M

BS-3799

ASTM A 350 GR.LF2

PBE

SWAGE.ECC

00.500

03.000

M,M

BS-3799

ASTM A 350 GR.LF2

PBE

CAP

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SCRF, 6000

CAP

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SCRF, 3000

CAP

02.000

14.000

B-16.9

ASTM A 420 GR.WPL6

BW

CPLNG.FULL

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.FULL

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

CPLNG-HALF

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.HALF

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

CPLNG.LH

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.LH

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW,3000

CPLNG.RED

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.RED

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

O’ let group(A4A) SOCKOLET 00.500

0.750

MSS-SP97

ASTM A 350 GR.LF2

SW, 6000

SOCKOLET

01.000

01.500

MSS-SP97

ASTM A 350 GR.LF2

SW, 3000

WELDOLET

02.000

10.000

MSS-SP97

ASTM A 350 GR.LF2

BW

M

M, XXS

Valves Group (A4A) VLV.GATE

00.500

01.500

API-602

BODY-ASTM A 350 GR. LF2, TRIM-STELLITED, STEM SS-304

SW,800, 3000,B16.11

VLV.GLOBE

00.500

01.500

BS-5352

BODY-ASTM A 350 GR.LF2, TRIM-STELLITED, STEM SS304

SW,800, 3000,B16.11

VLV.CHECK

00.500

01.500

BS-5352

BODY-ASTM A 350, GR.LF2, TRIM-STELLITED

SW,800, 3000, B16.11

00.500

14.000

B18.2

BOLT: A 320 GR.L7, NUT:A194 GR.4




REV-0 Page 41 of 68


00.500

14.000

B16.20ANSI B16.5

SP,WND, SS316+CAF



SPIRAL, 150

REV-0 Page 42 of 68

ANNEXURE F

PIPING MATERIAL SPECIFICATION (B4A - CLASS 300#)



REV-0 Page 43 of 68

PIPING CLASS

:

B4A, 300 #

BASE MATERIAL

:

CARBON STEEL

CORROSION ALLOWANCE

:

1.5 MM

SPECIAL REQUIREMENT

:



SERVICE NON CORROSIVE PROCESS-FLAMMABLE / NON-FLAMMABLE, NON-LETHAL-BELOW -29DEG C AND UPTO -45 DEG C.HYDROCARBONS, XYLENE, PROPYLENE, LPG, METHANOL, NH3, GAS FLARE ETC. NOTES 1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID. 2. NDT OF WELDS SHALL BE AS FOLLOWS: RADIOGRAPHY

:

ALL BUTT WELDS

-

100%

MPI

:

SOCKET WELDS

-

100%

3.


4.


5.


6.


7.

FOR DIMENSIONS OF HANDLE PROJECTION FOR SPACER & BLIND, REFER Std. SPEC. S-05-01-007

SPECIAL NOTES ITEM

SIZE

DESCRIPTION

MAINTENANCE JOINTS

ALL


PIPE JOINTS

1.5” & BELOW

SW COUPLING

2.0” & ABOVE

BUTT WELDED

ON LINES ≤1.5”


ON LINES ≥2.0”


ON LINES ≤1.5”


ON LINES ≥2.0”

AS PER P&ID OR 0.75”. S-05-01-004

TEMP. CONN

1.5”


PRESS. CONN

0.75”


DRAINS VENTS



REV-0 Page 44 of 68

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60

60

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58

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56

54

54

52

52

50

50

48

48

46

46

44

44

42

42

40

40

38

38

36

36

34

34

32

32

30

30

28

28

26

26

24

24

22

22

20

20

18

18

16

16

14

T

14

T

T

12

T

T

T

10

T

T

T

T

8.0

T

T

T

T

12 10 8.0 6.0

T

5.0 4.0

T

T

T

T

W

W

3.5 T

T

T

W

W

W

W

T

T

T

W

W

W

W

W

T

S

S

S

S

S

S

S

2.5

3.0 2.5

2.0 1.5

T

2.0 1.5

S

S

S

S

S

S

S

0.75

T T

T

T

S

S

S

S

S

S

S

S

0.5

6.000

8.000

10.000

12.000

14.000

5.000

S

S

4.000

S

S

3.500

S

S

3.000

S

T

2.500

T

T

2.000

T

T

1.500

1.0

1.250

T T

1.000

1.25

0.500 0.750

1.25

0.5

4.0 3.5

3.0

0.75

6.0 5.0

1.0

RUN PIPE (SIZES IN INCH) – B4A



REV-0 Page 45 of 68

CODE

DESCRIPTION

F H P R S

SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS Lower Upper Sch./ Size Size Thk (Inch) (Inch)

Item Type

T W I X L


Dim. STD

Material

Description

Pipe Group (B4A) PIPE

00.500

00.750

S160

B 36.10

ASTM A 333 GR.6

PE, SEAMLESS

PIPE

01.000

01.500

XS

B 36.10

ASTM A 333 GR.6

PE, SEAMLESS

PIPE

02.000

02.000

XS

B 36.10

ASTM A 333 GR.6

BE, SEAMLESS

PIPE

03.000

10.000

STD

B 36.10

ASTM A 333 GR.6

BE, SEAMLESS

PIPE

12.000

14.000

S40

B 36.10

ASTM A 333 GR.6

BE, SEAMLESS

NIPPLE

00.500

00.750

M

B 36.10

ASTM A 333 GR.6

PBE,SEAMLESS

NIPPLE

01.000

01.500

M

B 36.10

ASTM A 333 GR.6

PBE, SEAMLESS

Flange Group (B4A) FLNG. SW

00.500

1.50

M

B-16.5

ASTM A 350 GR. LF2

300, RF/125 AARH

FLNG. WN

02.000

14.000

M

B-16.5

ASTM A 350 GR. LF2

300, RF/125 AARH

FLNG.BLIND

00.500

14.000

B-16.5

ASTM A 350 GR. LF2

300, RF/125 AARH

FLNG.FIG.8

00.500

8.000

ASMEB16.48

ASTM A 350 GR. LF2

300, FF/125 AARH

SPCR &BLIND

10.000

14.000

ASMEB16.48

ASTM A 350 GR. LF2

300, FF/125 AARH

Fitting Group (B4A) ELBOW.90

00.500

0.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

ELBOW.90

01.000

1.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

ELBOW.90

02.000

14.000

B-16.9

ASTM A 420 GR.WPL6

BW, 1.5D

ELBOW.45

00.500

0.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

ELBOW.45

01.000

1.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

ELBOW.45

02.000

14.000

B-16.9

ASTM A 420 GR.WPL6

BW, 1.5D

T.EQUAL

00.500

00.750

B 16.11

ASTM A 350 GR.LF2

SW, 6000

T.EQUAL

01.000

01.500

B 16.11

ASTM A 350 GR.LF2

SW, 3000

T.EQUAL

02.000

14.000

B-16.9

ASTM A 420 GR.WPL6

BW

M

M

M



REV-0 Page 46 of 68

T.RED

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

T.RED

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

T.RED

02.000

14.000

M, M

B-16.9

ASTM A 420 GR.WPL6

BW

REDUC.CONC

02.000

14.000

M,M

B-16.9

ASTM A 420 GR.WPL6

BW

REDUC.ECC

02.000

14.000

M,M

B-16.9

ASTM A 420 GR.WPL6

BW

SWAGE.CONC

00.500

03.000

M,M

BS3799

ASTM A 350 GR.LF2

PBE

SWAGE.ECC

00.500

03.000

M,M

BS3799

ASTM A 350 GR.LF2

PBE

CAP

02.000

14.000

M

B-16.9

ASTM A 420 GR.WPL6

BW

CPLNG.FULL

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.FULL

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

CPLNG-HALF

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.HALF

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

CPLNG.LH

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.LH

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW,3000

CPLNG.RED

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.RED

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

O’ let group (B4A) SOCKOLET

00.500

0.750

MSSSP97

ASTM A 350 GR.LF2

SW, 6000

SOCKOLET

01.000

01.500

MSSSP97

ASTM A 350 GR.LF2

SW, 3000

WELDOLET

02.000

4.000

MSSSP97

ASTM A 350 GR.LF2

BW

M, XXS

Valves Group (B4A) VLV.GATE

00.500

01.500

API602

BODY-ASTM A 350 GR. LF2, TRIM-STELLITED, STEM SS304

SW,800, 3000,B-16.11

VLV.GATE

00.200

24.000

API600

BODY-ASTM A 352 GR. LCB, TRIM-STELLITED, STEM SS304

FLGD,300, B16.5, RF/125AARH

VLV.GLOBE

00.500

01.500

BS5352


SW,800, 3000,B-16.11



REV-0 Page 47 of 68

VLV.GLOBE

02.000

12.000

BS1873

BODY-ASTM A 352 GR.LCB, TRIM-STELLITED, STEM SS304


VLV.CHECK

00.500

1.500

BS5352


SW,800, 3000, B-16.11

VLV.CHECK

02.000

24.000

BS1868

BODY-ASTM A 352, GR.LCB, TRIM-STELLITED


VLV.BALL

00.500

16.000

BS5351

BODY-ASTM A 352, GR.LCB/ ASTM A350, GR.LF2, TRIM-BODY SEATRPTFE


00.500

14.000

B18.2


14.000

B16.20ANSI B16.5

SP,WND, SS316+CAF

SPIRAL, 300

GAIL STD.

B:A516GR.70(NORM);

CONETYPE,300,FF/125AARH

Bolt Group (B4A) BOLT.STUD

Gasket Group (B4A) GASKET

00.500

Trap/ Strainer Group (B4A) STRNR.TEMP

01.500

14.00

INT:SS304 STRNR.TEMP

00.500

1.500

GAIL STD.

B:A350GR.LF2

SW, Y-TYPE, 800

(NORM);INT:SS304 STRNR.TEMP

02.000

14.000

M

GAIL STD.

B:A420GR.WPL6;

BW, T-TYPE

INTR:SS304



REV-0 Page 48 of 68

ANNEXURE G

PIPING MATERIAL SPECIFICATION (D4A - CLASS 600#)



REV-0 Page 49 of 68

PIPING CLASS

:

D4A, 600 #

BASE MATERIAL

:

CARBON STEEL

CORROSION ALLOWANCE

:

1.5 MM

SPECIAL REQUIREMENT

:



SERVICE NON CORROSIVE PROCESS-FLAMMABLE / NON-FLAMMABLE, NON-LETHAL-BELOW -29DEG C AND UPTO -45 DEG C.HYDROCARBONS, XYLENE, METHANOL, NH3, GAS FLARE ETC. NOTES 1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID. 2. NDT OF WELDS SHALL BE AS FOLLOWS: RADIOGRAPHY

:

ALL BUTT WELDS

-

100%

MPI

:

SOCKET WELDS

-

100%

3.


4.


5.


6.


7.

FOR DIMENSIONS OF HANDLE PROJECTION FOR SPACER & BLIND, REFER Std. SPEC. S-05-01-007 SPECIAL NOTES ITEM

SIZE

DESCRIPTION

MAINTENANCE JOINTS

ALL


PIPE JOINTS

1.5” & BELOW

SW COUPLING

2.0” & ABOVE

BUTT WELDED

ON LINES ≤1.5”


ON LINES ≥2.0”

AS PER P&ID OR 0.75”, REFER STD. S-05-01-004

ON LINES ≤1.5”


ON LINES ≥2.0”


TEMP. CONN

1.5”


PRESS. CONN

0.75”


DRAINS VENTS



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8.0 6.0

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18

T

16 14

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T

T

T

T

T

T

12

T

T

T

T

10

T

T

T

T

T

T

8.0

T

T

T

T

T

T

W

6.0

T

T

T

W

W

W

W

5.0

5.0

4.0

T

3.5 3.0

T

T

T

W

W

W

W

W

W

2.5 1.5

T

T

T

T

W

W

W

W

W

W

W

T

S

S

S

S

S

S

S

S

S

2.0 1.5

S

S

S

S

S

S

S

S

S

0.75

T T

T

T

S

S

S

S

S

S

S

S

S

S

0.5

6.000

8.000

10.000

12.000

14.000

16.000

1.0

18.000

S

S

5.000

S

S

4.000

S

S

3.500

S

S

3.000

S

T

2.500

T

T

2.000

T

T

1.500

1.0

1.250

T T

1.000

1.25

0.500 0.750

1.25

0.5

3.0 2.5

2.0

0.75

4.0 3.5

RUN PIPE (SIZES IN INCH) – D4A



REV-0 Page 51 of 68

CODE

DESCRIPTION

F H P R S


Item Type

T W I X L


Dim. STD

Material

Description

Pipe Group (D4A) PIPE

00.500

00.750

S160

B 36.10

ASTM A 333 GR.6

PE, SEAMLESS

PIPE

01.000

01.500

XS

B 36.10

ASTM A 333 GR.6

PE, SEAMLESS

PIPE

02.000

02.000

XS

B 36.10

ASTM A 333 GR.6

BE, SEAMLESS

PIPE

03.000

3.000

STD

B 36.10

ASTM A 333 GR.6

BE, SEAMLESS

PIPE

4.000

4.000

XS

B 36.10

ASTM A 333 GR.6

BE, SEAMLESS

PIPE

06.000

06.000

XS

B 36.10

ASTM A 333 GR.6

BE, SEAMLESS

PIPE

08.000

8.000

XS

B 36.10

ASTM A 333 GR.6

BE, SEAMLESS

PIPE

10.000

10.000

XS

B 36.10

ASTM A 333 GR.6

BE, SEAMLESS

PIPE

12.000

12.000

19.0

B 36.10

ASTM A 333 GR.6

BE, SEAMLESS

PIPE

14.000

14.000

20.6

B 36.10

ASTM A 333 GR.6

BE, SEAMLESS

PIPE

16.000

16.000

22.2

B 36.10

ASTM A 333 GR.6

BE, SAW

PIPE

18.000

18.000

25.4

B 36.10

ASTM A 333 GR.6

BE, SAW

NIPPLE

00.500

00.750

M

B 36.10

ASTM A 333 GR.6

PBE,SEAMLESS

NIPPLE

01.000

01.500

M

B 36.10

ASTM A 333 GR.6

PBE, SEAMLESS

Flange Group (D4A) FLNG. SW

00.500

1.50

M

B-16.5

ASTM A 350 GR. LF2

600, RF/125 AARH

FLNG. WN

02.000

18.000

M

B-16.5

ASTM A 350 GR. LF2

600, RF/125 AARH

FLNG.BLIND

00.500

18.000

B-16.5

ASTM A 350 GR. LF2

600, RF/125 AARH

FLNG.FIG.8

00.500

8.000

ASMEB16.48

ASTM A 350 GR. LF2

600, FF/125 AARH

SPCR &BLIND

10.000

18.000

ASMEB16.48

ASTM A 350 GR. LF2

600, FF/125 AARH

Fitting Group (D4A) ELBOW.90

00.500

0.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

ELBOW.90

01.000

1.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000



REV-0 Page 52 of 68

ELBOW.90

02.000

14.000

M

B-16.9

ASTM A 420 GR.WPL6

BW, 1.5D

ELBOW.90

16.000

18.000

M

B-16.9

ASTM A 420 GR.WPL6-W

BW, 1.5D

ELBOW.45

00.500

0.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

ELBOW.45

01.000

1.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

ELBOW.45

02.000

14.000

M

B-16.9

ASTM A 420 GR.WPL6

BW, 1.5D

ELBOW.45

16.000

18.000

M

B-16.9


BW, 1.5D

T.EQUAL

00.500

00.750

B 16.11

ASTM A 350 GR.LF2

SW, 6000

T.EQUAL

01.000

01.500

B 16.11

ASTM A 350 GR.LF2

SW, 3000

T.EQUAL

02.000

14.000

M

B-16.9

ASTM A 420 GR.WPL6

BW

T.EQUAL

16.000

18.000

M

B-16.9


BW

T.RED

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

T.RED

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

T.RED

02.000

14.000

M, M

B-16.9

ASTM A 420 GR.WPL6

BW

T.RED

16.000

18.000

M, M

B-16.9


BW

SWAGE.CONC

00.500

03.000

M,M

BS3799

ASTM A 350 GR.LF2

PBE

SWAGE.ECC

00.500

03.000

M,M

BS3799

ASTM A 350 GR.LF2

PBE

CAP

00.500

0.750

B-16.11

ASTM A 350, GR.LF2

SCRF, 6000

CAP

01.000

1.500

B-16.11

ASTM A 350 GR.LF2

SCRF, 3000

CAP

02.000

18.000

B-16.9

ASTM A 420 GR.WPL6

BW

PLUG

00.500

0.750

B-16.11

ASTM A 350, GR.LF2

SCRM, 6000

PLUG

01.000

1.500

B-16.11

ASTM A 350 GR.LF2

SCRM, 3000

CPLNG.FULL

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.FULL

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

CPLNG-HALF

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.HALF

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

CPLNG.LH

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.LH

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW,3000

CPLNG.RED

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

M



REV-0 Page 53 of 68

CPLNG.RED

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

O’ let group (D4A) SOCKOLET

00.500

0.750

MSSSP97

ASTM A 350 GR.LF2

SW, 6000

SOCKOLET

01.000

01.500

MSSSP97

ASTM A 350 GR.LF2

SW, 3000

WELDOLET

02.000

6.000

MSSSP97

ASTM A 350 GR.LF2

BW

M, XXS

Valves Group (D4A) VLV.GATE

00.500

01.500

API602

BODY-ASTM A 350 GR. LF2, TRIM-STELLITED, STEM SS304

SW,800, 3000,B-16.11

VLV.GLOBE

00.500

01.500

BS5352


SW,800, 3000,B-16.11

VLV.CHECK

00.500

1.500

BS5352


SW,800, 3000, B-16.11

VLV.PLUG

00.500

1.500

BS5353

BODY-ASTM A 350, GR.LF2, PLUG:A350 GR.LF2+0.003” ENP

SW,800, 3000, B-16.11

VLV.PLUG

02.000

18.000

API-6D

BODY-ASTM A 352, GR.LCB/ ASTM A350, GR.LF2, TRIM-SS 304/ SS316

BW, 600, B-16.25

18.000

B18.2


18.000

B16.20ANSI B16.5

SP,WND, SS316+CAF

Bolt Group (D4A) BOLT.STUD

00.500

Gasket Group (D4A) GASKET

00.500


SPIRAL, 600


REV-0 Page 54 of 68

ANNEXURE H

PIPING MATERIAL SPECIFICATION (A93A - CLASS 150#)



REV-0 Page 55 of 68

PIPING CLASS

:

A93A, 150 #

BASE MATERIAL

:

CARBON STEEL

CORROSION ALLOWANCE

:

1.5 MM

SPECIAL REQUIREMENT

:


SERVICE FIRE WATER (ABOVE GROUND / UNDER GROUND) NOTES 1. FOR T-TYPE BW STRAINERS, REFER STD. NO.S-05-01-008 & S-05-01-009 2. FORGINGS ARE ACCEPTABLE IN LIEU OF PLATE MATERIAL. 3. SIZES GIVEN IN PMS ARE NOMINAL BORE FOR O.D. OF IS 3589 PIPES REFER ANSI B36.10. 4.

BUTTERFLY VALVE SHALL BE LUGGED WAFER TYPE UP TO 24” AND DOUBLE FLANGED BODY FOR SIZES BEYOND 24”.

5.

PIPE THICKNESS ARE JOB SPECIFIC BASED ON THE SOIL PROPERTIES OF JOB SITE AND DEPTH OF TOP OF PIPE OF 1.5M. NO LIVE LOAD HAS BEEN CONSIDERED FOR CALCULATION OF PIPE THICKNESS. LIVE LOADS WHEREVER EXPECTED SHALL BE SUITABLY TAKEN CARE OF.

6.

NDT REQUIREMENT SHALL BE SAME AS FOR CLASS A1A OF GAIL STANDARD S-05-02-012 AND TAC REQUIREMENT FOR RADIOGRAPHY SHALL ALSO BE COMPLIED WITH.

SPECIAL NOTES

ITEM

SIZE

DESCRIPTION

MAINTENANCE JOINTS

ALL


PIPE JOINTS

1.5” & BELOW

SW COUPLING

2.0” & ABOVE

BUTT WELDED

ON LINES ≤1.5”


ON LINES ≥2.0”


ON LINES ≤1.5”


ON LINES ≥2.0”

AS PER P&ID OR 0.75”REFER STD. S-05-01-003.

TEMP. CONN

1.5”


PRESS. CONN

0.75”


DRAINS VENTS



REV-0 Page 56 of 68

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16

14 12

14 12

T

R

T

R

R

10

T

R

R

R

8.0

T

P

R

R

R

6.0

R

P

R

R

R

10 8.0 6.0

T

5.0

5.0

4.0

T

3.5

3.5

3.0

T

P

R

P

R

R

R

T

P

P

R

P

R

R

R

T

H

H

H

H

H

H

H

2.5

3.0 2.5

2.0 1.5

T

2.0 1.5

H

1.0

H

H

0.75

T

T

T

H

H

H

H

H

H

H

H

0.5

10.000

12.000

14.000

5.000

H

H

4.000

H

H

3.500

H

H

3.000

H

H

2.500

H

H

2.000

H

H

1.500

H

T

1.250

T

T

0.500 0.750

T

T T

1.000

1.0 0.75

8.000

1.25

6.000

1.25

0.5

4.0

RUN PIPE (SIZES IN INCH) – A93A



REV-0 Page 57 of 68

CODE

DESCRIPTION

F H P R S


Item Type

T W I X L


Dim. STD

Material

Description

Pipe Group (A93A) PIPE

00.500

01.500

HVY

IS-1239-I

IS-1239 (BLACK)

PE, C. WELDED

PIPE

02.000

06.000

HVY

IS-1239-I

IS-1239 (BLACK)

BE, C. WELDED

PIPE

08.000

12.000

6.0

IS-3589

IS-3589 GR.410

BE, WELDED

PIPE

14.000

14.000

8.0

IS-3589

IS-3589 GR.410

BE, SEAMLESS

NIPPLE

00.500

01.500

HVY

IS-1239 (BLACK)

PBE, C. WELDED

M

B-16.5

ASTM A 105

150, RF/125 AARH

Flange Group(A93A) FLNG. SW

00.500

1.50

FLNG. SO

02.000

14.000

B-16.5

ASTM A 105

150, RF/125 AARH

FLNG.BLIND

00.500

14.000

B-16.5

ASTM A 105

150, RF/125 AARH

FLNG.FIG.8

00.500

8.000

ASMEB16.48

ASTM A 105

150, FF/125 AARH

SPCR &BLIND

10.000

14.000

ASMEB16.48

ASTM A 105

150, FF/125 AARH

B-16.11

ASTM A 105

SW, 3000

Fitting Group(A93A) ELBOW.90

00.500

1.500

ELBOW.90

02.000

6.000

STD

B-16.9

ASTM A 234 GR.WPB

BW, 1.5D

ELBOW.90

8.000

14.000

M

B-16.9

ASTM A 234 GR.WPB-W

BW, 1.5D

ELBOW.45

00.500

1.500

B-16.11

ASTM A 105

SW, 3000

ELBOW.45

02.000

6.000

STD

B-16.9

ASTM A 234 GR.WPB

BW, 1.5D

ELBOW.45

08.000

14.000

M

B-16.9

ASTM A 234 GR.WPB-W

BW, 1.5D

T.EQUAL

00.500

01.500

B 16.11

ASTM A 105

SW, 3000

T.EQUAL

02.000

6.000

B 16.9

ASTM A 234 GR.WPB

BW

STD



REV-0 Page 58 of 68

T.EQUAL

08.000

14.000

T.RED

00.500

01.500

T.RED

02.000

06.000

T.RED

08.000

REDUC.CONC

M

B-16.9

ASTM A 234 GR.WPB-W

BW

B-16.11

ASTM A 105

SW, 3000

STD.,STD

B-16.9

ASTM A 234 GR.WPB

BW

14.000

M, M

B-16.9

ASTM A 234 GR.WPB-W

BW

02.000

06.000

STD.,STD

B-16.9

ASTM A 234 GR.WPB

BW

REDUC.CONC

08.000

14.000

M, M

B-16.9

ASTM A 234 GR.WPB-W

BW

REDUC.ECC

02.000

06.000

STD.,STD

B-16.9

ASTM A 234 GR.WPB

BW

REDUC.ECC

08.000

14.000

M, M

B-16.9

ASTM A 234 GR.WPB-W

BW

SWAGE.CONC

00.500

03.000

M,M

BS-3799

ASTM A 105

PBE

SWAGE.ECC

00.500

03.000

M,M

BS-3799

ASTM A 105

PBE

CAP

00.500

1.500

B-16.11

ASTM A 105

SCRF, 3000

CAP

02.000

6.000

STD

B-16.9

ASTM A 234 GR.WPB

BW

CAP

08.000

14.000

M

B-16.9

ASTM A 234 GR.WPB

BW

CPLNG.FULL

00.500

01.500

B-16.11

ASTM A 105

SW, 3000

CPLNG.HALF

00.500

01.500

B-16.11

ASTM A 105

SW, 3000

CPLNG.LH

00.500

01.500

B-16.11

ASTM A 105

SW, 3000

CPLNG.RED

00.500

01.500

B-16.11

ASTM A 105

SW, 3000

UNION

00.500

01.500

BS-3799

ASTM A 105

SW, 3000

Valves Group(A93A) VLV.GATE

00.500

01.500

API-602

BODY-ASTM A 105, TRIMSTELLITED, STEM 13%CR. STEEL

SW,800, 3000,B-16.11

VLV.GATE

02.000

24.000

API-600

BODY-ASTM A 216 GR.WCB, TRIM-13% CR. STEEL

FLGD, 150, B16.5, RF/125AARH

VLV.GLOBE

00.500

01.500

BS-5352

BODY-ASTM A 105, TRIMSTELLITED, STEM 13%CR. STEEL

SW,800, 3000,B-16.11

VLV.GLOBE

02.000

16.000

BS-1873

BODY-ASTM A 216 GR.WCB, TRIM-13% CR. STEEL

FLGD, 150, B16.5, RF/125AARH

VLV.CHECK

00.500

1.500

BS-5352

BODY-ASTM A 105, TRIMSTELLITED,

SW,800, 3000,B-16.11

VLV.BTRFLY

02.000

24.000

BS-5155

BODY-ASTM A 216 GR. WCB, TRIM-13% CR.STEEL,

WAFL, 150, B16.5, WAF/ 125AARH



REV-0 Page 59 of 68

Bolt Group(A93A) BOLT.STUD

00.500

14.000

B18.2

BOLT: A 193 GR.B7, NUT:A194 GR.2H

14.000

B16.21ANSI B16.5

IS-2712-GR. W/3

RING, 150, 2MM

MNF’STD

B:A105;INT;SS304

SW, Y-TYPE, 800

Gasket Group(A93A) GASKET

00.500

Trap/ Strainer Group(A93A) STRNR.PERM

00.500

1.500

STRNR.PERM

02.000

6.000

M

GAIL STD

B:A234GR.WPB;INT:SS304

BW, T-TYPE

STRNR.PERM

08.000

14.000

M

GAIL STD

B:A234GR.WPBW;INT:SS304

BW, T-TYPE



REV-0 Page 60 of 68

ANNEXURE I

PIPING MATERIAL SPECIFICATION (J2A - CLASS 150#)



REV-0 Page 61 of 68

PIPING CLASS

:

J2A, 150 #

BASE MATERIAL

:

CS (Galv.)

CORROSION ALLOWANCE

:

0 MM

SPECIAL REQUIREMENT

:


SERVICE POTABLE WATER (ABOVE GROUND), FIRE WATER-SPRINKLER SYSTEM AFTER ORIFICE NOTES 1. NDT REQUIREMENTS AS PER GAIL STANDARD – S-05-02-012 2. THREADED JOINTS SHALL BE MADE WITH 1” WIDTH PTFE JOINTING TAPE. 3. SURFACES WHERE GALVANISING HAS BEEN BURNT OFF SHALL BE WIRE BRUSHED AND COLD GALVANISED WITH ZINC COATING COMPOUND. SPECIAL NOTES

ITEM

SIZE

DESCRIPTION

MAINTENANCE JOINTS

1.5” & BELOW

UNIONS (SCRF) TO BE KEPT MINIMUM

2” & ABOVE

FLANGED (SCREWED) TO BE KEPT MINIMUM

PIPE JOINTS

UP TO 6”

SCREWED COUPLING

DRAINS

ON LINES ≤1.5”


ON LINES ≥2.0”


ON LINES ≤1.5”


ON LINES ≥2.0”


TEMP. CONN

1.5”


PRESS. CONN

0.75”

SCREWED NIPPLE WITH VALVE TO SPEC. S-05-01-006

VENTS



REV-0 Page 62 of 68

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18

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16

16

14

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12

12

10

10

8.0

8.0

6.0

T

5.0 4.0

T

T

3.5

4.0 3.5

3.0

T

T

T

2.5

3.0 2.5

2.0 1.5

T

T

T

T

T

T

T

T

T

1.25

2.0 1.5 1.25

T

T

T

T

1.0

6.000

0.5

5.000

0.75

T

4.000

T

T 3.500

T

T 3.000

T

T 2.500

T

T

2.000

T

T

1.500

T

T

1.250

T T

1.000

0.75

T

0.750

T

0.500 0.500

1.0 0.5

6.0 5.0

RUN PIPE (SIZES IN INCH) – J2A



REV-0 Page 63 of 68

CODE

DESCRIPTION

F H P R S


Item Type

T W I X L


Dim. STD

Material

Description

IS-1239-I

IS-1239 (GALV)

SCRM, WELDED

Pipe Group (J2A) PIPE

00.500

06.000

HVY

Flange Group(J2A) FLNG. SCRD 00.500

06.00

B-16.5

ASTM A 105 (GALV.)

150, FF/125 AARH

FLNG.BLIND

00.500

06.000

B-16.5

ASTM A 105 (GALV.)

150, FF/125 AARH

FLNG.FIG.8

00.500

06.000

ASMEB16.48

ASTM A 105 (GALV.)

150, FF/125 AARH

Fitting Group(J2A) ELBOW.90

00.500

1.500

B-16.11

ASTM A 105 (GALV.)

SCRF, 3000

ELBOW.90

02.000

6.000

IS-1239-II

IS-1239 (PART-II) (GALV.)

SCRF, NA

ELBOW.45

00.500

1.500

B-16.11

ASTM A 105 (GALV.)

SCRF, 3000

ELBOW.45

02.000

6.000

IS-1239-II


SCRF, NA

T.EQUAL

00.500

01.500

B-16.11

ASTM A 105 (GALV.)

SCRF, 3000

T.EQUAL

02.000

6.000

IS-1239-II


SCRF, NA

T.RED

00.500

01.500

B-16.11

ASTM A 105 (GALV.)

SCRF, 3000

T.RED

02.000

6.000

IS-1239-II


SCRF, NA

SWAGE.CONC

00.500

03.000

M,M

BS-3799

ASTM A 105 (GALV.)

TBE

SWAGE.ECC

00.500

03.000

M,M

BS-3799

ASTM A 105 (GALV.)

TBE

CAP

00.500

1.500

B-16.11

ASTM A 105 (GALV.)

SCRF, 3000

CAP

02.000

6.000

IS-1239-II


SCRF, NA

CPLNG.FULL

00.500

01.500

B-16.11

ASTM A 105 (GALV.)

SCRF, 3000

CPLNG.HALF

00.500

01.500

B-16.11

ASTM A 105 (GALV.)

SCRF, 3000

CPLNG.LH

00.500

01.500

B-16.11

ASTM A 105 (GALV.)

SCRF, 3000

CPLNG.RED

00.500

01.500

B-16.11

ASTM A 105 (GALV.)

SCRF, 3000



REV-0 Page 64 of 68

UNION

00.500

06.000

IS-1239-II


SCRF, NA

Valves Group(J2A) VLV.GATE

00.500

01.500

IS:778 CL.2

BODY-IS 318 GR.2 LEADED TIN BRONZE, TRIM-IS320 ALLOY HT2

SCRF, CL.2, 3000, B1.20.1

VLV.GATE

02.000

6.000

IS:780

BODY-IS 210,GR.FG 200, TRIM-IS 320 ALLOY HT2

FLGD, PN 1.6, B 16.1,FF/125AARH

VLV.GLOBE

00.500

01.500

IS:778 CL.2


SCRF, CL.2, 3000, B1.20.1

VLV.CHECK

00.500

1.500

IS:778 CL.2


SCRF, CL.2, 3000, B1.20.1

VLV.CHECK

02.000

6.000

IS:5312 (PT-1)

BODY-IS 210 GR.FG 200, TRIM-IS 320 ALLOY HT2

FLGD, PN1.6, B-16.1, FF/125AARH

00.500

6.000

B18.2

BOLT: A 307, GR.B (GALV), NUT:A563 GR.B (GALV)

6.000

B16.21ANSI B16.5

BUTYL RUBBER

Bolt Group(J2A) BOLT.M/C

Gasket Group(J2A) GASKET

00.500


FULL FACE, 150, 2MM


REV-0 Page 65 of 68

ANNEXURE-I LIST OF ATTACHMENTS

Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

DOCUMENT Jack Screw for Spectacle Blind (150#, 300#, 600#) Jack Screw for Spacer and Blind (150#, 300#, 600#) Vents & Drains on lines (On lines 1- ½ “ & Below) Vents & Drains on lines (On lines 2 “ & above) Wells Installation 1- ½ “ Dia Taps Pressure Tappings – PG, PT, PI, PA, PC etc Dimn. For Handle Projections for Spacers and Blinds T-Strainer Type-1 2"-4" (150# RF, 300# RF and RTJ, 600# RF and RTJ) T-Strainer Type-1 6"-24" (150# RF, 300# RF and RTJ, 600# RF and RTJ) Standard Specification of LSAW pipe Standard Specification of HSAW pipe Standard Specification for Long Radius Bends for onshore Pipelines Specification for Barred Tees Specification for Insulating Joints for Onshore Pipelines Standard Specification for Seamless fittings & Flanges, Size up to DN 400 mm (16”) Specification for flanges & Welded Fittings (Size DN 450 mm (18") and above Specification for Seamless fittings & Flanges, Size up to DN 400 mm (16”) Technical Notes for Valves Technical Notes for Pipes Technical Notes for Butt Welded, Socket Welded and Screwed Fittings Technical Notes for Flanges, Spectacle Blinds and Drip Rings Technical Notes for Bolts and Nuts Technical Notes for Gaskets Inspection and Test Plan for Gaskets Specification for Shop and Field Painting Standard Specification for Fabrication and Erection of Piping Standard specification for Inspection, Flushing and Testing of Piping system Standard Specification of “Non-Destructive PIPING MATERIAL SPECIFICATION


DOCUMENT NO. S-05-01-001

REV . 0

S-05-01-002

0

S-05-01-003

0

S-05-01-004

0

S-05-01-005 S-05-01-006 S-05-01-007

0 0 0

S-05-01-008

0

S-05-01-009

0

S-04-02-001 S-04-02-002 S-04-02-015

0 0 0

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0 0 0 0 0

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REV-0 Page 66 of 68

29 30 31 32 33 34 35

Examination of Piping” Standard Specification for Scraper Traps for Onshore Pipelines Standard Specification for Quick Opening End Closure Standard Specification for Pig Signaller for Onshore Pipelines Standard Specification of Plug Valve Standard Specification of Ball Valve Standard Specification of Gas Powered Valve Actuators Standard Specification for Positive Material Identification at Vendor’s Works.

S-04-02-017

0

S-04-02-024

0

S-04-02-018

0

S-04-02-008 S-04-02-007 S-04-02-012

0 0 0

S-14-02-001

0

LIST OF DATASHEETS Sl. TITLE No. 1 Data Sheet for Scraper Launcher/ Receiver 2 Data Sheet for Pig Signaller 3 Data Sheet for Quick Opening End Closure 4 Data Sheet for Insulating Joints 5 Data Sheet for Flow Tee (Barred Tee) 18" X 18" , 600# 6 Data Sheet for Flow Tee (Barred Tee) 18" X 12" , 600# 7 Data Sheet for Flow Tee (Barred Tee) 18" X 8" , 600# 8 Data Sheet for Ball Valve 9 Data Sheet for Gas Powered Valve Actuator 10 Data Sheet for Plug Valve 11 Data Sheets for Gate Valves of Size below 2”

DATA SHEET NO. 0001-01-04-04-PL/PR-001

RE V. 0

0001-01-04-04-PSG-001 0001-01-04-04-QOEC-001

0 0

0001-01-04-04-IJ-001 0001-01-04-04-FLT-001

0 0

0001-01-04-04-FLT-002

0

0001-01-04-04-FLT-003

0

0001-01-05-04-BV-001 0001-01-04-04-GVA-001

0 0

0001-01-04-04-PV -001 0001-01-05-04-GV-001

0 0



REV-0 Page 67 of 68

TABLE-3

PIPELINE SPECIALITY ITEMS MAINLINE (FROM SCRAPER LAUNCHER TO SCRAPER RECEIVER) Sl. No. ITEM MATERIAL DESCRIPTION LONG RADIUS BENDS • API 5L Gr. X-70 PSL2, 11.7 mm wall thickness 1 (R=6D) FOR PIPELINES SUITABLE FOR PIGGING

for 18” dia. pipeline for Sultanpur to Neemrana • API 5L Gr. X-60 PSL2, 9.5 mm wall thickness for 12” dia. pipeline for Bhiwadi. • API 5L Gr. X-60 PSL2, 7.8 mm wall thickness for 10” dia. pipeline for Gurgaon 18 X 18 X 18 - MSS-SP-75 Gr. WPHY-70 18 X 18 X 12 - MSS-SP-75 Gr. WPHY-70 18 X 18 X 8 - MSS-SP-75 Gr. WPHY-70 Monoblock type • Pups / Body: 18” – API 5L Gr. X 70, PSL-2 / ASTM A694 Gr. F70 (CHARPY) 12” - API 5L Gr. X 60, PSL-2 / ASTM A694 Gr. F60 (CHARPY) 10” - API 5L Gr. X 60, PSL-2 / ASTM A694 Gr. F60 (CHARPY) 8” - API 5L Gr. X 60, PSL-2 / ASTM A694 Gr. F60 (CHARPY)

2

FLOW TEES (BARRED TEES)

3

INSULATING JOINTS

4

SCRAPPER LAUNCHER & RECIEVER

18” – Body: API 5L Gr. X-70 PSL2 Reducer: MSS-SP-75 Gr. WPHY-70 Neck: API 5L Gr. X-70 PSL2 QOEC: ASTM A 105 (CHARPY)

5

PIG SIGNALLER

Body: ASTM A 105 (CHARPY) Internals: SS316

For Mainline Items, corrosion allowance shall be 0.0 mm except for scraper traps where 3 mm corrosion allowance shall be taken.



REV-0 Page 68 of 68

WELDING SPECIFICATION FOR MAIN LINE

FOR TRANSPORTATION OF GAS SPUR LINE CHAINSA – JHAJJAR PIPELINE


WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS


REV- 0 Page 1 of 52


CONTENTS 1.0

SCOPE

2.0

APPLICABLE CODES AND STANDARDS

3.0

BASE MATERIAL

4.0

WELDING CONSUMABLES

5.0

EQUIPMENT AND ACCESSORIES

6.0

WELDING PROCESSES

7.0

BEVEL CLEANING AND BEVEL INSPECTION

8.0

ALIGNMENT AND SPACING

9.0

WEATHER CONDITIONS

10.0

WELDING

11.0

HEAT TREATMENT

12.0

INSPECTION AND TESTING

13.0

REPAIR OF WELDS ANNEXURE – 1 : DESTRUCTIVE TESTING ANNEXURE – 2 : ULTRASONIC TESTING ANNEXURE – 3 : AUTOMATED ULTRASONIC TESTING ANNEXURE – 4 : RADIOGRAPHY TESTING

EXHIBIT-A : ELECTRODE QUALIFICATION TEST RECORD EXHIBIT-B : STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION EXHIBIT-C : WELDING PROCEDURE QUALIFICATION TEST RECORD EXHIBIT-D : WELDER QUALIFICATION TEST RECORD EXHIBIT-E : WELDERS IDENTIFICATION CARD EXHIBIT-F : RADIOGRAPHIC PROCEDURE FOR PIPE WELDING




REV- 0 Page 2 of 52


1.0

SCOPE The requirements stated herein shall be followed for the fabrication of all types of welded joints of carbon steel main pipeline system and related facilities. The welded pipe joints shall include the following: a) All line pipe joints of the longitudinal and circumferential butt-welded and socket welded types. b) Attachments of castings, forgings, flanges and other supports to pipes. c) Welded manifold headers and other sub-assemblies. d) Welded branch connections. e) Joints in welded/fabricated piping components. f) The attachments of smaller connections for vents, drain drips and other instrument tappings. Any approval granted by the COMPANY shall not relieve the CONTRACTOR of his responsibilities and guarantees.

2.0

APPLICABLE CODE AND STANDARDS All welding work, equipment for welding, heat treatment, other auxiliary functions and the welding personnel shall meet the requirements of the latest editions of the codes, standards and specifications listed below: a)

Code for Gas Transmission and Distribution Piping Systems, ANSI B31.8.

b)

Standard for Welding of Pipelines and Related Facilities, API 1104.

c)

Specification for Welding Electrodes and Filler Materials, ASME Sec. II Part C

d)

Non-Destructive Examination, ASME Sec. V.

e) 3.0

Welding and Brazing Qualifications, ASME Sec. IX

BASE MATERIAL In general carbon steel is used in this specification. The details of material specifications are given in the welding Specification Chart attached along with other project data sheets. The CONTRACTOR will arrange and maintain the record of test certificates of all the materials for the reference of the welding engineer.

4.0

WELDING CONSUMABLES a) The CONTRACTOR shall provide at his own expense all the welding consumables necessary for the execution of the job such as electrode/filler wire, oxygen, acetylene etc. and these shall bear the approval of the COMPANY.




REV- 0 Page 3 of 52


b) The welding electrodes/filler wires supplied by the CONTRACTOR shall conform to the class specified in the welding specification chart attached along with other project data sheets. The materials shall be of the make approved by the COMPANY. c) The welding consumables shall suitable for the welding process recommended and the base metal used. The physical properties of the welds produced by an electrode/ filler wire recommended for the welding of a particular base metal shall not be lower than the minimum values specified for the base metal, unless otherwise specified in the welding specification chart and shall correspond to the physical properties of the class of electrode/ filler wire adopted. The choice of welding consumables shall be made after conducting the required tests on the electrode/ filler wire as per relevant standards, and shall be the sole prerogative of the COMPANY. d) The CONTRACTOR shall submit batch test certificate(s) from each electrode/ filler wire manufacturer(s) furnishing all details of physical and chemical tests carried out by them for each batch of electrodes to be used. e) Electrode/ filler metal qualification test records shall be submitted as per the attached Exhibit-A in respect of the electrodes/filler metal tested by the CONTRACTOR for obtaining the approval from the COMPANY. f) All electrodes/filler wire shall be purchased in sealed containers and stored properly to prevent deterioration. Except the cellulosic coated electrodes, the electrodes removed from the containers shall be kept in the holding ovens, at the temperature recommended by the electrode(s) manufacturer(s). Oven shall be used for the low hydrogen electrode only. Out-of-the oven time of electrodes before they are consumed shall not exceed the limits recommended by the electrode manufacturer(s). The welding consumables shall be handled with care to avoid any damage to the flux covering. Different grades of welding consumables shall be stored separately. Cellulosic electrodes shall be used as per the specific recommendation made by the manufacturer. g) The welding consumables used shall be free from rust, oil, grease, earth and other foreign matter, which affect the quality of welding. h) Shielding Gas The composition and the purity of the shielding gas required by the welding GMAW and FCAW processes shall bear the approval of the COMPANY. An appropriate gases or gas mixture of the following quality shall be used. 1. Argon gas complying with BS 4365. 2. Carbon dioxide gas complying with type 1 specified in BS 4105 3. Gas mixtures that have been proved to be satisfactory as a result of procedure approval tests.




REV- 0 Page 4 of 52


When a gas mixture is used, which has specified additions viz.. 2% O2, 5% CO2, the variation of such addition shall not exceed +10% of that stated. Moisture content shall correspond to a dew point of -300C or lower. 5.0

EQUIPMENT AND ACCESSORIES The CONTRACTOR shall have sufficient number of welding and cutting equipment, auxiliaries and accessories of sufficient capacities to meet the target schedules.

5.1

All the equipment for performing the preheating or heat treatment, including transformers, thermocouples, pyrometers, automatic temperature recorders with suitable calibration arrangements, etc. shall be provided by the CONTRACTOR, at his own expense and these shall bear the approval of the COMPANY. Adequate means of measuring current and voltage shall be available.

5.2

Redoing of any work necessitated by the faulty equipment or due to the wrong operation carried out by the CONTRACTOR shall be done at his own expense.

6.0

WELDING PROCESSES

6.1

Welding of various materials under this specification shall be carried out using the following process.

6.1.1 Main Line 18”Ø Sultanpur-Neemrana Pipeline, 12”Ø Bhiwadi Line, 10” Ø Manesar line & 10” Gurgaon Line Semi-automatic Flux Cored Arc Welding for fill and cap passes, with root pass welding by Surface Tension Transfer Process (STTP) or Gas Tungsten Arc Welding (GTAW) process and Manual SMAW where Semi-Automatic is not possible. 6.1.2 However semiautomatic welding processes shall be employed only with the approval of Engineer-in-Charge. Welding procedure shall be adopted and consumables used shall be specifically approved. A combination of different welding process could be employed for a particular joint only after duly qualifying the welding procedure to be adopted and obtaining the approval of Engineer-in-Charge. 6.1.3 Tie-Ins and Crossings Any of the processes specified above as per qualified procedures. 6.1.4 Double jointing of two pipe lengths using Submerged Arc Welding (SAW) process in a specially laid pipe welding yard is also permitted. Any deviation desired by the CONTRACTOR shall be obtained through the written consent of the COMPANY. 6.2

The welding procedure adopted and the consumables used shall be specifically approved.




REV- 0 Page 5 of 52


6.3

A combination of different welding processes or a combination of welding consumables of different classes/makes could be employed for a particular joint, only after duly qualifying the welding procedures to be adopted and obtaining the approval of the COMPANY.

7.0

BEVEL CLEANING/BEVEL INSPECTION The line pipe supplied by the COMPANY shall have bevel ends as specified in the applicable specification for the line pipe attached with the Bid Package. Any modification thereto, if required by the CONTRACTOR due to the specific welding technique, shall be carried out by the CONTRACTOR at his own cost. Before welding, all the rust and foreign matter shall be removed from the bevelled-ends by power operated tools. Bevel cleaning shall be effected both inside and outside and for a minimum distance of 25 mm from the edge of the weld bevel. The bevels shall be thoroughly inspected at this stage. If any of the ends of the pipe joint is damaged to the extent that satisfactory weld spacing cannot be obtained and local repair by grinding cannot be successfully done, the damaged end shall be cut and re-bevelled with an approved bevelling machine to the satisfaction of the COMPANY. Manual cutting and weld repairs of bevels is not allowed. Should laminations, split ends or inherent manufacturing defects in the pipe be discovered, the lengths of pipe containing such defects shall be removed. For such pipes, the new bevel shall be examined 100% visually and 100% by dye-penetrant or MPI method. A report shall examined 100% visually and 100% by dye-penetrant or MPI method. A report shall be generated after carrying out the tests and submitted to the COMPANY for approval.

8.0

ALIGNMENT AND SPACING Immediately prior to line-up, the CONTRACTOR shall inspect the pipe ends both inside and outside for damages, dents, laminations etc. Pipe for welding shall be set up, correctly spaced, allowing for the temperature changes during welding. Incorrect alignment shall in no circumstances be sprung into position. Temporary attachments of any kind shall not be welded to the pipe. Welds joining the sections of the pipeline, valve installation or similar welds classified as tie-in welds shall be made in the trench. Otherwise the alignment and welding shall be made alongside the ditch with the pipe supported on skids and pack pads or other suitable means approved by COMPANY, for at least 500 mm length above the ground, unless approved otherwise by the COMPANY in specific cases. Seam orientation of welded pipes shall be selected to ensure that, at the circumferential welds, the longitudinal welds shall be staggered in the top 900 of the pipeline, or 250 mm whichever is the lesser. A longitudinal joint shall pass an appurtenance of a structural element at a minimum distance of 50 mm. Should a section of the line containing uncompleted welds fall from the skids, the CONTRACTOR shall immediately inform the COMPANY. Every effort shall be made to reduce misalignment by the use of the line-up clamp and rotation of the pipes to the best fit. For pipe of the same nominal wall thickness, the offset shall not exceed 1.6 mm. The offset may be checked from GAIL (INDIA) LTD NEW DELHI



REV- 0 Page 6 of 52


outside using dial gauges. Any branch connection sleeve, etc. shall be at least 150 mm from any other weld. The welds for fittings shall be so located that the toe of the weld shall not come within 50 mm of the toe of any other weld. Cold adjustment is permissible only in cases of slight misalignment and may only be carried out with a bronze headed hammer. Hot adjustment shall not be permitted. When welding pipes of different wall thickness is permitted by the COMPANY, a special transition piece shall be used. This shall have a minimum of 1:4 taper. The weld in the transition piece shall be subjected to both Ultrasonic and Radiography Testing. The root gap shall be accurately checked and shall conform to the qualified welding procedure. The use of internal line-up clamps is mandatory for pipe diameters 10” and above. However, in some cases (tie-in welds, flanges, fittings, diameter of pipe10” etc.) where it is impossible to use internal clamps, an external line-up clamp maybe used. The internal line-up clamp shall not be released before the entire first pass has been completed. When an external line-up clamp is used, all the spaces between the bars or at least 60% of the first pass shall be welded before the clamp is released and the pipe shall remain adequately supported on both sides of the joint. Segments thus welded shall be equally spaced around the circumference of the pipe. Slag, etc. shall be cleaned off and the ends of the segments shall be prepared by grinding, so as to ensure continuity of the weld bead. 9.0

WEATHER CONDITIONS The parts being welded and the welding personnel shall be adequately protected from rain and strong winds. In the absence of such protection, no welding shall be carried out. The completed welds shall be suitably protected in case of bad weather conditions.

10.0 WELDING 10.1

Root Pass a)

The root pass shall be made with the electrodes/filler wires recommended in the welding specification chart attached. The size of the electrodes used shall be as per the qualified welding procedure.

b) Position or roll welding (for yard doubler jointing) may be permitted. Separate procedures shall be submitted and qualified for up hill, down hill, vertical down and roll welding. The vertical up method of welding shall be used for the root pass of the tie-ins, special crossings, fittings and special parts, fillet welds, repairs and when an external line up clamp is used. The down hill welding may be used for the root run welding of tie-ins and special crossings when (a) the GAIL (INDIA) LTD NEW DELHI



REV- 0 Page 7 of 52


edges are machined or have equivalent preparation, (b) line up clamps are used and the fit up is geometrically and mechanically similar to one of the ordinary line welding without misalignment or unevenness. c) The root pass of butt joints shall be executed properly so as to achieve full penetration with complete fusion of the root edges. Weld projection inside the pipe shall not exceed 1.6 mm wherever not specified by the applicable code. d) Any deviations from the recommended welding techniques and welding consumables indicated in the welding specification chart shall be permitted only after obtaining written approval of the COMPANY. e) Welding shall be continuous and uninterrupted during a pass. f)

On completion of each run, craters, welding irregularities, slag etc. shall be removed by grinding and chiseling.

g) While the welding is in progress, proper care shall be taken to avoid any kind of movement of the components, shocks, vibration and stresses to prevent occurrence of weld cracks. h)

i) 10.2

Fillet weld shall be made by Shielded Metal Arc Welding (SMAW) process, irrespective of the thickness and class of piping. SMAW electrode size shall not exceed 3.25 mm diameter for the socket joint. At least two passes shall be made on the socket weld joint. Peening shall not be used.

Joint Completion The first pass shall be carried out by a minimum of two welders/welding heads, working simultaneously and so placed as to cause minimum distortion of the pipe. The number of welders/ welding heads and the allowable welding sequences shall be as those laid down in the Qualified Welding Procedure Specification (QWPS). Once the deposit of the first pass has been started, it must be completed as rapidly as possible, reducing interruptions to the minimum. The welding and wire speed shall be approximately same as that established in the QWPS. The pipe shall always be adequately supported and must not be bumped or shaken during welding. The clamp shall be removed as indicated in Clause 8.0. Before starting the second pass, the first pass shall be cleaned and flattened with rotating grinders. The interruption between the completion of the first pass and the starting of the second pass shall be as per the qualified welding procedures.




REV- 0 Page 8 of 52


The welding speed selected shall enable production of a bead which is sufficiently thick and with consistent fusion and without any under cutting. The time lapse between the second and the third pass shall be as stated in the procedure specification, normally not exceeding five minutes. After completion of the third or following passes, welding operations may be suspended to allow the joint to cool down, provided the thickness of the weld metal deposited is equal to at least 50% of the pipe thickness. Upon restarting, depending on the materials, wall thickness and welding process, a preheating of at least 1000C shall be applied. Subsequent passes up to weld completion shall be protected to avoid rapid cooling, if meteorological conditions so dictate. Cleaning between the passes shall be done carefully to reduce the possibility of inclusions. The weld bead starting and finishing points shall be staggered from pass to pass. Arc-strikes outside the bevel on the pipe surface are not permitted. Arc-strike or arc burn on the pipe surface outside the weld, which are caused accidentally by electrical arcs between the electrode, electrode holder, welding cable or and the pipe shall be removed by grinding in accordance with a procedure approved by the COMPANY and the repair area shall be checked by Ultrasonic or Magnetic Particle or Dye-Penetrant testing approved by the COMPANY. The pipe wall thickness after grinding shall not be less than the minimum thickness permitted for the pipe. Repair of arc strikes by welding is prohibited. The completed weld shall be carefully brushed and cleaned and shall appear free from spatters, scales, etc. The above requirements apply not only to the completed welds but also to the bare strip at least so wide as to allow full skid examination at both ends of the pipe for a good Ultrasonic inspection when it is required. 11.0 PREHEATING Preheating, if required, shall be carried out as per the following: a) Preheating requirements for the various materials shall be as per the welding specification charts. b) Preheating shall be performed using resistance or induction heating methods. Preheating by gas burners is allowed only in exceptional cases with the permission of the COMPANY. c) Preheating shall extend uniformly to at least three times the thickness of the joint, but not less than 50 mm, on both sides of the weld. d) Preheating temperature shall be maintained over the whole length of the joint during welding. Temperature indicating crayons or other temperature indicating devices shall be provided by the CONTRACTOR to check the temperature.




REV- 0 Page 9 of 52


12.0


12.1

General a) The Inspector authorized by the COMPANY shall have free access to all the concerned areas, where the actual work is being performed. The CONTRACTOR shall also afford the Inspector all means and facilities necessary to carry out inspection. b) The COMPANY is entitled to depute its own Inspector to the shop or field where pre-fabrication and erection of pipelines are being done, with the following objectives, but not limited to: i) ii) iii) iv)

To check the conformance to relevant standards and suitability of various welding equipment and the welding performance. To supervise the welding procedure qualification. To supervise the welders’ performance qualification. To check whether shop/field welding being executed is in conformity with the relevant specifications and codes of practice followed in pipe construction.

c) The CONTRACTOR shall intimate sufficiently in advance the commencement of the qualification tests, welding works and acceptance tests to enable the authorized Inspector to be present to supervise them. 12.2

Welding Procedure Qualification a) Welding procedure qualification shall be carried out in accordance with the relevant requirements of API 1104 latest edition or other applicable codes and job requirements by the CONTRACTOR at his expense. The CONTRACTOR shall submit the welding procedure specifications in format as per Exhibit-C attached, immediately after the receipt of the order. b) COMPANY’S Inspector will review, check and approve the welding procedure specification submitted and shall release the procedure for procedure qualification tests. The procedure qualification test shall be carried out by the CONTRACTOR under field conditions at his own expense. A complete set of the test results in format as per Exhibit-C attached shall be submitted to the COMPANY’S Inspector for approval, immediately after completing the procedure qualification test and at least two (2) weeks before the commencement of actual work. Standard tests as specified in the code shall be carried out in all cases. In addition to these tests, other tests like Ultrasonic examination, Radiography, Macro/Micro examination, Hardness tests, Dye- Penetrant examination, Charpy V-notch etc. shall be carried out on the specimens following the respective qualified procedures. It shall be the responsibility of the CONTRACTOR to carry out all the tests required to the satisfaction of the COMPANY’s Inspector. The destructive testing of welded joints shall be as per Annexure -1. GAIL (INDIA) LTD NEW DELHI



REV- 0 Page 10 of 52


12.3

Welders’ Qualification a) Welders shall be qualified in accordance with the API 1104 and other applicable specifications by the CONTRACTOR at his expense. It shall be the responsibility of the CONTRACTOR to carry out qualification tests of welders. The butt weld test pieces of the qualification test shall meet the nondestructive examination requirements specified in Clause 12.5 and Annexure- 2, 3, 4 (as applicable) of this specification. The COMPANY’s Inspector shall witness the test and certify the qualification of each welder separately. Only those welders who have been approved by the COMPANY’s Inspector shall be employed for actual welding. The CONTRACTOR shall submit the welder qualification test reports in the standard format as shown in Exhibit-D and obtain written approval, before commencement of work. b) The welders shall always have in their possession the identification card as shown in Exhibit-E and shall produce it on demand by the COMPANY’s Inspector. It shall be the responsibility of the CONTRACTOR to issue the identity cards after the COMPANY has duly certified it. c) No welder shall be permitted to work without the possession of identity card. d) If a welder is found to perform a type of welding or in a position for which he is not qualified, he shall be debarred from doing any further work. All welds performed by an unqualified welder shall be cut and redone by a qualified welder at the expense of the CONTRACTOR.

12.4

Visual Inspection COMPANY shall carry out inspection of all welds as per the latest editions of the applicable codes and specifications. All finished welds shall be visually inspected for parallel and axial alignment of the work, excessive reinforcement, concavity, shrinkage, cracks, under-cuts, dimensions, surface porosity and other surface defects. Undercutting adjacent to the completed weld shall not exceed the limits specified in the applicable code/standard.

12.5

Non-Destructive Examination

12.5.1 The non-destructive examination of one hundred percent (100%) girth welds shall be carried out.The non-destructive examination shall mainly consist of examination using Automated Ultrasonic Testing (AUT) as detailed in Annexure-3. This shall be applicable for all welds made by automatic GMAW process with narrow gap edge preparation and welds made by semi-automatic FCAW process. The CONTRACTOR shall make all the arrangements for the AUT of work covered by the specification at his expense. The CONTRACTOR shall furnish all the reports to the COMPANY, immediately after examination together with the corresponding interpretation reports on the approved format. The details of the AUT reports along with the joint identification number shall be duly entered in a register and signed by the GAIL (INDIA) LTD NEW DELHI





CONTRACTOR and submitted to the COMPANY for approval. The COMPANY will review all the AUT records of welds and inform the CONTRACTOR to those welds, which are unacceptable. The decision of the COMPANY shall be final and binding in this regard. All the requirements mentioned in the specification shall be arranged and executed by the CONTRACTOR through his own resources. In addition, Radiography examination shall be required in the following cases as per Annexure-4 of this specification: a)

On the first 100 welded joints corresponding to each automatic GMAW and semi automatic FCAW welding procedures used.

b)

When welds are repaired.

c)

When in the opinion of COMPANY, Radiography Testing is required to confirm or clarify defects indicated by Ultrasonic Testing.

d)

Welding of transition piece of pipe. In addition, Radiography inspection may be required for certain critical welds of the pipeline, i.e. tie-ins, welding of valves, flanges, randomly selected at COMPANY discretion. All fillet and groove welds, other than those AUT examined, shall be subjected to Dye-Penetrant /MP testing followed by manual Ultrasonic testing. The non-destructive testing system used for inspecting welds must by approved by the COMPANY.

12.5.2

All other welds made of FCAW and SMAW processes and the Tie-in joints having API bevel shall be examined by Radiography. When Radiography is used, the provisions stated in this para shall be applicable. -

For all production welds, X-ray Radiography by internal crawlers be used. Welds shall meet the standards of acceptability as set forth in API 1104 and as well as the requirements laid in subsequent paragraphs. The CONTRACTOR shall make all the arrangements for the Radiography examination of work covered by the specification at his expense. The COMPANY will review all the radiographs of welds and inform the CONTRACTOR regarding unacceptable welds. The decision of the COMPANY shall be final and binding in this regard.

12.5.3

All the requirements mentioned in the specification shall be arranged and executed by the CONTRACTOR through his own resources. In addition, Ultrasonic inspection is required in the following cases as per Annexure-2 of this specification: a)

On the first 10 welded joints corresponding to each automatic GMAW and semi-automatic FCAW welding procedures used.

b)

When welds are repaired.






c)

12.5.4

When in the opinion of COMPANY, Ultrasonic inspection is required to confirm or clarify defects indicated by Radiography. In addition, Ultrasonic inspection may be required for certain critical welds of the pipeline, i.e. tie-ins, welding of valves, flanges, randomly selected at COMPANY discretion. All fillet and groove welds, other than those are subjected to Radiography, shall be subjected to Dye-Penetrant/MP inspection. The non-destructive testing system used for inspecting welds must by approved by the COMPANY. Acceptance Criteria

Weld quality as judged on the basis of the acceptability criteria mentioned below:

12.6

i)

Any weld, which as a result of Radiography and/or Ultrasonic examination in the opinion of COMPANY exhibits imperfections greater than the limits stated in API 1104 latest edition or as superseded in this specification, shall be considered defective and shall so be marked with an identification point marker.

ii)

In addition to the API 1104 requirements, the welds containing cracks. including crater cracks regardless of size or location are unacceptable. Suitable records shall be maintained by the CONTRACTOR on the day to day work done on welding Radiography, Ultrasonic testing. The CONTRACTOR shall present the records to the COMPANY on day-to-day basis and whenever demanded, for approval.

Destructive Testing Welds cut out for defects or for other reason may be subjected to destructive testing. The re-execution of welds shall be carried out by the CONTRACTOR at his own expense. If the results are unsatisfactory, the welding operations shall be suspended and may not be restarted, until the causes have been identified and the suitable measures that guarantee acceptable results have been adopted by the CONTRACTOR. If it is necessary in the COMPANY’s opinion, the procedure shall be re-qualified. The weld joint represented by unsatisfactory welds shall stand rejected, unless investigation proves otherwise.

13.0 REPAIRS OF WELDS 13.1 With the prior permission of COMPANY welds, which do not comply with the standards of acceptability, shall be repaired or the joint cut out and re-welded. A separate welding procedure specification sheet shall be formulated and qualified by CONTRACTOR for repair welds simulating the proposed repair to be carried out. Separate procedures are required to be qualified for (a) through thickness repair (b) external repair and (c) internal repair. Welders shall be qualified in advance for repairs. The root pass, for repairs opening the root, shall be replaced by the vertical uphill technique. The procedure shall be proven by satisfactory procedure test to APIGAIL (INDIA) LTD NEW DELHI





1104 including the special requirements of the specification, and shall also be subjected to Metallographic examination, Hardness surveys and Charpy V-Notch testing to determine the effects of repair welding on the associated structure. Root sealing or single pass repair deposits shall not be permitted at the root. The internal root defects shall be ground out thoroughly and weld repaired with a minimum of two layers, with the last layer ground off. However, while grinding for repairs, care shall be taken to ensure that no grinding marks are left on the pipe surface anywhere. The repair shall be subjected, as a minimum requirement to the same testing and inspection requirements as the original weld. Re-Radiography of the repaired area shall be carried out. In addition, a minimum of 6” weld on either side of the repaired area shall be subjected to re-Radiography. A 100% Ultrasonic testing shall be done at the repaired area externally. Any repaired area that is wide, irregular or rough shall be rejected and a full cut out shall be done. Single pass repairs shall be subjected to 100% Dye-Penetrant/MP testing. Repairs are limited to a maximum of 30% of the weld length. Not more than two repairs are permitted on the same location. All repairs shall be carried out the day after initial Radiography or earlier. A full report of all repairs made shall be submitted every day to the COMPANY. 13.2

Weld Rejected by Accumulation of Defects Where a weld is rejected by the accumulation of defect as defined by API-1104 and this specification, repairs within these limitations are permitted. Defects in the filling and capping passes shall be repaired preferentially.






ANNEXURE – 1 (DESTRUCTIVE TESTING) 1.0 1.1

DESTRUCTIVE TESTING OF WELDED JOINT- BUTT WELDS PREPARATION OF SPECIMEN After satisfactory completion of all visual and non-destructive testing, the procedure test weld shall be set-aside for a period not less than 24 hours. No further work on the test weld and no cutting of test specimens from the weld shall be performed until a period of at least 24 hours has expired. Having passed the visual and the nondestructive inspection, the test weld shall be subjected to mechanical test. Weld specimens shall be taken from the positions indicated in FIG.1 & 1A of this specification from areas as free from defects as possible and for this reason it is necessary to take the previous non-destructive testing report into account. The minimum number of tests to be carried out is given in Table-1 of this specification. The test shall be carried out at laboratories approved by the COMPANY. The specimens shall be prepared in accordance with the figures given in the paragraphs that refer to the individual test.

1.2

TENSILE STRENGTH Specimens shall be taken from the position indicated in FIG.1, FIG.1A of this specification. Two (2) ISO type specimens and two (2) API type specimens shall be taken. The ISO test specimens are shown in FIG.2 of this specification.

1.2.1 Method The test shall be carried out in accordance with ISO 375.






TABLE – 1

1.3

NICK-BREAK TEST

1.3.1 Preparation Specification for Nick-Break test with notches thus worked can break in the base metal, instead of in the fusion zone. Therefore, an alternative test piece may be used after authorization by the COMPANY with a notch cut in the reinforcement of outside weld bead to a maximum depth of 1.5 mm measured from the surface of the weld bead. 1.4

MACROSCOPIC INSPECTION

1.4.1 Preparation Specimens shall be taken from the positions indicated in FIG.1 of this specification and shall be prepared in accordance with ASTM E2 and E3.The width of the macro section has to be at least three (3) times the width of the weld. The section is to be prepared by grinding and polishing and etched to clearly reveal the weld metal and heat affected zone. 1.4.2

Method Specimens shall be carefully examined under the microscope, with a magnification of at least 25 x. The COMPANY may ask for a macrograph with 5x magnification for documentation purposes.

1.4.3 Requirements






Under macroscopic examination, the welded joints shall reveal good penetration and fusion without any defect exceeding the limits stated in the evaluation criteria of the Nick-Break test. 1.5

HARDNESS TEST

1.5.1 Preparation The prepared macro section is to be used for hardness testing using the Vickers method with 10 kg load. Indentations are to be made along traverses each approximately 1.0 mm below the surface at both side of the weld. In the weld metal, a minimum of 6 indentations equally spaced along the traverses are to be made. The HAZ indentations are to be made along the traverses for approximately 0.5 mm each into unaffected material, and starting as close to the fusion line as possible. One indentation at each side of the weld along each traverse has to be made on parent adjacent region as well as on the opposite side of the macro section along the specified traverses. 1.5.2 Method The test shall be carried out in accordance with recommendation ISO R81, Vickers hardness, using a laboratory type machine controlled as pre-recommendation ISO R146 and using a diamond pyramid penetrator set at 2.37 rad (136") with a load of 10 kg. 1.5.3 Requirements Hardness value shall not exceed the limit specified in welding specification chart. In case of a single reading strictly (+10HV) higher than the specified limit, further indentations shall be made to check if the high value was an isolated case. All the measured hardness values of the heat-affected zone shall not exceed 100 HV with respect to the average hardness value of the base metal. If the additional tests give hardness value within the specification limit, the slightly higher value may be accepted. 1.6

CHARPY V-NOTCH IMPACT TESTING

1.6.1

Specimens shall be taken from the position indicated in FIG.1 of this specification. The test specimens will be prepared in accordance with ISO R 148. Charpy VNotch specimens shall have dimensions as given in Fig.3 of the specification. Three (3) test specimens shall be taken from each sample and they shall be cut and worked so that their length is transversal and perpendicular to the weld bead with the notch position as shown in FIG.4 of this specification. The notch shall be perpendicular to the roller surface. The test specimen width shall depend upon the pipe wall nominal thickness as per the following table:






1.6.2 Test Method The test shall be carried out as indicated in ISO R148 “Beam Impact Test V-Notch”. Test pieces shall be immersed in a thermostatic bath and maintained at the test temperature for at least 15 minutes. They shall then be placed in the testing machine and broken within 5 seconds of their removal from the bath. The test temperature shall be as mentioned in welding specification chart. 1.6.3 Requirements The impact energy values shall be as follows:

Note 1:

These values are specified for resistance to brittle fracture only. Where additional requirements are specified in project data sheet, as for example, pipeline material with arrest properties i.e. a higher upper shelf Charpy V Notch energy for resistance against propagating ductile fractures, the same shall be followed.

Note 2:

Only one value is permitted to be lower than average value up to the value specified.

1.7

BEND TEST REQUIREMENTS The Bend test specimens shall be made and tested as per the requirements of API 1104, Nineteenth Edition, September 1999. The dimensions of the Jig for guided bend test in Figure.9 of API 1104 shall be modified as specified below: Radius of the Plunger `A' = 2t






Radius of the die. `B' = 3t + 1.6 mm Width of the die. `C' = 50.8 Where t = thickness of the specimen The acceptance criteria shall however be as per para 5.6.4.3 and 5.6.5.3 of API 1104 Nineteenth edition, September 1999.






ANNEXURE – 2 (ULTRASONIC TESTING) 1.0

ULTRASONIC TESTING In addition to the Radiography testing, Ultrasonic testing is required as per conditions listed in paragraph 12.5 of this specification. This section concerns manual Ultrasonic inspection. However Ultrasonic inspection by automatic equipment may be used if approved by the COMPANY.

1.1

GENERAL: The CONTRACTOR who carries out the Ultrasonic inspections shall have sufficient no. of qualified personnel, equipment and instruments at his disposal to be carried out the tests without hindering or delaying the pipeline assembly operations. The CONTRACTOR appointed shall supply all the requisite instruments to carry out Ultrasonic inspection at site.

1.2

SPECIFICATION FOR ULTRASONIC TESTING PROCEDURE The CONTRACTOR shall present a Specification describing the proposed Ultrasonic testing procedure qualification. This specification shall state the following information including all the parameters described in API 1104:

1.3

a)

Type of Ultrasonic testing equipment to be used

b)

Type and dimensions of transducers

c)

Frequency range

d)

Details for calibration

e)

Coupling medium

f)

Inspection technique

g)

Reference to the welding procedure where it is intended to adopt the specification

h)

Temperature range of the joints to be inspected

I)

Record details.

QUALIFICATION OF ULTRASONIC TESTING PROCEDURE






Before the actual inspection begins, the COMPANY may require the qualification test of the Ultrasonic testing procedure. The qualification test shall be conducted under normal operating conditions on some weld made by the CONTRACTOR according to the same production procedure, where there are typical defects are intended to be detected. The qualification test shall be conducted in the presence of the COMPANY’s representative. The Ultrasonic inspection procedure shall be approved by the COMPANY. 1.4

TEST PROCEDURE Circumferential welds shall be inspected from both sides using angle probes. The surface with which the probe comes into contact shall be free of metal spatter,dirt, iron oxide, and scales of any type. Therefore, it shall be necessary to clean a strip at least 50 mm wide on both sides of the weld with steel-wire brushes. The cleaned strip must be at least wide enough to allow one and a half skip examination. If echoes of doubtful origin appear during the test, it shall be necessary to inspect a convenient area on the pipe surface close to the weld, with a straight beam transducer in order to check whether any manufacturing defects are interfering with the ultrasonic beam. The equipment shall include but not be limited to the following: a)

Ultrasonic equipment and coupling medium

b)

Sample sections for calibration of instruments

c)

Equipment for cleaning of surface to be examined

d)

Rules calibrated in centimeters for exact location of the position of defects.

The characteristics of the above listed instruments and equipment shall guarantee: a)

The required standards of the inspection procedure previously established and approved by the COMPANY are satisfied

b)

Continuous operation.

All the instruments and equipment shall be approved by the COMPANY before being used. The COMPANY has the authority to reject any item that is considered unsuitable. The decision of the COMPANY is final. The CONTRACTOR appointed to carry out Ultrasonic inspections shall also ensure the operational efficiency and maintenance of the instruments and equipment, and shall immediately substitute any item rejected by the COMPANY.






All the instruments and equipment necessary for carrying out Ultrasonic inspection on site shall satisfy the requirements laid down by the public boards of institutions that regulate `safety at work'. 1.5

ULTRASONIC INSTRUMENTS The Ultrasonic instruments shall have the following: a)

Pulse-echo type; able to generate, receive and display on the screen of a Cathode Ray Tube (CRT); pulse at frequencies between 1 and 6 MHz. The useful part of the CRT screen shall be at least 70mm wide and at least 50mm high. Variable amplification, with steps of 1 or 2 dB over a range of a least 60 dB.

b)

The regulation control shall be accurate to within ±1 dB and this accuracy shall be certified by the instrument manufacturer.

c)

May be powered by a battery or an electric generator. In the first case, the autonomy of operation (endurance) of the instrument shall be sufficient to carry out work without frequent interruptions, and the instrument shall be equipped with an automatic switch, which switches if off when the battery runs down. In the second case, there must be a voltage stabilizing device with a tolerance of ±2 volts.

1.6

PROBES The probes used shall have dimensions, frequencies, and a refraction angle suited to the type of steel, the diameter, and the thickness of the pipeline and to the joint design.

1.6

REFERENCE SAMPLE PIECES The efficiency of the equipment, the effective refraction angle of the probe, and the beam output point shall be checked using a V1 and V2 sample block, IIW type or the calibration block ASTM E-428. For manual Ultrasonic testing and automated Ultrasonic testing, the reference sample pieces shall be as described in API 1104, Nineteenth Edition, para 11.4.5.

1.7

CALIBRATION The calibration, qualification of the testing procedure shall be done as provided in API 1104.

1.9

REGULATION OF AMPLIFICATION DURING PRODUCTION TESTING Scanning sensitivity shall be as provided in API 1104 para 11.4.7.2 &11.4.7.3.

1.10 QUALIFICATION OF ULTRASONIC TESTING OPERATORS






Before the actual inspection begins, the COMPANY may require a qualification test for the ultrasonic equipment operators. The operators shall be fully qualified as per a recognized standard (ASME Sec V or equivalent) and they shall have as minimum level II as described in para 11.4.3, API 1104, Nineteenth Edition. The operators shall be able to: a)

Calibrate the equipment

b)

Perform an operational test under production conditions

c)

Interpret the screen picture

d)

Evaluate the size and location of reflectors

e)

Interpret the type of defects detected.

The COMPANY has the option of checking the ability of personnel employed for Ultrasonic testing by means of qualification tests. 1.11 EVALUATION OF INDICATIONS GIVEN BY ULTRASONIC TESTING Each time that echoes from the instrument amplification shall amplifications and the probe obtained, paying attention all the

weld bead appear during production testing, the be altered to coincide with the reference shall be moved until maximum response is time to the probe-tube coupling.

If, under these conditions, the height of the defect echo is equal to or greater than that of the reference echo, the defect shall be evaluated according to clause 12.5 of this specification. If the defect has also been detected by the Radiography and/or Visual examination, the dimensions shall be judged according to the type of examination that detects the greater defect. Returns that are less than 50% of the reference echo will not be considered. If returns are above 50% but lower than 100% of the reference echo, and if the operator has good reasons to suspect that the returns are caused by unfavorably oriented cracks, he shall inform the COMPANY. Moreover, when there is a defect to be repaired, such defect shall be removed for a length corresponding to the one where no more return echo is given. 1.12 OTHER EQUIPMENT The use of rules calibrated in centimeters, attached to the probe is recommended for the precise location of the position of welding defects. Defect location is effected by measuring the projection distance between the probe output and the reflecting surface.






The operators carrying out the tests may require other equipment besides the probing instrument, tools for cleaning the pipe surface viz. files, brushes etc., and coupling liquid or paste appropriate for the temperature of the section to b examined.






ANNEXURE – 3 AUTOMATED ULTRASONIC TESTING (AUT) 1.0

INTRODUCTION

2.0

REFERENCE DOCUMENTS

3.0

APPROVED AGENCIES

4.0

AUT SYSTEM

5.0

COUPLING

6.0

SEARCH UNITS

7.0

CALIBRATIONS

8.0

PROCEDURE

9.0

TRAINING AND QUALIFICATION

10.0

FIELD EXAMINATIONS AND REPORTING

11.0

INTERPRETATION OF RESULTS

12.0

ACCEPTANCE CRITERIA






1.0

INTRODUCTION The specification shall be applicable for Automated Ultrasonic Testing (AUT) system suitable for pipeline girth welds. The system shall be based on focused pulse-echo, tandem or through transmission methods enhanced with mapping image and augmented by Time Of Flight Diffraction (TOFD) technique.

2.0

REFERENCE DOCUMENTS ASTM E 1961-98 “Standard Practice for Mechanized Ultrasonic examination of Girth Welds using Zonal Discrimination with Focused Search Units”. The inspection system shall meet and exceed the requirements of ASTM E 1961-98. Appendix-E, “Automated Ultrasonic Girth Weld Testing”, OS-F101, Submarine Pipeline Systems, January 2000. API Std. 1104 – “Welding of Pipeline and Related Facilities”.

3.0

APPROVED AGENCIES Automated Ultrasonic Testing (AUT) systems and agencies who have proven track record and have done a single project of diameter 20” or above and minimum length of 50 km and also have inspected a cumulative length of 500 km or above on large diameter Pipe lines in the last ten years shall be accepted. The agency should have been approved by the reputed inspection agencies. The track record shall be submitted to the COMPANY for approval prior to engagement.

4.0

AUT SYSTEM The system shall meet and exceed the requirements of ASTM E1961-98. The system shall provide an adequate number of examination channels to ensure the complete volumetric examination of the weld through the thickness in one circumferential scan. The evaluation zones should be of maximum 2.0mm height. The instrument linearity should be such that the accuracy is within 5%. Each examination channel should be selective for pulse-echo or through transmission mode gate position and length for a minimum of two gates and gain. TOFD techniques & B-scan mapping should be available to improve characterization. Recording thresholds should be selectable to display signals between 0 and 100% of full screen height for simple amplitude and transit time recording and it should be from 0 to 100% for B-scan or mapping type recording of data. Two recordable signals output per gate should be available being either analog or digital and representative of signal height and time of flight. Measuring distance accuracy of circumferential weld shall be within 1.0 cm from zero (0) position. GAIL (INDIA) LTD NEW DELHI





Electronic noise shall be lower than acoustical noise in all channels for the probes and sensitivities to be used during inspection. The signal to noise ratio for each channel during examination shall be at least ≥ 20 dB for shear waved probes. 5.0

COUPLING The coupling shall be obtained by using a medium suitable for the purpose. It shall be suitable for the temperature used. No residue shall remain on the pipe surface. A method should be employed to determine that constant coupling is achieved during examination. An examination of the test piece with its surface wiped dry should produce a record showing an absence of the couplant recording signal.

6.0

SEARCH UNITS The search unit shall meet all the requirements specified in Para 6.4 of ASTM E1961- 98.

7.0

CALIBRATIONS Reference standards shall be manufactured from a section of unflawed project specific line pipe supplied by pipeline CONTRACTOR. The agency shall then submit the reference standard design to the COMPANY before manufacturing. No design changes in the reference standard shall be made without the prior approval. Annexure A3 of the standard ASTM E1961-98 provides an example for minimum requirements for reference standards. The system shall be optimized and calibrated as stated in Para 7.0 and 8.0 of ASTM E 1961-98. Static and Dynamic calibration shall be done and the approved procedure shall clearly state the gain setting fixed for each channel. The reference standard should be used to verify the scanning sensitivity at the start of each shift and thereafter at intervals not exceeding two (2) hours or ten (10) welds. A re-calibration shall be carried out if: a) b)

The calibration of an inspection function differs more than +/- 3dB from the previous calibration The gate settings need to be adjusted with more than +/- 1.5 mm with the previous calibration – i) after a weld repair, ii) after equipment breakdown.

In case the calibration differs from the initial setting, outside the given tolerances, the applicable probe(s) coupling shall be checked. If the calibration has to be changed, the welds before this calibration up to the previous calibration will be reexamined.






The reference standard design for calibration shall be approved separately. The procedure for calibration and verification shall be same as given above. 8.0

PROCEDURE A detailed AUT procedure shall be prepared and qualified for each wall thickness and joint geometry to be examined prior to the start of any NDT work. Repair procedure shall be separately qualified for each joint geometry. All the requirements of ASTM E1961-98 should be met. The procedure as a minimum shall include the following: - Functional description of equipment - Reference standards and guidelines controlling equipment maintenance - Instructions for scanning device, Ultrasonic instrument, Ultrasonic electronics, Hard & Software for recording processing, Display presentation and storage of inspection data - Transducer configuration(s), characteristics types coverage. - Number of examination zones for each wall thickness to be examined. - Gate settings - Equipment settings - Description of calibration blocks including type, size and location of calibration reflectors, a) calibration intervals, b) calibration records - Static and dynamic calibration procedure - Identification of inspection starting point scanning direction and indication of length inspected - Method for scanner alignment and maintenance of alignment - Allowed temperature range - Couplant coupling and coupling control and channels provided to indicate lack of coupling and method to ensure constant coupling - Transducer and over all functional checks - Height and length sizing methodology - Surface condition and preparation - Description of inspection work - Acceptance criteria and instructions for reporting including example of recorder chart and form to be used. - A table indicating corresponding channel no., probe, type, location of reflector, probe coupling etc.

8.1

Setting of Inspection Gates

8.1.1 Pulse-echo and Tandem Channels With each transducer positioned for the peak signal response from the calibration reflector the detection gates are to be set. The gate shall start 2-6mm (allowance for width of heat affected zone) before the theoretical weld bevel preparation. The gate ends shall be after the theoretical weld centerline. All gates will be programmed to record amplitude and/or transit distance information.






The length of the transit distance in the root channel will be extended root penetration registration.

to

enable

8.1.2 Mapping Channels 8.1.3 The mapping gates in the body of the weld shall start 2-6mm (allowance for width of heat affected zone) before the theoretical weld bevel preparation. The gate length will be extended to enable cap reinforcement registration. The mapping gates in the root will be set identical to the pulse-echo transit distance channels to enable the registration of the root penetration. 8.1.4 TOFD Channel The TOFD gate start will be set 1 µSec before the arrival of the lateral wave and should extend up to the first back wall echo to achieve full cover of wall thickness. Note: The gate settings may be altered if geometry indications dictate. 8.1.5 Sensitivity Settings With each transducer positioned for the peak signal response from the calibration reflector (flat bottom holes), the detection gates are to be set. In this position, the probe holder is fixed to the probe frame. The equipment sensitivity (echo amplitude) for all inspection channels shall be set at 80% Full Screen Height (FSH). Mapping channels in the body of the weld will be used to detect the presence of porosity and in addition to identify the position of the weld cap reinforcement for pattern recognition purpose. The sensitivity as a minimum is equal to the related pulse- echo channels, increased with additional gain to ensure proper detection. Mapping channels in the root will be used to identify the position of the root penetration for pattern recognition purpose. The sensitivity as a minimum shall be equal to the related pulse-echo channels, increased with additional gain to ensure proper detection. he lateral wave of the TOFD channel sensitivity is set at 80% FSH. 9.0

TRAINING AND QUALIFICATION

1.

All Inspectors’ of the COMPANY (Owner) shall be imparted training at the CONTRACTOR’s cost. The inspector shall be provided complete awareness and knowledge regarding the equipment, limitations, capabilities complete range, method of operation, calibration, scanning, including development of suitable procedure, training on variables effecting the system performance and interpretation of results.

2.

The Ultrasonic lead operator performing the examination shall be qualified in accordance with the COMPANY’s written practice and in accordance with ASNT Practice SNT-TC-1A and EN 473 Level II. He should have experience in multichannel UT equipment and be trained in using mechanized UT manipulators.






10.0

FIELD EXAMINATIONS AND REPORTING All the requirements stated in Para 9 and 10 of ASTM E1961-98 shall be followed a minimum.

11.0 INTERPRETATION OF RESULTS 11.1

General With the transit distance measurements and with the information from the mapping and TOFD channels visible on the result presentation, indications shall be judged whether they are from the weld geometry or from the defects. The coupling channels will check for coupling loss; in case of coupling loss, a re-scan shall be carried out.

11.2

Inspection Result The inspection result should be evaluated and/or reported as follows: Welds shall be evaluated using both the pulse-echo and TOFD criteria shown below. This shall be performed in parallel and rejection against either of these criteria shall be cause for rejection of the weld. The exceptions to this are described in the following notes: 1. 2.

3.

4.

All indications in the pulse echo channels should be evaluated which exceed the threshold level of 20% FSH. Defect length shall be measured for the pulse-echo channels from the point where the signal exceeds 20% FSH to the point the signal falls below. The largest height assessed with TOFD or the greatest measured amplitude with pulse-echo shall be assumed to apply over the whole defect length. If the indication cannot be resolved by TOFD i.e. the upper and lower flaw diffraction tips cannot be separately distinguished, no measurement can be made to determine the defect height. In this case, the signal from the pulse echo channels will be solely used to determine that particular area of the scan. Defects shall be assessed for interaction as follows: a) Horizontal interaction If the distance between two adjacent defects is less than the length of the smaller of the two defects, then the defect shall be treated as a single defect. b) Vertical interaction Vertical interaction of defects shall be assessed using TOFD. If the distance between the two adjacent defects is less then the height of the shorter of the two defects, than the defect shall be treated as a single defect. Where the individual defects cannot be resolved by TOFD for the vertical interaction, then the defects are assumed to interact and shall be treated as a single defect.






5.

The maximum allowable accumulated defect length shall be as per the criteria given in welding specification para 12.5.1.

12.0 ACCEPTANCE CRITERIA Weld quality shall be judged on the basis of the acceptability criteria mentioned in Para 12.5.1 of welding specification.






1.0

SCOPE

ANNEXURE-4 (RADIOGRAPHY TESTING)

This annexure covers the Radiography Testing of all types of welded joints of the main pipeline. The welded joints shall include the following: i) Full girth welds on the mainline construction including double jointing of pipe, if adopted. ii) Welds for installation of block valves, insulating joints and other appurtenances and tie-ins. iii) Welds at scraper launching and receiving barrels. iv) Terminal Piping. 2.0

APPLICABLE STANDARDS This specification shall apply in conjunction with the following (all latest editions): i) API 1104, Standard for welding Pipelines and Related Facilities ii) ANSI B 31.8, Code for Gas Transmission and Distribution Piping Systems. iii) ANSI B 31.4, Code for Transportation System for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia and Alcohols. iv) ASTM E 94, Recommended practice for Radiographic Testing v) ASTM E 142, Standard Method for Controlling Quality of Radiographic Testing v) The American Society for Nondestructive Testing. Recommended Practice No. SNT-TC 1A Supplement A.

3.0

PROCEDURE

3.1

The Radiography examination procedure to be adopted shall be submitted by the CONTRACTOR as per Exhibit - F.

3.2

The procedure of Radiography examination shall be qualified to the entire satisfaction of COMPANY prior to use. It shall include but not be limited to the following requirements: i)

Lead foil intensifying screens, at the rear of the film shall be used for all exposures.

iii)

Type 2 and 3 films as per ASTM E-94 shall be used.

iv)

A densitometer shall be used to determine film density. The transmitted film density shall be between 2.0 and 3.5 throughout the weld. The unexposed base density of the film shall not exceed 0.30.

v)

Radiography identification system and documentation for Radiography interpretation reports and their recording system.






3.3

The CONTRACTOR shall qualify each procedure in the presence of the COMPANY prior to use.

3.4

The procedure of Radiography examination shall produce radiographs of sufficient density, clarity and contrast so that defects in the weld or in the pipe adjacent to the weld are clearly discernible.

3.5

All the girth welds of mainline shall be subjected to 100% Radiography examination. The CONTRACTOR shall furnish all the radiographs to the COMPANY, immediately after processing them, together with the corresponding interpretation reports on approved format. The details of the radiographs along with the joint identification number shall be duly entered in a register and signed by the CONTRACTOR and submitted to the COMPANY for approval.

3.6

When the radiation source and the film are both on the outside of the weld and located diametrically opposite each other, the maximum acceptable length of film for each exposure shall not exceed the values given. The minimum film overlap, in such cases, shall be 40mm. The ellipse exposure technique may be used on nominal pipe sizes of 2 inch and smaller provided that the source of film distance used is a minimum of 12 inch.

3.7

Three (3) copies of each acceptable Radiography procedure (as per Exhibit-F) and three (3) copies of Radiography qualification records, shall be supplied to COMPANY. One set of the qualifying radiographs on the job shall be kept by the CONTRACTOR's authorized representative to be used as a standard for the quality of production Radiography during the job. The other two sets shall be retained by COMPANY for its permanent record.

3.8

Three (3) copies of the exposure charts relating to material thickness, kilo voltage, source to film distance and exposure time shall also be made available to COMPANY by the CONTRACTOR.

3.9

The CONTRACTOR shall record for each radiograph on a daily basis (1) radiograph's number, (2) approximate chainage of weld location, (3) whether or not the welds meet the specified acceptance standards, and (4) the nature and approximate location of unacceptable defects observed to correlate to a particular butt weld and welder on piping drawing and pipeline alignment drawing.

3.10

Each day's production of processed radiographs shall be properly packaged separately, identified by (1) date, (2) radiography unit, (3) job locations, (4) starting and ending progress survey stations, and (5) shall include original and three (3) copies of the daily radiography record. The package shall be submitted to the COMPANY daily when possible, but in no event later than noon of the following day.

3.11

The CONTRACTOR shall provide all the necessary facilities at site, such as a dark room with controlled temperature, film viewer etc. to enable the COMPANY to examine the radiographs. GAIL (INDIA) LTD NEW DELHI





3.12

The CONTRACTOR, if found necessary, may modify the procedure of Radiography examination suiting to the local conditions prevailing. This shall be subjected to the approval of the COMPANY.

3.13

COMPANY shall have free access to all the CONTRACTOR's work facilities in the field.

3.14

Any approval granted by the COMPANY shall not relieve the CONTRACTOR of his responsibilities and guarantees.

4.0

RADIATION SOURCE

4.1

Radiography examination shall be carried out using X-radiations. Radiography examination by Gamma rays using slow speed films may be allowed, at the discretion of the COMPANY in case of inaccessible joints. Radiography by Gamma ray for tie-in-joints shall be acceptable provided D4 AGFA film or equivalent is used and the required sensitivity obtained.

4.2

Whenever possible, pipeline welds will be inspected by placing the radiation source inside the pipe, on the pipeline axis, with a radiation of 6.28 red. (360) If it is impossible to place the radiation source inside the pipe, the weld will be inspected with the source on the outside. An overlap of at least 40 mm at the ends of each film shall be required to ensure that the first and last location increment numbers are common to successive films and to establish that no part of a weld has been omitted.

5.0

LEVEL OF QUALITY The quality level of Radiography sensitivity required for Radiography inspection shall be at least equivalent to the values in FIG.5.

6.0

PENETRAMETERS

6.1

The Image Quality Indicator (IQI) shall be used for the qualification of the welding procedure and during normal line production. Radiography sensitivity shall be measured with the wire image quality indicator (Penetrameter). The Penetrameter shall be selected according to DIN-54109 or ISO-1027. For radiographs made with the source on the outside, a Penetrameter shall be placed on each side of the film with the smaller wire of the Penetrameter turned towards the end of the film itself. When a complete weld is radiographed in a single exposure using a source inside the piping, four pentrameters approximately equally spaced around the circumference shall be used. During the procedure qualification, IQI shall be placed both on the source side and on the film side. The sensitivity obtained with IQI on the source side shall not be less than the values shown in FIG.5 of this specification. The sensitivity limit may be considered to have been reached when






the outline of the IQI, its identification number and the wire of the required diameter show up clearly on the radiograph. The COMPANY may authorize use of types of IQI other than those planned, provided that they conform to recognized standards and only if the CONTRACTOR is able to demonstrate that the minimum sensitivity level required is obtained. For this demonstration, a test shall be carried out comparing the IQI specified. The CONTRACTOR shall show up the identification number and other details of the proposed IQI, which must be visible in the test radiograph. 2.0

FILM IDENTIFICATION MARKERS All films shall be clearly identified by lead numbers, letters, and/or markers. The image of the markers shall appear on the films, without interfering with the interpretation. These markers positions shall also be marked on the part to be radiographed and shall be maintained during Radiography.

8.0

PROTECTION AND CARE OF FILM

8.1

All unexposed films shall be protected and stored properly as per the requirements of API 1104 standard and ASTM E.94.

8.2

The exposed and unexposed film shall be protected from heat, light, dust and moisture. Sufficient shielding shall be supplied to prevent exposure of film from radiation prior to the use of the film for Radiography exposure.

9.0

RE-RADIOGRAPHY

9.1

The weld joints shall be re-radiographed in case of unsatisfactory quality of the radiographs, at the expense of the CONTRACTOR.

9.2

All the repaired weld joints shall be re-radiographed at no extra cost to the COMPANY in the same manner as that followed for the original welds. In addition, the repaired weld areas shall be identified with the original identification number plus the letter R to indicate the repair.

9.3

When evaluating repair film, radiographers shall compare each section (exposure) of the weld with the original film to assure repair is correctly being done and original defects are removed. Prior to any repair of welds, the COMPANY will review all the radiographs of welds that contain unacceptable defects. The final disposition of all unacceptable welds shall be decided by the COMPANY.

9.4

10.0 QUALIFICATION OF RADIOGRAPHERS






10.1

Pipeline radiographers shall be qualified in accordance with the requirement of API 1104 and to the full satisfaction of COMPANY.

10.2

Certification of all the radiographers qualified as per 10.1 above shall be furnished by the CONTRACTOR to the COMPANY, before a radiographer will be permitted to perform production Radiography. The certificate record shall include: i) Background and Experience Record ii) Training Course Record iii) Technical Examination Record iv) Doctor's report on radiographer's Jacque 0-1 acquity eye test v) Date of qualification

10.3

The radiographers shall be required to qualify with each Radiography procedure they use, prior to performing the work assigned to him in accordance with the specification.

11.0

PRESERVATION OF RADIOGRAPHS

11.1

The radiographs shall be processed to allow storage of films without any discoloration for at least three (3) years. All the radiographs shall be presented in suitable folders for preservation along with necessary documentation.

11.2

All radiographs shall become property of the COMPANY.

12.0 EQUIPMENT AND ACCESSORIES 12.1

CONTRACTOR shall make necessary arrangements at his own expense, for providing the radiographic equipment, radiographic films and all the accessories for carrying out the Radiography examination for satisfactory and timely completion of the job.

12.2

For carrying out the mainline Radiography examination, the CONTRACTOR shall be equipped with suitable mobile/stationary type dark rooms. These shall have all the required facilities for film processing. Film viewer used shall be equipped with the film illuminator that has a light source of sufficient intensity and suitably controlled to allow viewing film densities up to 4.0 without damaging the film.

13.0 RADIATION PROTECTION 13.1 13.2 13.3

CONTRACTOR shall be responsible for the protection and personnel monitoring of every man with or near radiation sources. The protection and monitoring shall comply with local regulations. In view of visual hazards in the handling of Radioactive source of material, CONTRACTOR shall be solely responsible for complying with all rules and regulations set forth by Atomic Energy Commission or any other Government GAIL (INDIA) LTD NEW DELHI





agencies of India in this regard and COMPANY shall not be responsible and shall be kept indemnified by the CONTRACTOR for default (s) of whatever nature by the CONTRACTOR. Safety equipment as considered adequate by the COMPANY for all necessary personnel shall be made available for use and maintained for immediate and proper use by the CONTRACTOR. 14.0

DISPLAY OF SAFETY INSTRUCTIONS

14.1

The safety provisions shall be brought to the notice of all concerned by display on a notice board at prominent place at the work spot. The person responsible for the “Safety” shall be named by the CONTRACTOR.

15.0 ENFORCEMENT OF SAFETY REGULATIONS 15.1

To ensure effective enforcement of the rules and regulations relating to safety precautions, the arrangement made by the CONTRACTOR shall be open to inspection by COMPANY or its representatives.

16.0 FIRST AID AND INDUSTRIAL INJURIES 16.1

CONTRACTOR shall maintain first aid facilities for its employees and those of subcontractors.

16.2

CONTRACTOR shall make outside arrangements for ambulance service and for treatment of industrial injuries. Names of those providing these services shall be furnished to COMPANY, prior to start of work and their telephone nos. shall be posted prominently in CONTRACTOR'S field office.

16.3

All critical industrial injuries shall be reported promptly to the COMPANY and a copy of CONTRACTOR's report covering each personal injury requiring the attention of physician shall be furnished to the COMPANY.

17.0 NO EXEMPTION Notwithstanding the above there is nothing in these to exempt the CONTRACTORN from the operation of any other act or rules in force.






Sheet – 1 of 3 EXHIBIT- A A:

B

(ELECTRODE QUALIFICATION TEST RECORD)

Tested at (Site name) Date: Manufacturer’s Name Brand Name Batch Number & Size tested Classification & Code Intended for welding in position : In combination with (if any) Code of Reference (used for testing) Special Requirements (if any) All-weld Tensile Test Base Material used Pre-heat temperature Post weld heat treatment details Visual examination Radiographic examination results Tensile test results


: : : : : : :

: : : : : :





EXHIBIT – A (CONTD.) Sheet 2 of 3 C.

D.

Impact Test Results Test Temperature :

Notch in :

Type of Specimens (Charpy) :

Size of Specimens :

Chemical Analysis Results Electrode Size Result : Batch No. :

E.

Fillet Weld Test Results : Welding Positions : Base Materials : Size of electrode used : Visual Inspection Results : (1) (2) (3)






EXHIBIT – A (CONTD.) Sheet 3 of 3 Macro Test Results

:

Fracture Test Results

:

Remarks

:

F.

Other Test Results

:

1.

Transverse tensile test : In combination with

:

Base material used

:

Position of welding

:

Preheat temperature

:

Post weld heat treatment

:

Radiography

:

Identification No. U.T.S. Fracture in Remarks 2.

Guided Bend Test

:

G. Any other tests :

H. Conclusions :

--------------------PREPARED BY (CONTRACTOR)


-------------------REVIEWED BY (CONTRACTOR)


------------------------APPROVED BY (OWNER)




Sheet – 1 of 1 EXHIBIT - B (STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION) Name of the Heat-Treater : Name of the Project : Specification Reference No. : 1.

General Detail : 2. Furnace Details : Name of the Equipment : Type of Heating : Gas/Oil/Elect. Name of the Assembly/Part : Res./Induction Type of Heating : Drawing No : Capacity (Size) : Material : Maximum Temp.( °C) : Method of temp. Measurement : Atmosphere Control :

3.

Heat Treatment Cycle Details : Charging Temp. (°C) : Rate of heating, (°C)/Hr : Soaking Temp. (°C) : Soaking Time, (Hrs.) : Rate of Cooling, (°C)/Hr : Mode of Cooling :

4.

Other Details, if any : Notes : The following documents shall be furnished along with the specifications: i) Material test certificates

ii) Assembly/Part Drawing

--------------------PREPARED BY (CONTRACTOR)


-------------------REVIEWED BY (CONTRACTOR)


------------------------APPROVED BY (OWNER)




EXHIBIT - C (FORM FOR WELDING PROCEDURE QUALIFICATION TEST RECORD) Sheet – 1 of 3

























































WELDING SPECIFICATION CHARTS FOR PIPE WELDING- A1A, B1A, D1A, A3A

SPECIFICATION 0001-01-04-02-001-WSC1

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JOB SPECIFICATION FOR GEOTEXTILE BAGS FOR ANTI-BUOYANCY

SPUR LINES OF CHAINSA-JHAJJAR PIPELINE


SPECIFICATION FOR GEOTEXTILE BAGS FOR ANTI-BUOYANCY


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TABLE OF CONTENTS

1.0

SCOPE

2.0

DESIGN

3.0

MATERIAL

4.0

DELIVERY, STORAGE, HANDLING

5.0

MARKING

6.0


7.0

INSTALLATION

9.0

DOCUMENTATION




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1.0 SCOPE 1.1

This specification covers the minimum requirements for design, manufacture and supply of non-biodegradable geo-textile bags (made from polypropylene fabric) intended to be used for providing anti-buoyancy measures when filled with Gravel/stone ballast materials.

2.0 DESIGN 2.1

Geo-textile bags shall be suitable for filling with Gravel/stone ballast materials for 18” 12” & 10” three layer polyethylene coated pipeline carrying liquid hydrocarbon for anti buoyancy measures in place of concrete coating.

2.2

Composition and the details of materials shall be as per recommendation of anufacturer

2.3

The geo-textile bags shall meet the following requirements: a.

Body fabric material must be rated for geo-textile use and as such must be woven with minimum permeability rating to suit specified Gravel/stone ballast materials.

b.

Geo-textile bags shall be of top loading fabric-type made from woven polypropylene material.

c.

The center to center spacing between a set of geo-textile bags shall be kept minimum possible but in no case shall it exceed 7.0 meters in case 18” pipeline and 5.0 meters in case of 12” pipeline and below.

2.4

Manufacturer shall take prior approval from Owner on details of geo-textile bags and design calculations.

2.5

The fabric weights to be used in the pipeline should be from a manufacturer with a minimum of 5 years continuous, successful experience in production of geo-textile fabric weights for pipeline buoyancy control application. Manufacturing plants must be an ISO 9002 certified facility to ensure consistency in quality.

2.6

The proposed bags and associated straps etc. shall not be detrimental to the pipeline coating in any manner.

2.7

Repair of bags, in any manner is not permitted.

3.0 MATERIAL GAIL (INDIA) LTD NEW DELHI



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3.1

The body fabric must be treated for UV protection and longevity. The weight of the 2

body fabric must be a minimum of 400 gms/m . 3.2

All material used in the fabrication of geo-textile bags such as webbing, lifting loops, threads etc. shall be polypropylene material.

3.3

All webbing must have a minimum individual tensile rating of at least 2268 kg. With a combined safety rating of 4 times the capacity.

3.4

Body fabric must have a maximum elongation rating of 15% and be stable within a pH range between 2 to 12.

3.5

All testing should be as per ASTM or equivalent standards

4.0 DELIVERY, STORAGE AND HANDLING 4.1

Geo-textile bags shall be delivered on pallets with a black protective cover for easy handling and storage.

4.2

Protective cover to be maintained to ensure the proper protection from oil, dirt and sunlight.

5.0 MARKING 5.1

On each black protective cover the following shall be marked by suitable means “Maintain cover or provide separate cover on bags until use. Ensure proper protection from oil, dirt, sunlight etc.”

5.2

Each geo-textile bag shall be marked by indelible paint or other suitable methods with the following minimum information: a. b.

Product model Name of Manufacturer

c.

Dimensions of bag in mm.

d.

Weight carrying capacity (Total weight when filled)

e.

Year, month of manufacture and product batch number

6.0 OTHER TECHNICAL REQUIREMENTS GAIL (INDIA) LTD NEW DELHI



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6.1

Manufacturer shall provide skilled persons for initial assistance / on the job training during filling and installation of supplied geo-textile bags till the pipeline installation contractor will get trained in filling & installation to the satisfaction of Engineer In charge

7.0 INSTALLATION 7.1

The geo-textile bags shall be filled by using proper sized filling hoppers with appropriate stone as recommended by manufacturer.

7.2

While picking up fabric weights for transportation, it shall be ensured that all hooks and clevises are free of large, sharp defects that may damage the lift straps. Only suitable devices or bag type slings shall be used during lifting.

7.3

Trailers with rails or strapping to secure the load shall be used for transportation to site. The bags shall not be stacked.

7.4

Weights are to be kept in upright and leaning in supported position in ROU for easy accesses to the lifting loops.

7.5

Extra trench width and depth shall be excavated to accommodate the Geo– textile bags. Backhoe or side boom shall be used for installation of the same.

8.0 DOCUMENTATION Following documents shall be submitted for review before installation of geo-textile bags 8.1

All necessary calculations to demonstrate the suitability of proposed geo-textile bags for pipeline anti-buoyancy measures under the specified design conditions. The manufacturer shall provide an undertaking that the proposed geo-textile bags are suitable for 18”/12” & 10”, 3 layer polyethylene coated line pipe. Three layers PE coating shall be minimum 2.2 mm thick.

8.2

All details of proposed geo-textile bags (such as dimensions, material used etc.) shall be furnished. Contractor shall highlight any special features if any.

8.3

General arrangement drawings of all items viz. set of geo-textile bags, hopper, loading arrangement etc.

8.4

Details of all associated equipments (hoppers etc), spares, tools etc required to fill, transport and install geo-textile bags on the pipeline. GAIL (INDIA) LTD NEW DELHI



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8.5

Complete descriptive technical catalogues describing the materials offered along with samples of geo-textile bags, its properties, testing results and installation instruction as applicable specifically to the project, Specific storage and handling instructions.

8.6

Manufacturer shall highlight any precautions / safety measures to be taken.




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TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING SPUR LINES OF CHAINSA-JHAJJAR PIPELINE


TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING


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TABLE OF CONTENTS 1.0

INTRODUCTION

2.0

RESPONSIBILITY OF CONTRACTOR

3.0

SCOPE OF WORK 3.1

Precommissioning activities

3.2

Commissioning related activities

4.0

DOCUMENTATION

5.0

SPARES AND COMSUMABLES

6.0

SAFETY




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1.0 INTRODUCTION This specification covers the minimum technical requirements for: i.) Precommissioning of : Sl.

Pipeline

Tap-off Point

Size(Inch) X Length (Km)

1

Sultanpur Haryana) to Neemrana (Rajasthan)


18” X 85.28

2

Spur Line to Bhiwadi

Tap-off point at Chainage – 12” X 9 31.6 Km in Sultanpur – Neemrana Line

3

Hayatpur to Manesar


4

Hayatpur to Gurgaon

Tap-off point at Chainage – 10” X 11 61.14 Km in Chainsa-Jhajjar line

10” X 5.4

ii.) Commissioning activities consisting of Drying, Inertisation, Gas-in / Commissioning, stabilization and 72 hours run of Pipeline as mentioned above in Table 1.0 - ( i ) Contractor, along with his bid documents, is required to submit the following: •

Execution plan and method statement for pre-commissioning and commissioning activities.



Past experience of pre-commissioning and commissioning activities carried out for a similar pipeline system / network.



Plan to engage an agency / subcontractor for these activities (if envisaged).



Organization charts of bidder’s proposed pre-commissioning and commissioning team indicating the positions with the required qualifications and experience.



Clause wise list of deviations, if any, from this technical specification. In the




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absence of this, it shall be considered that the bidder has no deviation. 

2.0

Questionnaire as given in Appendix-I duly filled by bidder.

RESPONSIBILITY OF CONTRACTOR The contractor shall be responsible for all the pre-commissioning and commissioning activities that need to be carried out for the pipeline system.

2.1

Precommissioning In order to execute and perform pre-commissioning activities, the contractor shall be responsible for (but not limited to): •

Carrying out precommissioning checks of the underground pipeline system including above ground piping at dispatch station and at receipt stations, Sectionalising Valve (SV) stations, CGS/ PRS Station, tap-off / hook-up piping and all terminals.



Dewatering of the pipeline.



Flushing and dry air blowing of under ground & above ground piping at dispatch and receipt stations, SV stations, all Terminal stations and hook–up point.



Swabbing of pipeline.



Low pressure leak check (with air) for the aboveground section of the pipelines.



Supply and supervision of manpower for precommissioning.



Supply and operation of machinery & equipment for precommissioning.



Supply and use of materials precommissioning activities.



Design and supply all temporary line connections, pig launcher/receiver, valves, instruments, manpower etc. as required during various operations.



Preparation of detailed precommissioning procedures, activity schedules, bar charts, schemes etc.



This shall include preparation of detailed procedures for dewatering, flushing, swabbing, and low pressure leak check and shall address the sequence and


and


consumables

as

required


for

the

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methodology describing all operations, data on materials, equipment, instruments, consumables, communication systems, necessary calculations, detailed time schedule and organization chart. 

All necessary work to perform the job successfully including all modifications that would be required. The contractor shall demonstrate to the COMPANY (for COMPANY’s approval) the successful completion of all of the above-mentioned activities. In the event of any detail, which is not fully addressed, contractor should warrant that work shall be performed in accordance with the relevant codes, Company's specifications and the best recognized Engineering guidelines and practices being followed in the on-shore pipeline industry.

2.2

Drying, Inertisation, Gas-in / Commissioning, stabilization and 72 hours run In order to execute and perform commissioning related activities, the contractor shall be responsible for (but not limited to): 

Drying of the underground pipeline and above ground piping system at dispatch and receipt stations, above ground piping system at all Terminal stations, CGS/PRS Station, SV stations and hook-up / tap-off points to a water dew point of 0°C at atmospheric pressure, and maintain this dew point in the pipeline, till inertisation and gas-in activities commence.



Commissioning checks including Safety review prior to start of commissioning activities to achieve ‘Ready for commissioning’ status for underground pipeline and above ground piping system at dispatch and receipt stations, above ground piping system at IP stations, SV stations and hook-up / tap-off points.



Inertisation of the pipeline system including above ground piping system at dispatch and receipt stations, above ground piping system at all Terminal stations, CGS/PRS Station, SV stations and hook-up / tap-off points.



Gas-in activities including pressurization, carrying out high pressure leak checks and establishment of flows in the pipeline system including above ground piping at dispatch and receipt stations, SV stations, all Terminal station, CGS/ PRS station and hook-up points.



Stabilization and 72 hours run of the pipeline system.




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3.0



Supply and supervision of manpower for commissioning.



Supply and operation of machinery & equipment for commissioning.



Supply and use of materials and consumables as required for the commissioning activities.



Design and supply all temporary line connections, pig launcher/receiver, valves, instruments, manpower etc. as required during various operations.



Preparation of detailed commissioning procedures, activity schedules, bar charts, schemes etc.



This shall include preparation of detailed procedures for Drying, Inertisation, Gas-in / commissioning operations, high pressure leak check operations, pressurization, establishing flows and 72 hours run of the pipeline system, and shall address the sequence and methodology describing all operations, data on materials, equipment, instruments, consumables, communication systems, necessary calculations, detailed time schedule and organization chart.



Ensuring all communication facilities are in place and in proper working condition prior to start of commissioning activities of the pipeline system.



All necessary work to perform the job successfully including all modifications that would be required.



The contractor shall demonstrate to the COMPANY (for Company’s approval) the successful completion of all of the abovementioned activities.



In the event of any detail, which is not fully addressed, contractor should warrant that work shall be performed in accordance with the relevant codes, Company's specifications and the best recognized Engineering guidelines and practices being followed in the on-shore pipeline industry.

SCOPE OF WORK The work to be performed by the Contractor as part of the precommissioning activities for the facilities outlined in paragraphs and Table (i) of Section-1.0 above and commissioning related activities for the facilities outlined in paragraphs (ii) of Section-1.0 above shall consist of the following:

3.1

Precommissioning activities

3.1.1 Precommissioning checks GAIL (INDIA) LTD NEW DELHI



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Pre-commissioning checks shall be carried out for the pipeline system to ascertain that the pipeline system has been mechanically completed in all respects. These checks shall cover the main pipeline including distribution network system, dispatch and receipt stations, all Terminal Stations, CGS/ PRS stations, sectionalizing valve stations and the hook up points. The pre-commissioning checks shall include the following: A) System Checks The entire facilities shall be checked against the latest P&ID's, Engineering and Vendor drawings / documents and other design specifications. Any shortcomings observed shall be listed down in the form of punchlists and duly attended. B) Checking of Field Instruments All the field instruments like actuated valves, control valves, shutdown valves, transmitters, solenoid valves, shut down switches, alarms etc. shall be checked physically and also for their intended application by simulating the operating condition. It will also include checking of different meters, gauges, action of actuated valves, control valves, shutdown valves etc. C) Survey of the Pipelines This shall be performed to confirm that proper fittings/supports, Cathodic protection system, route markets, warning signs, fencing around SV stations, crash barriers etc. have been installed along the pipeline. D) Checking of Communication System This is to check that there is proper communication with adequate back-up power to ensure uninterrupted communication. E) Checking of Electrical Distribution System This is to ensure safety and also to ensure an uninterrupted power supply during startup and normal pipeline operation. F) Checking of Instruments, Controls & Interlocks This is to check that instrument controls and interlocks are functional as per the normal operating conditions.




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G) Checking of Utilities This is to check that utilities like power, nitrogen, UPS system, instrument air, etc. are available prior to start-up. H) Any other checks as may be considered necessary. 3.1.2 Dewatering 3.1.2.1 General Dewatering of a pipeline section shall be done subsequent to the hydro-test of the respective pipeline section. During the dewatering operation, the major quantity of hydro-test water shall be removed from the main pipelines and distribution network. It is the responsibility of the contractor to develop suitable dewatering procedure and submit the same for Company's approval. The disposal of the water shall be performed such that no harm is done to the environment and the Dewatering procedure should indicate this disposal methodology. 3.1.2.2 Operational requirements The dewatering operation for pipeline shall consist of a number of dewatering pig runs and dry air shall be used as propellant for pig trains. Bi-directional cup pigs shall be used and will be suitable for traversing the entire length of the pipeline/pipe segment being dewatered. Contractor shall ensure that all the pigs are designed to prevent damage to the pipeline’s internal coating (if any). The contractor shall propose the minimum speed and the backpressure of the pigs in order that continuous operation will be performed without the pig getting stuck. Contractor shall submit all the calculations regarding this procedure and a contingency plan for implementation in case the pigs get stuck. Contractor shall provide a suitable compressor for oil-free air with sufficient capacity and pressure. Upon arrival of the pigs at the receiving end, the Contractor in the presence of Company's representative shall remove the pigs without delay. Flushing of aboveground piping




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Flushing of above ground piping at dispatch and receipt stations, SV stations, hook-up / tap-off points and IP stations shall be done with water to remove debris from within the piping and then with dry air to remove the residual amount of water from the aboveground piping. Acceptance criteria Before proceeding to the next stage of operations, Contractor shall ensure that bulk of the water has been removed from the pipeline system. Contractor shall specify when the dewatering phase (for the underground pipeline) and flushing and dry air blowing (for above ground piping) is finished and shall obtain approval of the company before proceeding to the next phase. 3.1.3 Swabbing 3.1.3.1 General The swabbing operation, which shall be done subsequent to the dewatering operation, is meant to reduce the remaining water in the pipeline to acceptable condition and to ensure removal of free water left inside the pipeline prior to final drying, Inertisation and commissioning of the Pipeline system. This is done by driving number of foam pigs propelled by oil free compressed dry air, which can pick up free water in the pipeline. Hence for swabbing, air compressors of required capacity, after-coolers and dryers should be deployed by the contractor. Contractor may suggest alternate methodology for Swabbing operation. The swabbing activity is precursor for drying of the pipeline and is basically to reduce duration of drying. The contractor shall submit the detailed procedure and the duration of the swabbing operation and obtain approval of the company before starting the operation. 3.1.3.2 Acceptance criteria The Contractor shall ensure that swabbing operation is considered to be completed when it is considered that there is no free water left in the pipeline.This shall be subject to Company’s approval. 3.2 Commissioning related activities




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3.2.1 Drying 3.2.1.1 General The pipeline system including the underground pipeline and the above ground piping at dispatch and receipt stations, SV stations, all Terminal station, CGS/ PRS stations and hook-up / tap-of points needs to be dried prior to charging natural gas. Drying is required to prevent internal corrosion of the pipeline & to meet the supply specification and also as a means of preservation of the pipeline sections subsequent to the precommisisoning activities. The pipeline shall be dried by using super dry air / vacuum method or by any other suitable method. Contractor shall submit the detailed procedure and the duration of the drying operation and obtain Company's approval on the same prior to start of the drying operation. Commissioning contractor shall assess any requirement of swabbing for entire pipeline to reduce the time for drying and shall carryout such activity. 3.2.1.2 Acceptance criteria Contractor shall ensure that drying operation is complete before proceeding to the next step of inertisation. The drying of the pipeline system shall be considered to be achieved on attaining a water dew point of 0°C at atmospheric pressure and this water dew point in pipeline shall be continuously maintained till inertisation or commissioning of the pipeline. 3.2.2 Low Pressure leak check for aboveground piping

3.2.2.1 General The aboveground piping sections of the pipeline system shall be checked for leaks at flange points of piping and equipment, instrument impulse tubing points etc. This shall be done by pressurizing the system piping / equipment with dry compressed air (for this purpose, oil free air compressors shall be used) and testing the system by means of soap solution for leaks. The contractor shall submit the detailed procedure and the duration of the leak check operations and obtain approval of the company before starting the operation. 3.2.2.2 Acceptance criteria



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The leak check operation shall be considered to be completed when the piping 2

system / equipment is free of leaks when tested at a pressure of 6.0 Kg/cm g. This shall be subject to Company’s approval. 3.2.3 Ready for Commissioning After completion of drying activities and safety review prior to startup, Contractor shall notify the Company that the systems associated with the pipeline system including the underground pipeline and the above ground piping at dispatch and receipt stations, SV stations, al Terminal Station, CGS/ PRS stations and hook-up / tap-of points are ready for gas-in/commissioning. 'Ready for commissioning status' shall be jointly reviewed by Company and Contractor and final clearance for start-up shall be given by the Company. After such joint assessment, if all the criteria are met, it will then be declared that the pipeline system has reached a stage of 'Ready for Commissioning'. 3.2.4 Inertisation 3.2.4.1 General Contractor shall carry out inertisation of the entire pipeline system including the underground pipeline and the above ground piping at dispatch and receipt stations, SV stations, IP stations and hook-up / tap-of points). 3.2.4.2 Operational requirements During the Inertisation operation, the dry air left in all the pipeline shall be replaced by dry nitrogen before admitting the natural gas into the pipeline for safe commissioning. Depending on the commissioning plan / strategy, sections of the pipeline system may be taken up for commissioning in steps. One of the suggested methods for Inertisation of the underground pipeline is by the usage of nitrogen slugs separated by pigs. Depending on the length of the pipeline portion to be taken up for commissioning, the amount of the nitrogen used may vary. In general, the totalised length of the nitrogen slug train must be at least 10% of the total length of the pipeline under consideration. The last pig in the pig train shall be propelled by natural gas (during commissioning stage of the pipeline). In case Vacuum drying procedure is adopted, the pipeline can be inertised under vacuum condition, followed by gas charging to reduce the time for commissioning activities.



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For above ground piping at dispatch and receipt stations, SV stations, IP stations and hook-up / tap-of points, the piping shall be purged with nitrogen till the residual oxygen content in the piping is below 1% (vol/vol). Nitrogen required for Inertisation purpose of the pipeline and aboveground piping shall be supplied by the contractor and should be of purity level 99.9% or above. Nitrogen gas at ambient temperatures (AND NOT LIQUID NITROGEN) and in completely vaporized and gaseous state shall be used as the inertising medium. In case the source of gaseous nitrogen is from liquid nitrogen tankers, then all precautions (including verification of the lowest tolerable temperature of all components in the system under commissioning) should be ensured. The contractor shall submit the detailed procedure (in line with the above suggested method or any other acceptable one) and the duration of the inertisation operation and obtain approval of the company before starting the operation. Inertisation shall be followed immediately by charging of pipeline by natural gas. 3.2.4.3 Acceptance Criteria Inertisation of all the pipeline may be accepted to be complete when the required quantity of nitrogen has been introduced into the pipeline. The contractor has to ensure this condition for safe commissioning of the pipeline. For above ground piping at dispatch and receipt stations, SV stations, IP stations and hook-up / tapof points, the inertisation may be accepted to be complete when the residual oxygen content in the piping is below 1% (vol/vol). 3.2.5 Safety review prior to start of Commissioning activities A pre-startup safety review of the pipeline system including the underground pipeline and the above ground piping at dispatch and receipt stations, SV stations, all Terminal stations, CGS/ PRS stations and hook-up / tap-of points shall be carried out by the Contractor before permitting entry of natural gas into the new pipeline facility. Company / Company's representative shall also participate in the pre-startup safety review. 3.2.6 Gas-in/Commissioning and Stabilization 3.2.6.1 General Contractor shall carry out gas-in and commissioning activities of the entire pipeline system including the underground pipeline and the above ground piping at dispatch and receipt stations, SV stations, IP stations and hook-up / tap-of points.



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3.2.6.2 Operational requirements During introduction of natural gas into the pipeline, natural gas shall be the motive fluid for driving the last pig of the nitrogen slug train. The pig train speed shall be maintained at 3 to 4 Km/hr. Maintenance of proper backpressure shall control pig train speed. Venting shall be controlled at the pig-receiving end to achieve the desired dynamics. In this fashion, slowly the desired portion of the pipeline shall be commissioned. Alternatively contractor may propose procedure for introduction of gas in pipeline under vacuum condition after inertisation with Nitrogen. Subsequently, the pipeline system shall be slowly pressurized upto its operating conditions and high pressure leak checks of the pipeline system at flange points, instrument points etc. shall be carried out with soap solution at regular intervals during the course of pressurization of the pipeline system. Once the pipeline system is pressurized at its operating conditions, normal gas flows shall be established in the pipeline system. The contractor shall submit the detailed procedure (in line with the above suggested method or any other acceptable one) and the duration of the commissioning operation and obtain approval of the company before starting the operation. Commissioning shall also include establishing the process control parameters first at turn down & then at design value stipulated in the process package along with supplementary instructions, if any, from Company / Company’s Representative. 3.2.6.3 Acceptance Criteria The system shall be considered to be commissioned successfully when the pipeline system including the underground pipeline and the above ground piping at dispatch and receipt stations, SV stations, all Terminal Station, CGS/ PRS stations and hook-up / tap-of points is charged with natural gas, is free of leaks and run successfully at stable operating conditions with instrumentation / control systems process utilities and support systems taken on line for a minimum period of 72 hours. The commissioning of pipeline system shall include commissioning of branch lines and associated facilities including auxiliary facilities and aboveground piping.

4.0

DOCUMENTATION Contractor shall submit for approval of the Company, the complete description, detailed procedures and time schedule for all of the following activities: • Pre-commissioning checks



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• • • • •

Dewatering Flushing Swabbing Drying Low pressure leak check of aboveground piping system with dry compressed air • Inertisation • Gas in and commissioning activities (including pressurization of pipeline system, high pressure leak check, establishment of flows and 72 hours run). All these documents should be prepared covering all aspects of HSE, quality assurance and quality control plans. Contractor shall ensure that his documents are related to “as-built” conditions of the pipeline and structure involved. Documents shall also contain all safety plans, procedures, to be followed while carrying out the activities. Upon successful completion of the work, contractor shall prepare a final report of the work which shall include necessary charts, diagrams, graphs, calculations, recordings, daily logs, measurements, details of the operation, etc. Report shall also include all certificates of calibration of instruments required, together with records of calibration performed at site prior to the start of any operation and the approved precommissioning and commissioning formats and checksheets. 5.0

SPARES AND CONSUMABLES Contractor shall identify and arrange for supply of manpower, spares, tools, tackles and consumables as required for pre-commissioning and commissioning activities.

6.0

SAFETY Contractor shall follow the safety practices during execution of precommissioning and Commissioning works as detailed in the scope of work. He shall also maintain and follow all safety practices equivalent or better than those being practiced by the industry during pre-commissioning and commissioning activities.



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APPENDIX-I QUESTIONNAIRE {PRIVATE }CLAUSE DESCRIPTION OF CLAUSE NO.

AGREED

NOT REMARKS AGREED

1.0

SCOPE

[ ]

[ ]

2.0

DEFINITIONS

[ ]

[ ]

3.0

MANUFACTURER REPRESENTATIVE

[ ]

[ ]

4.0

DOCUMENT FOR PRECOMMISSIONING AND COMMISSIONING

[ ]

[ ]

5.0

OTHER REQUIREMENTS

[ ]

[ ]

6.0

REVIEW/CHECKLISTING/INSPECTION/COORDINATION

[ ]

[ ]

7.0

COMMISSIONING

[ ]

[ ]

8.0

CONSUMABLES

[ ]

[ ]

9.0

SPECIAL REQUIREMENTS

[ ]

[ ]

10.0

SAFETY

[ ]

[ ]

NOTE: 1) 2)

PLEASE TICK THE RELEVANT BOX. MENTION THE REASON & THE SUB-CLAUSE NOT AGREED IN THE REMARKS COLUMN.



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STANDARD SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDED (LSAW) LINE PIPE (ONSHORE)


SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

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Abbreviations: ASTM

American Society for Testing and Materials

API

American Petroleum Institute

ID

Inside Diameter

LSAW

Longitudinal Seam Submerged Arc Welded

HAZ

Heat Affected Zone

NDT

Non Destructive Testing

NPS

Nominal Pipe Size

OD

Outside Diameter, Specified

WT

Wall Thickness, Specified




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CONTENTS 1

SCOPE

2

REFERENCES

5

PROCESS OF MANUFACTURE AND MATERIAL

6

MATERIAL REQUIREMENTS

7

DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS, AND END FINISHES

9


10

MARKING

11

COATING AND PROTECTION

12

DOCUMENTS

14 (New)

INSPECTIONS OF FIELD TESTS & WARRANTY

APPENDIX-B

REPAIR OF DEFECTS BY WELDING (NORMATIVE)

APPENDIX-C

REPAIR WELDING PROCEDURE (NORMATIVE)

APPENDIX-F

SUPPLEMENTARY REQUIREMENTS (NORMATIVE)

SR 5

FRACTURE TOUGHNESS TESTING (CHARPY V-NOTCH) FOR PIPES OF SIZE 4½ OR LARGER

SR 6

DROP WEIGHT TEAR TESTING ON WELDED PIPE OF SIZE 20 OR LARGER, GRADE X52 OR HIGHER.

SR 19

ADDITIONAL FRACTURE TOUGHNESS REQUIREMENTS (TRANSVERSE CHARPY V-NOTCH) FOR PSL 2 PIPE

APPENDIX-H

PURCHASER INSPECTION (NORMATIVE)

APPENDIX-I

MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE)

ANNEXURE-I

MANUFACTURING PROCEDURE SPECIFICATION

(New) ANNEXURE-II

FIRST DAY PRODUCTION TESTS

(New) ANNEXURE-III

INFORMATION TO BE FURNISHED AT THE TIME OF BIDDING

(New) FIGURE 6.2.6.1

METALLOGRAPHIC SPECIMEN EXTRACTION PLAN

FIGURE 6.2.6.2

LOCATIONS FOR HARDNESS MEASUREMENT

FIGURE 7.8.3

PROCEDURE FOR MEASUREMENT OF OUT OF LINE WELD BEAD

FIGURE9.8.5.2

REFERENCE STANDARD FOR UT OF LONGITUDINAL WELD SEAM




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1.0

SCOPE

1.1

PURPOSE AND COVERAGE This specification establishes the minimum requirements for the manufacture of longitudinal seam submerged arc welded steel line pipe in accordance with the requirements of API (American Petroleum Institute) Specification 5L, Forty-Third Edition, 2004 and makes restrictive amendments/ Supplements to API Spec. 5L. Unless modified and or deleted by this specification, the requirements of API Spec. 5L shall remain applicable. The sections, paragraphs and appendices contained herein have the same numbering as that of API Spec 5L in order to facilitate reference. Additional requirements, which are not specified in API Spec 5L, have also been numbered and marked as "(New)". The coverage by this specification is limited to line pipe to be used in onshore pipelines transporting non-sour hydrocarbons in liquid or gaseous phase. The Manufacturer shall have a valid license to use API Monogram in accordance with the requirements of Specification 5L, Forty-Third Edition, 2004 on line pipe as Product Specification Level PSL 2.

1.2

PRODUCT SPECIFICATION LEVEL (PSL) Line pipe supplied to this specification shall conform to Product Specification Level PSL 2.

1.3

GRADES This specification is applicable to PSL 2 line pipes of grade B through X70.

1.4

DIMENSIONS This specification shall be applied to line pipe of size 16” through 48” (both sizes included)

2.0

References

2.1

The latest editions (edition enforces at the time of issue of enquiry) of following additional references are included in this specification: ASTM ASTM E 92

: Test Method for Vickers Hardness of Metallic Materials.

ASTM E 112

: Standard Test Methods for Determining Average Grain Size.

BS BS 5996

: Specification for the Acceptance Level for Internal Imperfection in Steel Plate, Strip and Wide Flats based on Ultrasonic Testing.

ASME IX ASME B31.8

: Boiler & Pressure Vessel code: Welding & brazing quality. : Gas Transmission & Distribution piping system.




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OISD – 141 API RP 5 L1

: Oil Industries safety distribution piping system : Recommended practice for railroad transmission of line pipe

5.0

Process of Manufacture and Material

5.1

PROCESS OF MANUFACTURE Following paragraphs of API Spec 5L shall be applicable to the line pipe manufactured as per this specification:

5.2

Welding Process

:

Submerged Arc Welding as per para 5.1.2.2.1

Type of Pipe per para 5.1.3.5

:

Longitudinal Seam Submerged Arc Welded Pipe as

Type of Seam Weld para 5.1.4.3

:

Submerged Arc Weld (Longitudinal Seam) as per

COLD EXPANSION All pipes shall be mechanically cold expanded for full length. The expansion measured on the circumference shall range between 0.8 to 1.5% of the value measured before the expansion. The expansion shall be measured and recorded for one out of every 50 pipes.

5.3

MATERIAL Line pipe furnished to this specification shall be made from steel produced in basic oxygen (New) or electric arc furnace. The steel used for manufacture of pines shall be fully killed and fine grained with a grain size of ASTM 7 or finer as per ASTM E 112. Steel shall be made by continuous casting only.

5.4

HEAT TREATMENT The pipes shall be produced from plates/skelp which shall be quenched and tempered or controlled rolled or combined controlled rolled and accelerated cooled to impart uniformly fine ferritic grain structure to the finished steel. Other types of heat treatment shall be agreed upon between Purchaser and Manufacturer.

6.0

Material Requirements

61

CHEMICAL PROPERTIES

6.1.1 Chemical Composition The chemical composition of each heat of steel on product analysis shall be in accordance with Table 2B and notes given below. Table 2B of API Spec 5L is cancelled. GAIL (INDIA) LTD NEW DELHI



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Table - 2B: PSL 2 Chemical Requirements for Heat and Product Analyses by Percentage of Weight Element

Product Analysis (percent by weight )

C

0.16

max.

Mn

1.50

max. (For Grade B

1.60

max. (For Grade X56 to X70)

0.15

min.

Si

0.45

to X52)

max.

S

0.015

max.

P

0.02

max.

Al

0.07

max.

Nb

0.05

max.

V

0.08

max.

Ti

0.04

max. (For Grade B

0.06

toX60)


Cr

0.20

max.

Mo

0.10

max.

Cu

0.35

max.

Ni

0.20

max.

N

0.012

max.

B

0.0005

max.

Note: g (New) i.

V+Nb+Ti shall not exceed 0.1 5%

ii.

Cu-+-Ni shall not exceed 0.40%

iii.

Al/N shall be min. 2

Note: h (New) If alloying elements other than those specified in Table 2B above are added to the steel, the limits of the additional components shall be agreed with the Purchaser. Note: i(New) Minimum for Si is not applicable for Al killed steel.




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6.1.2 Elements Analysed For heat analysis and product analysis, all the elements listed in Table 2B of this specification shall be analysed and reported, even if those are not purposely added but are present as residuals only. 6.1.3

Carbon Equivalent (PSL 2 Only)

6.1.3.1

Calculation of Carbon Equivalent

Boron content shall be considered in CE (PCM) formula even if it is less than 0.0005%. 6.1.3.2

Maximum Carbon Equivalent

For pipes of all grades, size and wall thickness, Carbon Equivalent shall comply with the following limits:

6.2

CE (Pcm )

‫ﮐ‬

0.20 %

CE (IIW )

‫ﮐ‬

0.40 %

MECHANICAL PROPERTIES

6.2.1 Tensile Properties The finished pipe (after all heat treatment and expansion or sizing operations) shall conform to the requirements of Table 3B of API Spec 5L and as modified herein. The actual yield strength shall be as close as possible to the specified minimum yield strength (SMYS) but in no case it shall exceed the limits specified here under; API Spec 5L Grade Up to and including X46

Permissible in excess of SMYS. Psi (MPa) 19,000 (131)

X52 TO X65

22,000(152)

X70 and Above

20.000 (138)

The ratio of body yield strength and body ultimate tensile strength of each test pipe on which body yield strength and body ultimate tensile strength are determined, shall not exceed 0.90, when tested using flattened tensile specimen. The ratio between yield strength and ultimate tensile strength for weld metal of finished expanded pipe shall not exceed 0.90, when tested using cylindrical all weld specimen. The ultimate tensile strength of the weld shall be equal to or better than the specified minimum ultimate tensile strength of the base metal. The minimum elongation of base metal shall be determined in accordance with the formula given in foot note (a) of Table-3B and shall comply with the minimum values of GAIL (INDIA) LTD NEW DELHI



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API Spec 5L. Appendix D. However elongation in no case shall be less than 20%. API Spec 5L, Appendix D stands modified accordingly. 6.2.5

Fracture Toughness Tests

6.2.5.2

Charpy Impact Tests for PSL 2

For all pipe sizes and specified wall thickness, additional fracture toughness requirements as per Supplementary Requirements Appendix-F SR 19 of API Spec 5L and as modified in this specification shall be applicable for body, weld and heat affected zone. 6.2.5.3

Supplementary Fracture Toughness Tests

For pipe of all grades and specified wall thickness, the Charpy V-notch Impact Test for determination of Shear Area in accordance with Supplementary Requirement SR 5A of API Spec 5L and as modified in this specification shall be performed. In addition, whenever line pipes are specified for hydrocarbon service in gaseous phase and Liquefied Petroleum Gas (LPG) service in Purchase Order. Drop Weight Tear Test in accordance with Supplementary Requirements SR 6 of API Spec 5L and as modified in this specification shall be also performed for all pipe size, grade and wall thickness. 6.2.6

Metallographic Examination

6.2.6.1 A test specimen for metallographic & hardness examination shall be taken transverse to the longitudinal weld, from one finished pipe from each lot of 50 pipes per heat or at least once per operating shift (12 hrs maximum) whichever is occurring more frequently and whenever changes of grade, diameter or wall thickness are made and whenever significant excursions from operating heat treatment conditions are encountered. The specimen extraction shall be as per Fig. 6.2.6. 1 of this specification. The specimen shall be suitably ground, polished and etched to reveal the macro-structure. The specimen shall be visually examined using a minimum 10X magnification to provide evidence that proper fusion has been obtained for the full thickness, and there is proper interpretation of passes, their alignment and texture of weld zone. In case imperfections or defects are observed, it will become a cause for re-evaluation of welding parameters and heat treatment as deemed necessary by Purchaser's Representative. 6.2.6.2 Vickers hardness tests shall be carried out on each specimen taken for metallographic examination in accordance with ASTM E-92, at locations indicated in Fig. 6.2.6.2 of this specification i.e. at weld, heat affected zone and body. Indentation in the Heat Affected Zone shall start as close to the fusion line as possible. The resulting Vickers hardness value at any point shall not exceed 248 HV10, Modalities of re-test shall be in accordance with para 9.12.2 of API Spec. 5L. 7

Dimensions, Weights, Lengths, Defects and End Finishes

7.2

DIAMETER Pipe Body

The outside diameter of pipe body, as determined by taping the circumference, shall not deviate by more than the values given below from that given in Table E-6C, Appendix E. API GAIL (INDIA) LTD NEW DELHI



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Spec 5L Table 7 stands modified accordingly. Size

Tolerances

≥16 and < 20

± 3 mm

≥20 and ≤36

+ 3 mm, 0.25% of specified OD

>36

± 3 mm.

Pipe Ends Diameter tolerances for the pipe ends indicated in API Spec 5L Table 8 shall be applicable on the inside diameter. The inside diameter, based on circumferential measurement, over a length of 100 mm from the end shall comply with the tolerances specified in API Spec 5L. Inside diameter is defined as ID = (OD-2WT.) where ID, OD & WT are the inside diameter, specified outside diameter and specified wall thickness respectively. Out of Roundness Out of Roundness i.e., the difference between the maximum and minimum inside diameter at pipe ends, shall not exceed the following: Size

Tolerance

<36” :

0.5%of OD

>36

< 5mm

:

Out of roundness tolerance indicated in API Spec 5L, Table 8 stands deleted. Out of roundness tolerances apply to maximum and minimum diameters as measured with a bar gauge, caliper or device measuring actual maximum and minimum diameter. Each pipe shall be measured for conformance to above requirements. All dimensions and tolerances shall be measured and recorded at least 3 times per operating shift (12 hrs. maximum). 7.3

WALL THICKNESS

In addition to API requirements, the wall thickness of each pipe shall be checked along the circumference at both ends and at the mid location of pipe body at 12 o'clock, 3 o'clock, 6 o'clock and 9 o'clock positions. The wall thickness tolerance shall comply with the requirements of this specification. The tolerances on specified wail thickness shall be (+) 15% and (-) 0%. API Spec 5L Table 9 stands cancelled. Wall thickness shall be measured and recorded at least 3 times per operating shift (12 hours maximum).




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7.5

LENGTH

All pipes shall be supplied with length between 11.5 m and 12.5 m. However pipe with length between 10.0 m and 11.5 m can also be accepted for a max. of 5% of the ordered quantity. The minimum average length of the entire ordered quantity in any case shall be 12.0m. API Spec 5L Table 11 shall not be applicable. Overall length tolerance shall be (-) 'Zero and (+) One pipe length to complete the ordered quantity. Each pipe shall be measured for conformance to above requirements and all measurements shall be recorded. 7.6

STRAIGHTNESS

The deviation from a straight line for all pipe sizes shall not exceed 12 mm. Each pipe shall be checked for conformance to this requirement. Straightness shall be measured and recorded at least 3 times per operating shift (12 hours maximum). 7.7

JOINTERS Jointers on pipes are not permitted.

7.8

WORKMANSHIP AND DEFECTS

7.8.1

Dents

Allowable dent size shall be as per API Spec 5L. Disposition of dents shall be carried out in accordance with API Spec 5L para 9.9 (c) or (d). Dents on weld and heat affected zone (HAZ) are not acceptable. 7.8.2

Offset of Plate Edges

All pipes shall be checked for offset of plate/ skelp edges. Offset shall be measured and recorded at least 3 times per operating shift (12 hours maximum). 7.8.3

Out-of-Line Weld Bead for Pipe with Filler Metal Welds

A misalignment of weld seam exceeding 3.5 mm shall be rejected. The misalignment shall be measured on radiographic film and calculated using the formula (a+b)/2 where 'a’ and 'b' are the relative offsets of the outside edges of the seam (refer Figure 7.8.3 of this specification). All pipes shall be checked for out-of-line weld bead and shall be measured and recorded at least 3 times per operating shift (12 hours maximum). Checking of the weld seam misalignment shall also be carried out on metallographic examination specimen as stated at para 6.2.6, 7.8.4

Height of Outside and Inside Weld Beads - Submerged Arc Welds

The maximum height of outside and inside weld bead shall not be more than 3.2 mm (1/8 in.) for all specified wall thickness. All pipes shall be checked for weld bead height using a template having a cut out for weld bead and shall be measured and recorded at least 3 times per operating shift (12 hours maximum). GAIL (INDIA) LTD NEW DELHI



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7.8.8

Hard Spots

Any hard spot having a minimum dimension greater than 2 in. (50.8 mm) in any direction and hardness greater than 248 HV10 shall be rejected. The section of pipe containing the hard spot shall be removed as a cylinder. 7.8.9

Cracks, Sweats and Leaks

Sections of the pipe containing cracks, sweats and leaks shall be cut off as per the requirement of API Spec 5L para 9.9 (c) or (d). 7.8.10

Laminations

Any lamination or inclusion either extending into the face or bevel of the pipe or present within 25 mm from pipe ends is considered defect and pipe containing such defects shall be cut back until such defects are eliminated. The acceptance limit and disposition of lamination and other type of detects on the plate/skelp shall be as per para 9.8.5.4 of this specification. 7.8.12

Undercuts

Undercutting not classified as minor shall be considered a defect. Disposition shall he as follows: 1. Undercut defects not exceeding 1/32 in. (0.8 mm) in depth and not exceeding 12 ½ % of the specified wall thickness shall be removed by grinding in accordance with API Spec 5L para 9.9 (a) and as modified in this specification. 2. Disposition of undercuts greater in depth than 1/32 in. (0.8 mm) or 12 ½ % of the specified wall thickness shall be in accordance with API Spec 5L para 9.9 (c) or (d). 7.8.14 Other Defects Any imperfection (measured from the surface) with a depth greater than 5% of the specified wall thickness of the pipe shall be considered a defect and shall be repaired in accordance with para 9.9 and as modified in this specification. 7.8. 15 Peaking (New)Deviation from the circular arc at the weld seam at pipe ends shall not exceed 1.6 mm. Each pipe shall be checked for conformance to above requirement. Peaking shall be measured and recorded at least 3 times per operating shift (12 hrs. maximum). Pipes not complying with these requirements shall be disposed off as per API Spec. 5L para 9.9 (c) or (d). 7.9

PIPE ENDS

7.9.1

General Pipes shall be furnished with plain ends.

7.9.3

Plain Ends Unless specified otherwise, the pipe ends shall be bevelled as per API Spec. 5L.

In removing the inside burrs at the pipe ends, care shall be taken not to remove excess metal GAIL (INDIA) LTD NEW DELHI



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and not to form an inside cavity or bevel. Removal of excess metal beyond the minimum wall thickness as indicated in para 7.3 of this specification, shall be a cause for rebevelling. In case root face of bevel is less than that specified, the pipe ends shall be rebevelled and rectification by filing or grinding shall not be done. 7.9.6 Bevel Protectors (New) Both pipe ends of each pipe shall be provided with metallic or high impact plastic bevel protectors as per Manufacturer's standard. Bevel protectors shall be of a design such that they can he re-used by coating applicator for providing on externally anti-corrosion coated pipes subsequent to coating of line pipe. 9.0

Inspection and Testing

9.2

TESTING OF CHEMICAL COMPOSITION

9.2 1 Heat Analysis Where the steel mill is not a part of an integrated pipe mill, heat analysis shall be reported by the Manufacturer prior to start of pipe production. 9.2.2 Product Analysis 9.2.2.1 Sampling Frequency Two pipes per inspection lot shall be analyzed. Inspection lot shall be 100 pipes per heat. Pipes selected shall be such that one at the beginning of the heat and one at the end of the heat are also represented. 9.2.2.2 Sampling Method 9.2.2.2.2 Welded Pipe Samples used for product analysis shall be taken from finished pipes. Samples for product analysis from plate/skelp may be used provided the traceability of samples is guaranteed. 9.3

TESTING OF MECHANICAL PROPERTIES

9.3.1

Tensile Tests

Tensile property shall be determined from specimen removed from pipe which has been subjected to all mechanical operations. 9.3.1.2 Tensile Testing Frequency Tensile tests shall be made at the frequency of one test per inspection lot as shown in Table 13, except as modified below: . Table 13: Maximum Inspection Lot Size for Tensile Testing For Size 12¾”, Weld Tensile Tests (Column 3 of API Spec 5L) Note "a" of Table 13 shall also be applicable.




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9.3.1.4

Transverse Tensile Tests

The transverse tensile tests shall be carried out on flattened rectangular specimen. 9.3.1.5

Weld Tensile Tests

Inside and outside weld reinforcement in excess of pipe wall thickness shall be removed from the specimen either by grinding or machining. Specimen shall be tested for ultimate tensile strength only. A cylindrical all weld tensile test shall be carried out at the time of first day production test as specified in Annexure-II of this specification to determine the yield strength, ultimate tensile strength and elongation. The cylindrical all weld specimen shall have gauge length, L = 5d, where; L = gauge length (mm) D = diameter of the test specimen (mm) The results of the test shall meet the minimum requirements of the plate/skelp with regard to yield, tensile and elongation parameter. 9.3.5


9.3.5.1

Charpy Test Specimens

In addition to the specimen taken from the body of the pipe, three transverse specimens with weld in middle and three transverse specimens with heat affected zone (HAZ) in the middle shall also be taken. 9.3.5.2

Charpy Testing Frequency

The minimum test frequency shall he one test (a set of three specimen each for body, weld and HAZ) per heat per lot of 100 pipes per combination of pipe size and specified wall thickness. 9.4

HYDROSTATIC TESTS

9.4.1

Hydrostatic Test Requirements

Hydro test shall be carried out after cold expansion. Test pressure shall be held for a minimum period of I5 seconds for all sizes and grades of pipes. 9.4.2 Verification of Hydrostatic Teat The pressure gauge used for hydrostatic testing shall have a minimum range of 1.5 times and maximum range of 4 times the test pressure. The pressure gauge shall be calibrated by means of a "Dead Weight" tester only and record shall be maintained. Calibration record shall be GAIL (INDIA) LTD NEW DELHI



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furnished to the purchaser’s representative on request. 9.4.3

Test Pressure

The test pressure for all sizes and grades of pipe shall be such that hoop stress (fibre stress) generated is at least 95% of SMYS, computed based on the formula mentioned in API Spec 5L para 9.4.3 (Note 2). 9.4.5

Burst Test

(New)Burst test shall be done on each type of pipe for each size on lowest thickness. Burst pressure & location of failure shall be recorded. Technical audit shall be carried out by OWNER / OWNER’S representative during manufacturing. Minimum Burst Test pressure shall not be less than the actual tensile stress factor computed pressure. DIMENSIONAL TESTING

9.5

The measuring equipment requiring calibration or verification under the provisions of API Spec 5L shall be calibrated with manual instruments at least once per operating shift (12 hours maximum). Such calibration records shall be furnished to Purchaser's Representative on request. 9.7

VISUAL INSPECTION

All pipes shall be visually examined both externally and internally (to the extent feasible) and shall be free of defects in the finished condition. NON DESTRUCTIVE INSPECTION

9.8

The Purchaser reserves the right to depute its Representative(s) to perform inspection and witness tests in all phases of manufacturing and testing starting from steel making to finished line pipe ready for shipment. Manufacturer shall comply with the provisions regarding inspection notice, plant access, compliance and rejection mentioned in Appendix H of API Spec 5L. The Manufacturer shall give the Purchaser reasonable notice of the starting date of normal production and the work schedule. Any action or omission on part of Purchaser's Representative shall not relieve the Manufacturer of his responsibility and obligation to supply material in strict accordance with this specification. 9.8.1

Qualification of Personnel

All personnel performing NDT activities shall be qualified in the technique applied, in accordance with latest edition of ISO 9712 or ASNT No. ASNT-TC-1A or equivalent. All NDT shall be performed in accordance with written procedures. These procedures shall have prior approval of the Purchaser. Inspector Qualification GAIL (INDIA) LTD NEW DELHI



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Acceptable qualification for NDT inspectors shall be as specified below: i. For UT For UT, at least one level III qualified inspector shall be available to the mill for overall supervision. A level II inspector is required for shift supervision, manual weld inspection and calibration of all systems (both manual and automated). ii.For all other NDT methods Evaluation of indications :

Level I, II, III inspector

Supervision

Level II or Level III inspector (in case evaluation is by Level I inspector)

9.8.3

:

Methods of Inspection Location of NDT equipment in the manufacturer's facility shall be such that final inspection of weld seam of cold expanded pipe shall be performed after cold expansion and hydrotesting. Plate/Skelp Inspection The longitudinal edges of the plate/skelp shall be 100% ultrasonically inspected over a width of at least 25 mm from the trimmed plate/skelp edge. Remaining plate/skelp shall be ultrasonically tested for laminations using an oscillating or straight running pattern of probes, so as to provide inspection coverage of at least 20% of the plate/skelp surface uniformly spread over the area. Locations showing indications above the acceptance limits may be re-examined by manual ultrasonic method. If no defects are located during re-examination, the original findings may be ignored. Additional scanning may be requested by Purchaser's Representative to check questionable areas. Pipe Ends Inspection The full circumference of both ends of each pipe after bevelling shall be 100% ultrasonically tested for laminations from inside over a circumferential band of at least 25 mm width. In addition, full circumference of both ends of each pipe shall be 100 % ultrasonically tested over a circumferential width of at least 50 mm with angular probes to detect cracks. In case of non availability of angular probes at the mill, the full circumference of both ends of each pipe shall be inspected with magnetic particle technique over a circumferential width of at least 50 mm to detect surface cracks. Bevel Inspection Bevel face of all pipes shall be inspected by magnetic particle method to detect defects. Weld Inspection Submerged-arc welds shall be inspected by ultrasonic methods (Refer Table 24) using




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automatic ultrasonic equipment in accordance with API Spec 5L para 9.8.5 and as modified in this specification. Pipe end welds shall be inspected in accordance with Para 9.8.3.1. Locations showing indications above the allowable limits during ultrasonic inspection shall be re-examined by radiography. If during production, repeated ultrasonic indications occur requiring re-inspection by radiography and it appears from radiographs that the nature of defects causing the ultrasonic indications cannot be definitely established, the Manufacturer shall prove by other inspection methods (e.g. by making some cross-sections in accordance with para 6.2.6 of this specification at locations where such indications occur near the end of the pipe) to the satisfaction of Purchaser that these are not injurious defects as stipulated in this specification. 9.8.3.1

Pipe End Weld Inspection

Pipe ends not covered by automatic ultrasonic equipment shall be inspected by manual ultrasonic equipment with same sensitivity and capability as automatic equipment. Submerged-arc weld seam shall be radiographically examined for a minimum distance of 8 in. (200 mm) from each pipe end. The results of radiographic inspection shall be recorded. 9.8.4

Radiological Inspection-Weld Seams

9.8.4.1

Radiological Inspection Equipment

The homogeneity of weld seams examined by radiological methods shall be determined by means of X-rays directed through the weld material in order to create a suitable image on radiographic film. The film used for radiographic inspection of weld seam shall be class 1 or 2 as per Table 2 of ASTM E 94, with minimum density greater than 1.8 measured in connection with radiographic image of the welding and shall be suitable to allow a sensitivity of at least 1 .8 percent of nominal wall thickness. 9.8.4.2

Radiological Sensitivity Reference Standard

The reference standard shall be ISO wire-type image quality indicator described in 9.8.4.4. 9.8.4.8

Defects Observed During Radiological Inspection

Defects in the weld such as cracks, slag inclusions, porosity and defects in the pipe material shall be removed by cutting off the section of pipe containing these defects. The remaining defects-free section of the pipe will be acceptable provided its length is within the specified minimum length, the weld at the new pipe end contains no defects other than those permitted. 9.8.5

Ultrasonic and Electromagnetic Inspection

9.8.5.1

Equipment

All automatic ultrasonic equipment shall have an alarm device, which continuously GAIL (INDIA) LTD NEW DELHI



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monitors the effectiveness of the coupling. The equipment for the automatic inspection shall allow the localization of both longitudinal and transverse defects corresponding to the signals exceeding the acceptance limits of the reference standard. The equipment shall be fitted with a paint spray or automatic marking device and alarm device for areas giving unacceptable ultrasonic indications. All ultrasonic testing equipment shall be provided with recording device. In addition, an automatic weld tracking system shall be provided for correct positioning of the probes with respect to weld centre. 9.8.5.2

Ultrasonic and Electromagnetic Inspection Reference Standards

The reference standard (calibration pipe) shall have the same specified diameter and wall thickness as specified for the production pipe being inspected and shall be of sufficient length to permit calibration of ultrasonic inspection equipment at the speed to be used in normal production. The reference standard (calibration pipe) shall also be of the same material, type and have the same surface finish and heat treatment as the pipe being inspected. The reference standard for weld UT shall contain machined notches/holes as per Figure 9.8.5.2 of this specification and as given below: -

Two longitudinal inside notches of type N 5 at both edges of weld seam.

-

Two longitudinal outside notches of type N5 at both edges of weld seam.

Two longitudinal notches of type N5 at the centre of the weld seam, one outside and one inside. Two transverse notches of type N5 across the weld seam, one outside and one inside. A drilled hole in the centre of the weld seam, of diameter equal to 1.6 mm The reference standard for plate/skelp UT shall contain continuous machined notch of 8 mm width x½ t depth, where ‘t’ is the specified wall thickness. The reference standard for plate/skelp edge UT and pipe ends shall have ¼ inch dia FBH X1/2 t depth, where 't' is the specified wall thickness. The calibration shall be performed at following intervals: a.

At the beginning of each operating shift (12 hours maximum).

b.

At least once during each operating shift (12 hours maximum).

c.

Every time the running of the system gives rise to doubts on its efficiency.

If during the above calibration verification, it is found that the equipment has not functioned satisfactorily in the opinion of the Purchaser's Representative, all the pipes or plate/skelp already inspected after the previous verification shall be inspected again at Manufacturer's cost. 9.8.5.4 Acceptance limits 9.8.5.4.1Plate/Skelp Edges GAIL (INDIA) LTD NEW DELHI



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(New) Acceptance limit for material edge examination shall be as per criteria laid down for Acceptance Level E2 of BS 5996:1993, which is reproduced hereunder for ready reference. 1. No individual imperfection of length less than 20 mm shall be considered for population density assessment. 2.

Maximum length of imperfection in any direction shall not exceed 30 mm.

3.

Maximum area of individual imperfection shall not exceed 500 mm2.

4. Maximum population density (number of imperfections smaller than the maximum permissible imperfection size and longer than 20 mm per 1m length) shall not exceed 4. Disposition of any defect shall be as per API Spec 5L para 9.9 (c) or (d). 9.8.5.4.2

Remaining Plate/Skelp

(New) Acceptance limit for material body examination shall be as per criteria laid down for Acceptance level B4 of BS 5996: 1993 which is reproduced hereunder for ready reference: 1. No individual imperfection that does not exceed all of the following dimensions shall be considered for population density assessment: Area: 300 mm2, Length: 35 mm, Width: 8 mm. (The length is the dimension at right angles to the scan track-and the width is the dimension parallel to the scan track.) 2. Maximum area of any individual discontinuity shall not exceed 1000 mm2. 3. Maximum population density of imperfections smaller than the maximum permissible imperfection size and larger than the minimum imperfection size per I m x 1 m square shall not exceed 10. 4. Any imperfection exceeding 100 mm length shall not be acceptable and any planar imperfection not parallel to the plate surface is not acceptable. Disposition of any defects shall be as per API Spec 5L para 9.9 (c) or (d). 9.8.7

Residual Magnetism Measurement Requirements

The average of the four readings shall not exceed 20 gauss and no one reading shall exceed 25 gauss when measured with Hall-effect gaussmeter. All residual magnetism measurements shall be recorded. 9.9

DISPOSITION OF PIPE CONTAINING DEFECTS

a. The repaired area shall be 100% rechecked by magnetic particle or ultrasonic inspection to ensure complete removal of defects. However for repair of cosmetic type of defects, MPI may not be conducted if so directed by Purchaser's Representative on case to case basis. The pipes having a thickness less than the minimum allowed in accordance with this specification, after repair by grinding shall be treated for disposition in accordance with 9.9 (c) or (d). b.

Repair welding on parent metal is not permitted.

In addition to all NDT requirements random radiography of0.1%the total length shall be done. The area to be radiographed shall be at the sole discretion of the Third Party Inspection GAIL (INDIA) LTD NEW DELHI



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Agency. 9.10

TEST METHODS

9.10.3

Guided-bend Test

One face and one root guided bend weld test shall be made on samples cut from pipe. The frequency of testing shall be same as for tensile test as per para 9.3.1.2 of this specification. The dimension 'A' in guided bend test shall not exceed 4.0 times the thickness of the specimen. 9.10.4

Charpy Test

Individual test value for any specimen shall not be less than 80% of the required minimum average absorbed energy value as per this specification. 9.12

RETESTS

9.12.1

Recheck Analysis

Modalities of recheck analysis shall be as per API Spec. 5L as applicable to the lot being tested (refer para 9.2.2.1 of this specification). However, during individual testing, each pipe shall be fully analyzed to meet the requirements of Table 2B of this specification. 9.12.6

Charpy Retests

In the event that a set of Charpy test specimen fails to meet the acceptance criteria, the manufacturer may elect to replace the lot (refer para 9.3.5.2 of this specification) of material involved or alternatively to test two more lengths from that lot. If both the new tests meet the acceptance criteria, then the entire pipe in that lot, with the exception of the original selected length, shall be considered to meet the requirement. 9.13

REPROCESSING

This para stands cancelled. 10

Marking

10.1

GENERAL

Marking specified in API Paragraphs and otherwise specified in the Purchase Order shall be in English language and International System (SI) of units. Marking shall comply with Appendix I of API Spec 5L, and as modified in this specification. 11

Coating and Protection

11.1

COATINGS

Unless otherwise specified in the Purchase Order, the pipes shall be delivered bare, free of any trace of oil, stain, grease and paint. Varnish coating shall be applied on the marking area. Bevels shall be free of any coating. 12

Documents

12.1

CERTIFICATION




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Manufacturer shall furnish to Purchaser a certificate of compliance stating that the material has been manufactured, sampled, tested, and inspected in accordance with this specification and has been found to meet the requirements. In addition all details as per Appendix F Supplementary Requirement SR 15 shall also be submitted to Purchaser/Purchaser Representative during inspection at pipe mill. 12.2

RETENTION OF RECORDS

In addition to the records indicated in API Spec 5L Table 27, the Manufacturer shall retain the records of all additional tests and calibration records mentioned in this specification including the hard copy records of ultrasonic testing carried out on pipe/plate/skelp as well as pipe ends. 12.3

PRODUCTION REPORT

(New) The Manufacturer shall provide six copies of production report in English language indicating at least the following for each pipe. International System of units (SI) shall be adopted. -

Pipe number

-

Heat number from which pipe is produced

-

Pipe length and weight.

-

Pipe grade

The Manufacturer shall provide six copies of acceptance certificates which shall include the results of all tests required as per this specification and performed on delivered material giving details of, but not limited to, the following: -

All test certificates as per SR 15.1.

-

Records of qualification of welders and procedures for repair welding.

-

Certified reports of dimensional, workmanship and defects inspection.

-

Data on test failures, rejected heats/lots, etc.

-

All other reports and results required as per this specification.

The certificates shall be valid only when signed by the Purchaser's Representative. Only those pipes, which have been certified by the Purchaser's Representative shall be dispatched from the pipe mill. In the event of small quantities of pipes supplied against this specification, like those for bends and other similar applications, as specifically called out in the Purchase Order, the production report may consist of only test certificates required as per SR 15 of API Spec 5L and other test reports/results required as per this specification. 12.4

LINE PIPE TRACEABLITY DATA

(New) The line pipe data shall be provided in MS EXCEL/MS ACCESS format in compact Disc (CD). The specific data to be recorded shall be agreed between Purchaser and the Manufacturer and shall include, but not limited to, the following: GAIL (INDIA) LTD NEW DELHI



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- All marking information - Data of skelp and pipe manufacture - All mechanical properties from test results - All dimensional records - All workmanship and defects inspection records - Final inspection and release date - Description and disposition of repairs - Load-out /dispatch date - Destination - Consignment details. 14

Inspection of Field Test & Warranty

(New) Purchaser shall be reimbursed by Manufacturer for any pipe furnished on this order that fails under field hydrostatic test if such failure is caused by a material/manufacturing defect in the pipe. The reimbursement cost shall include pipe, labour and equipment rental for finding, excavating, cutting out and installation of replaced pipe in position. The field hydrostatic test pressure will not exceed that value which will cause a calculated hoop stress equivalent to 95 percent of specified minimum yield strength. In case Manufacturer so desires, he will be advised at least two weeks in advance so that his Representative may witness the hydrostatic test in field, however, the testing and leak (if any) finding and repair operation shall not be postponed because of absence of the Manufacturer's Representative.




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APPENDIX B REPAIR OF DEFECTS BY WELDING (NORMATIVE) B.I. 2

WELD SEAM OF WELDED PIPE

B. 1.2.1 Repaired welds shall be inspected both by X-ray and UT. B.3

Procedure for Repair of Submerged-Arc and Gas Metal-Are Welds

B.3.1 The defective part of the weld shall be clearly marked on the pipe so that the defect can be easily located and repaired. B.3.2

Following requirements shall also be complied with for repair welding;

a.

No repair of weld seam is permissible after cold expansion.

b.

No repair of weld seam is permissible at pipe ends up to a length of 300 mm.

c. Cumulative length of weld seam repairs on one pipe length shall not exceed 10% of the length of pipe. Maximum two repairs per pipe are allowed. d.

Repair welding shall be executed only after specific approval by Purchaser

Representative for each repair. e.

No repair of a repaired weld is permitted.

f.

The repair weld shall be performed with a minimum of two passes.

B.3.4 (New) The Manufacturer shall also maintain a record of repairs carried out. The records shall include repair number, pipe identification number, welding procedure applicable and NDT details.




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AFPENDIX- C REPAIR WELDING PROCEDURE (NORMATIVE) C.2

Repair Welding Procedure Qualification

C.2.2

Mechanical Testing

C.2.2.3 Transverse Guided-Bend Test The radius of male member of the jig used for guided bend teats shall be RA=2.25 t, where t is specified wall thickness of pipe. C.2.2.5 (New) For all pipes where fracture toughness test is specified, Charpy V-Notch impact test as specified shall be included in the Repair Welding Procedure Qualification. C.2.2.6 (New) Hardness test as specified in para 6.2.6.2 of this specification shall be included in the procedure qualification. The location of the hardness measurements is to be indicated taking into account the new HAZ of the repaired area.




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APPENDIX-F SUPPLEMENTARY REQUIREMENTS (NORMATIVE) SR5

Fracture Toughness Testing (Charpy V-Notch) for Pipe of Size 4 ½ or Larger

SR 5.1 The Manufacturer shall perform Charpy V-notoh test for determining Shear Area. SR 5.3 The specimen shall be full sized or largest obtainable, sub size in case pipeline diameter and thickness does not permit full size specimen. SR 5.4

Flattened specimen shall not be used.

SR 5.5 This para stands deleted. SR 5A

Shear Area

SR 5A.1 Three transverse specimens representing one test shall be taken from one length of pipe per heat per lot of 100 pipes per combination of pipe size and specified wall thickness, SR 5A.2 Unless specified otherwise in the Purchase Order, the specimen shall be tested at +32°F (0°C). The average shear value of the fracture appearance of the three specimen shall not be less than 75% and the all heat average for each order, per diameter, size and grade shall not be less than 80%. Note: The acceptance criteria of shear area as referred in API Spec. 5L para SR 5A.3 SR 5A.4 and SR 5A.5 stand modified based on above mentioned requirements. Wherever 'heat’ indicated in API Spec 5L.SR 5A.3, SR 5A.4, SR 5A.5 and SR 5A.6 shall be replaced by Mot'. Lot shall be as per SR5A.1 as above. SR6

Drop Weight Tear Testing (DWTT) on Welded Pipe

SR6.1 When required as per para 6.2.5.3 of this specification, fracture toughness for all pipe size, grades and specified wall thickness shall be determined using Drop Weight Tear Test (DWTT) by the Manufacturer in accordance with the requirements of SR 6.2 thru SR 6.8 of API Spec 5L and as modified in this specification. SR 6.2 Two transverse specimen shall be taken from one length of pipe per heat per lot of 100 pipes per combination of pipe size and specified wall thickness. Unless specified otherwise, the test shall be conducted at +32°F (0°C). SR 6.4 At least 80% of the heats shall exhibit a fracture appearance shear area of 75% or mare for the specified test temperature. Note: Acceptance criteria for retesting indicated in API Spec 5L para SR 6.5 stands modified based on above mentioned requirements. Wherever 'heat' indicated in API Spec SR6.5 shall be replaced by Hot'. Lot shall be as per SR6.2 as above. SR19 Additional Fracture Toughness Requirements (Transverse Charpy V-Notch) for PSL 2 Pipe SR 19.1 Except as allowed by SR 19.2 of API Spec 5L,, fracture toughness testing shall be performed in accordance with the requirements of para 9.3.5.1 and 9.3.5.2 of API Spec 5L and GAIL (INDIA) LTD NEW DELHI



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as modified in this specification, with a test temperature of 32°F (0°C) or at a lower temperature as specified in the Purchase Order. The required minimum all heat average full size absorbed energy value (based on a set of three specimens) for transverse body specimen shall be the greater of SR 19.1 (a) and SR 19.1 (b) of API Spec 5L. In case longitudinal specimen is applicable as per Table 14 of API Spec. SL, the minimum average absorbed energy value shall be 1.5 times that applicable for transverse specimen. The required minimum average full size absorbed energy value for weld and HAZ specimen shall also be the greater of SR 19.1 (a) and SR 19.1 (b) of API Spec 5L. In addition, the lowest individual absorbed energy value of the three specimens shall not be less than 80% of the value specified.




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APPENDIX-H PURCHASER INSPECTION (NORMATIVE) H.4

Rejection If Purchaser Representative rejects pipes repeatedly for any recurring cause, tins shall be adequate reason to refuse final inspection of subsequent pipes until the cause has been investigated and corrective action taken by the Manufacturer.




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APPENDIX-I MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE) 1.1

General

1.1.1 Marking shall also include API monogram, Purchase Order number, item number, pipe number, wall thickness (mm), heat number and weight. 1.2

Location of Markings Marking shall be paint stenciled on length of the pipe at right angles to the pipe axis. Stencil marking shall be placed on the inside surface length except that on pipe size smaller than 16, marking may either be placed on inside or outside. Paint used for stencil marking shall withstand a temperature up to 250°C expected to be experienced during further external anti-corrosion coating operations of line pipe by coating applicator.

1.3

Sequence of Marking

1.3.4 Specified Dimensions: Actual pipe weight in kg shall also be marked. 1.3.5 Grades and Class: A colour code band shall be marked on inside surface of finished pipe for identification of pipes of same diameter but different wall thickness, as indicated in the Purchase Order. The colour code band shall be 50 mm wide and shall be marked at a distance of 150 mm from the pipe ends. 1.5

Length Actual length shall be marked in metres.

1.7

Die Stamping Additionally, the pipe number shall be placed by cold rolling or tow stress dot marking on the outside surface of the pipe at an approximate distance of 50 mm from both ends. In case of non-availability of either cold rolling or low stress dot marking facility in pipe mill, an alternative marking scheme of a permanent nature may be proposed by the Manufacturer.




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ANNEXURE I (NEW) MANUFACTURING PROCEDURE SPECIFICATION A Manufacturing Procedure Specification (MPS) outlining the successive steps and associated inspection procedures from steel making to finished line pipe shall be prepared and submitted to Purchaser for approval prior to start of production. Manufacture of pipes shall start only after the approval of Manufacturing Procedure. The approved Manufacturing Procedure shall be strictly followed in all phases of the production of pipes. The manufacturing procedure shall as a minimum include the following information. - Steel/Plate/skelp maker and plant at which steel is produced. - Steel making process with details of secondary refining process and continuous casting process, nominal weight of each heat. - Target chemistry, range of intentionally added elements, limits on heat and product analysis to be placed on steel maker. - Plate/skelp rolling procedure indicating number of passes, their temperature and thickness reduction in each pass required by Controlled Rolling Procedure and the finishing temperature. - Heat treatment procedure document established as per para 5.4. - Ultrasonic testing of plates/skelp and pipes using automatic and manual equipment including details of equipment, techniques, scanning pattern, probe frequency, scanning sensitivity, reference standard for calibration, dynamic calibration procedure, method of marking defects and indicating loss of coupling, inspection and recording. - Pipe making procedure including plate edge preparation, forming and any other special process proposed. - Welding procedure specification including the details of welding process, brand name, classification, size and grade of filler metal and flux, speed of welding, number of electrodes and polarity of each electrode, welding current and voltage for each wire, edge preparation, tack welding method and spacing of tack weld, details of seam tracking system for both inside and outside welding, method of checking the setup of the system, limits of internal and external weld reinforcement etc. GAIL (INDIA) LTD NEW DELHI



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In addition to the WPS carried out at mill WPS & PQR shall be carried out at the pipe mill by approved welders of the EPC Contractor to establish the weldability of pipe. EPC Contractor accordingly arrange for the welders to carry out the WPS / PQR at the pipe mill. Establishing the WPS of pipe mill doesn’t absolve the EPC contractor of his responsibility of carrying out WPS / PWR at site. - Method of weld defect removal. - Detailed methodology of cold expansion. - Ultrasonic testing of longitudinal weld seam of pipe using automatic equipment including details of equipment, scanning pattern, probe frequency, scanning sensitivity, calibration pipe, extent of weld length at pipe ends not covered by all probes, method of marking defect and indicating loss of coupling, inspection and records. - Full details of radiographic testing equipment including radiographic film. - Dimensional tolerances, frequency of checking, measurement and record in a tabular form including details of instruments and equipments proposed. - Detail of techniques proposed for measurement of end square ness and peaking at the welds. - Hydrostatic testing including details of testing equipment, procedure and the relevant test pressure calculations. - Marking details. - Handling, storage and shipment procedure. - Production Report Formats. - Complete details of computerized pipe tracking system. Note: In the event of small quantities of pipe ordered against this specification, the requirements of submission of manufacturing procedure details can be moderated subject to agreement between Purchaser and Manufacturer.




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ANNEXURK -II(NEW) FIRST DAY PRODUCTION TESTS Two lengths each of completely finished pipes of first day's production from two different heats (i.e. a total of four pipe lengths) shall be selected at random for testing to verify that the manufacturing procedure results in the quality of pipes which are in complete compliance with this specification. The pipes thus tested shall be considered to be the test pipes required per heat or per lot as per relevant clauses of this specification. These first day's production tests shall be repeated upon any change in the manufacturing procedure as deemed necessary by Purchaser Representative. The first day production tests shall be carried out on pipes for each wall thickness, each diameter and each grade of steel. In addition ,change of width of coil shall also call for first day production tests. The Manufacturer shall submit to Purchaser a report giving the results of all tests mentioned below. The report shall be agreed and signed by Purchaser Representative, prior to start of regular production. Note: In the event of small quantities of pipes ordered against this specification, like those for bends and other similar applications, as specifically called out in the Purchase Order, the first day production test shall not be carried out. Pipes in such case shall be accepted based on regular production tests. The various tests to be conducted on each pipe shall be as follows. The test method and acceptance values shall be as per this specification unless specified differently in this Annexure. a. Visual Examination All pipes shall be examined visually for dimensional tolerances and apparent surface defects. b. Ultrasonic Examination The weld seam of all pipes shall be examined ultrasonically by automatic ultrasonic equipment. All ultrasonic indications suggesting imperfections in the weld shall be carefully investigated against the corresponding points on the radiographs. If the ultrasonic indication cannot be fully explained from the radiograph, a cross section of the weld, at the location of the abovementioned ultrasonic indication shall be made in such a way that the nature of the imperfection can definitely be established. c. Radiographic Examination The weld seam of all pipes shall be examined radiographically for the entire length. d. Mechanical Properties The mechanical properties of all pipes shall be tested and shall meet the requirements of this specification. Purchaser Representative will select the places in pipe from where the test specimen shall be removed.




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The following tests shall be conducted: i. Four (4) weld guided bend test specimen transverse to the longitudinal weld shall be removed. Of the four specimens, two specimens shall be used for the face bend test and two for the root bend test. ii. Tensile tests shall be conducted on: -

Two (2) transverse base material specimens.

-

Two (2) transverse weld material specimen of the longitudinal weld.

-

Two (2) cylindrical all-weld specimen of the longitudinal weld.

iii. Six (6) weld cross-section specimen, three (3) from each end of pipe joint shall be taken for metallographic examination. Two of these specimens shall be tested for hardness at room temperature after etching. iv. Fracture toughness testing specimen shall be extracted as follows: -

Four sets of three transverse specimen each from base metal

-

One set of 3 transverse specimen with weld in middle

-

One set of 3 transverse specimen with HAZ in middle

The base metal specimen shall be tested at - 40, -10, 0, + 20° C for shear area and absorbed energy to produce full transition curve. The value at the test temperature specified in SR 5A and SR 19 of API Spec. 5L and duly modified in this specification for shear area and absorbed energy respectively shall be complied with. For other temperatures, the value shall be for information only. The sets of weld and HAZ specimen shall be tested for absorbed energy only at the same test temperature applicable as per SR 19 of API Spec. 5L. v. At points selected by Purchaser, twelve (12) DWTT specimens shall be removed from base metal in a transverse direction. The sets of 3 base metal specimen shall be tested at -40, 10, 0, +20°C for shear area to produce full transition curve. The value at the test temperature specified in SR 6 of API Spec 5L duly modified in this specification shall be complied with. For other temperatures, the value shall be for information only. (Note: This test is to be carried out only when required as per para 6.2.5.3 of this specification) vi. Hardness test shall be conducted on selected pipes as per requirement of para 6.2.6 of this specification. e. In addition, all the tests and inspections require to be conducted as per this specification shall be conducted on all the pipes selected for testing during first day production test. f. In case of any test failure, no re-testing shall be applied and the entire first day production shall be rejected.




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ANNEXURE III (NEW) INFORMATION TO BE FURNISHED AT THE TIME OF BIDDING The following information as applicable shall be furnished at Bid stage with respect to line pipe to be supplied. - Name(s) of proposed Manufacturer(s) - Authorization letter(s) from Manufacturer(s) where applicable. - Authorization letter(s) from Manufacturer(s) of steel plates, in case plate manufacturing facility is not an integral part of the Supplier’s pipe mill. - Record of similar supplies made earlier by the Manufacturer for both plates and pipes, giving complete details of diameter, thickness, length, grade of plate / pipe, service, year, name of project, name of client, and contact person. In particular, details of similar supplies made over the last five years shall be furnished. Descriptive technical catalog(s) of the proposed Manufacturer(s). - Copy of valid certificate of Authority to use API monogram as per clause 1.2 of this specification. - A clause wise list of technical deviations, if any, from the requirements of this specification shall be furnished in the Performa enclosed with the Enquiry. Deviations indicated anywhere else in the offer shall not be considered valid. In case of no deviations, Bidder shall write “NO DEVIATIONS” in the said performa.




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FIGURE: 6.2.6.1 METALLOGRAPHIC SPECIMEN EXTRACTION PLAN




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FIGURE: 7.8.3 X-RAY FILM PROCIDURE FOR MEASUREMENT OF OUT OF LINE WELD BEAD




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SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDED (HSAW) LINE PIPE (ONSHORE)


SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)


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Abbreviations: ASTM


API


ID

Inside Diameter

HSAW

Helical Seam Submerged Arc Welded

HAZ

Heat Affected Zone

NDT


NPS

Nominal Pipe Size

OD


WT





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CONTENTS 1

SCOPE

2

REFERENCES

5


6


7


9


10

MARKING

11


12

DOCUMENTS

14

(New) INSPECTIONS OF FIELD TESTS & WARRANTY

APPENDIX-B

REPAIR OF DEFECTS BY WELDING (NORMATIVE)

APPENDIX-C

REPAIR WELDING PROCEDUR (NORMATIVE)

APPENDIX-F


SR 5

FRACTURE TOUGHNESS TESTING (CHARPY V-NOTCH) FOR PIPES OF SIZE 4½ OR LARGER

SR 6

DROP WEIGHT TEAR TESTING ON WELDED PIPE OF SIZE 20 OR LARGER, GRADE X52 OR HIGHER.

SR 7

ADDITIONAL FRACTURE TOUGHNESS REQUIREMENTS (TRANSVERSE CHARPY V-NOTCH) FOR

PSL 2 PIPE APPENDIX-H


APPENDIX-I

MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE)




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ANNEXURE-I

MANUFACTURING PROCEDURE SPECIFICATION

ANNEXURE-II

FIRST DAY PRODUCTION TESTS (New)

FIGURE 6.2.6.1

METALLOGRAPHIC SPECIMEN EXTRACTION PLAN

FIGURE 6.2.6.2

LOCATIONS FOR HARDNESS MEASUREMENT

FIGURE 7.8.3

PROCEDURE FOR MEASUREMENT OF OUT OF LINE WELD BEAD

FIGURE9.8.5.2 SEAM

REFERENCE STANDARD FOR UT OF LONGITUDINAL WELD




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1.

SCOPE

1.1

PURPOSE AND COVERAGE This specification establishes the minimum requirements for the manufacture of helical (spiral) seam submerged arc welded steel line pipe in accordance with the requirements of API (American Petroleum Institute) Specification 5L, Forty-Third Edition, 2004 and makes restrictive amendments to API Spec. 5L. Unless modified and or deleted by this specification, the requirements of API Spec. 5L shall remain applicable. The sections, paragraphs and appendices contained herein have the same numbering that of API Spec 5L in order to facilitate reference. Additional requirements, which are not specified in API Spec 5L, have also been numbered and marked as "(New)". The coverage by this specification is limited to line pipe to be used in onshore pipelines transporting non-sour hydrocarbons in liquid or gaseous phase. The Manufacturer shall have a valid license to use API Monogram in accordance with the requirements of API Spec. 5L, Forty-Third Edition, 2004 on line pipe as Product Specification Level PSL 2.

1.2

PRODUCT SPECIFICATION LEVEL (PSL) Line pipe supplied to this specification shall conform to Product Specification Level PSL

2. 1.3

GRADE This specification is applicable to PSL 2 line pipes of grade B through X70.

1.4

DIMENSIONS This specification shall be applied to line pipe of size 18 through 48 (both sizes included)

2.0

References

2.1

The latest edition (edition enforce at the time of issue of enquiry) of following additional references are included in this specification: ASTM E 92

:

Test Method for Vickers Hardness of Metallic Materials.

ASTM R 112

:

Standard Test Methods for Determining Average Grain Size.

BS 5996

:

Specification


for

the


Acceptance

Level


for

Internal

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Imperfection in Steel Plate, Strip and Wide Flats, based on Ultrasonic Testing. ASME IX

:

ASME B31.8

:

Gas Transmission & Distribution piping system.

OISD – 141

:

Oil Industries safety distribution piping system

:

Recommended practice for railroad transmission of line pip

API RP 5 L1 5

Boiler & Pressure Vessel code: Welding & brazing quality.


Following paragraphs of API Spec 5L shall be applicable to the line pipe manufactured as per this specification: Welding Process

: Submerged Arc Welding as per para 5.1.2.2.1

Type of Pipe

: Helical Seam Submerged Arc Welded Pipe as per para 5. 1.3.11

Type of Seam Weld

: Submerged Arc Weld (Helical Seam) as per para 5.1.4.3

A manufacturing procedure specification (MPS) as described in Annexure-I of this specification shall be prepared and submitted to purchaser for approval prior to start of production. 5.1.2.2.1

Submerged Arc Welding Process The submerged arc welding equipment shall have an automatic weld tracking system capable of ensuring accurate positioning of welding head and the welding edges of the skelp.

5.2

COLD EXPANSION Pipes furnished to this specification shall be non-expanded.

5.3

MATERIAL

5.3.3

(New) GAIL (INDIA) LTD NEW DELHI



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Line pipe furnished to this specification shall be made from steel produced in basic oxygen or electric arc furnace. The steel used for manufacture of pipe shall be fully killed and fine grained with a grain size of ASTM 7 or finer as per ASTM B 112. Steel shall be made by continuous casting only. 5.4

HEAT TREATMENT The pipes shall be produced from skelp which shall be quenched and tempered or controlled rolled or combined controlled rolled and accelerated cooled to impart uniformly fine ferritic grain structure to the finished steel. Other types of heat treatment shall be agreed upon between Purchaser and Manufacturer.

5.5

SKELP END WELDS IN HELICAL SEAM PIPE Junctions of skelp end weld and helical seam welds in finished pipe are not permitted.

6


6.1

CHEMICAL PROPERTIES

6.1.1

Chemical Composition The chemical composition of each heat of steel on product analysis shall be in accordance with Table 2B and notes given below. Table 2B of API Spec 5L is cancelled. Table - 2B: PSL 2 Chemical Requirements for Heat and Product Analyses by Percentage of Weight Element

Product Analysis (percent by weight)

C

0.16

max

Mn

1.50

max. (For Grade B to X52)

1.60 Si

max (For Grade X56 to X70)

0.15

min

0.45

max

S

0.015

max

P

0.02

max

0.07

max

Al GAIL (INDIA) LTD NEW DELHI



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Nb

0.05

max.

V

0.08

max.

Ti

0.04

max. (For Grade B

0.06


Cr

0.20

max.

Mo

0.10

max.

Cu

0.35

max

Ni

0.20

max

N

0.012

max

B

0.0005

to X60)

max

Note: g (New) i. V+Nb +Ti shall not exceed 0.15% ii. Cu+Ni shall not exceed 0.40% iii. Al/N shall be min. 2 Note:

h (New)

If alloying elements other than those specified in Table 2B above are added to the steel, the limits of the additional components shall be agreed with the Purchaser. Note: i (New) Minimum for Si is not applicable for Al killed steel. 6.1.2 Elements Analysed For heat analysis and product analysis, all the elements listed in Table 2B of this specification shall be analyzed and reported, even if those are not purposely added but are present as residuals only. 6.1.3

Carbon Equivalent (PSL 2 Only) GAIL (INDIA) LTD NEW DELHI



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6.1.3.1 Calculation of Carbon Equivalent Boron content shall be considered in CE (PCM) formula even if it is less than 0.0005%. 6.1.3.2

Maximum Carbon Equivalent For pipes of all grades, size and wall thickness, Carbon Equivalent shall comply with the following limits:

6.2 6.2.1

CE (Pcm)

≤

0.20

CE (IIW)

≤

0.40

MECHANICAL PROPERTIES Tensile Properties The finished pipe shall conform to the requirements of Table 3B of API Spec 5L and as modified herein. The actual yield strength shall be as close as possible to the specified minimum yield strength (SMYS) but in no case it shall exceed the limits specified here under: API Spec 5 L Grade Up to and including X46 X52 to X65 X70 and above

Permissible in excess of SMYS. psi (MPa) 19,000 (131) 22,000(152) 20,000(138)

The ratio of body yield strength and body ultimate tensile strength of each test pipe on which body yield strength and body ultimate tensile strength are determined, shall not exceed 0.90, when tested using flattened tensile specimen. The ratio between yield strength and ultimate tensile strength for weld metal of finished pipe shall not exceed 0.90, when tested using cylindrical all weld specimen. The ultimate tensile strength of the weld shall be equal to or better than the specified minimum ultimate tensile strength of the base metal. The minimum elongation of base metal shall be determined in accordance with the formula given in foot note (a) of Table-3B and shall comply with the minimum values of API Spec 5L Appendix D. However elongation in no case shall be less than 20%. API Spec 5L Appendix D stands modified accordingly. GAIL (INDIA) LTD NEW DELHI



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6.2.5


6.2.5.2


f. (New) For all pipe sizes and specified wall thickness, additional fracture toughness requirements as per Supplementary Requirements Appendix-F SR 19 of API Spec 5L and as modified in this specification shall be applicable for body, weld and heat affected zone. 6.2.5.3

Supplementary Fracture Toughness Tests For pipe of all grades and specified wall thickness, the Charpy V-notch Impact Test for determination of Shear Area, in accordance with Supplementary Requirement SR 5A of API' Spec 5L and as modified in this specification shall be performed. In addition, whenever line pipes are specified for hydrocarbon service in gaseous phase and Liquefied Petroleum Gas (LPG) service in Purchase Order, Drop Weight Tear Test in accordance with Supplementary Requirements SR 6 of API Spec 5L and as modified in this specification shall be also performed for all pipe size, grade and wall thickness.

6.2.6


6.2.6.1(New) A test specimen for metallographic & hardness examination shall be taken transverse to the helical weld, from one finished pipe from each lot of 50 pipes per heat or at least once per operating shift (12 hrs maximum) whichever is occurring more frequently and whenever changes of grade, diameter or wall thickness are made and whenever significant excursions from operating heat treatment conditions are encountered. The specimen extraction shall be as per Fig. 6.2.6.1 of this specification. The specimen shall be suitably ground, polished and etched to reveal the macro-structure. The specimen shall be visually examined using a minimum 10X magnification to provide evidence that proper fusion has been obtained for the full thickness, and there is proper interpretation of passes, their alignment and texture of weld zone. In case imperfections or defects are observed, it will become a cause for re-evaluation of welding parameters and heat treatment as deemed necessary by Purchaser's Representative. 6.2.6.2(New) Vickers hardness tests shall be carried out on each specimen taken for metallographic examination in accordance with ASTM E-92, at locations indicated in Fig. 6.2.6.2 of this specification i.e. at weld, heat affected zone and body. Indentation in the Heat Affected Zone shall start as close to the fusion line as possible. The resulting Vickers hardness GAIL (INDIA) LTD NEW DELHI



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value at any point shall not exceed 248 HV10. Modalities of retest shall be in accordance with para 9.12.2 of API Spec. 5L. 6.2.7

Residual Stress Test (New) Helical pipes shall meet the testing and minimum acceptance criteria set forth in this paragraph. The residual stress test shall be carried out on the pipe after hydrostatic test.

6.2.7.1

Testing Frequency (New) One test shall be carried out at the beginning of each shift. Minimum of one test shall be carried out for pipes of each grade, size and specified wall thickness. In addition, whenever the production line settings are changed, the first produced pipe shall be tested for residual stress.

6.2.7.2

Test Specimen (New) The teat specimen shall be 150mm wide ring cut from one end of the pipe. The specimen shall either be cut using flame cutting torch or by sawing from the parent pipe.

6.2.7.3

Testing (New) The specimen ring shall be severed by flame cutting or sawing parallel to the longitudinal axis of the pipe. The cut shall be 180 degree from the spiral weld. (Specimen ring shall be allowed to cool down to ambient temperature prior to cutting)

6.2.7.4

Computation of Residual Stress (New) The increase in circumference, if any, after severing shall be measured using fiducial marks of known separation on the specimen prior to severing. The residual stress then shall be calculated using following formula. S = {(E*t*C)/(12.556 *R2)}-{(F*R2)/t} Where: S

-

Residual Stress, kPa (psi)

C

-

Increase in circumference, mm (in)

t

-

Specified wall thickness, mm (in)

E

-

Young's Modulus of Elasticity, 2 x 108kPa, (29 x 106psi)




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6.2.7.5

R

-

Pipe Radius, mm (0.5 * Specified outside diameter), mm (in)

F

-

0.1154 in SI units, (0.425 in conventional units)

Acceptance Criteria (New) The computed residual stress shall not exceed 10% of the Specified Minimum Yield Stress (SMYS) of the pipe.

6.2.7.6

Retests (New) If any specimen fails to meet the requirements of paragraph 6.2.7.5 above, the pipe may be retested once. The retest specimen shall be obtained from the same end of the pipe from where the failed specimen was obtained. If the results obtained from the retest specimen are acceptable, normal test schedule shall be resumed. If the results obtained from retest specimen are not acceptable, the pipe shall be rejected and testing shall resume on the next pipe in the production line. If this test also fails all pipes back to the last acceptable test shall be individually tested and those pipes which pass the test shall be accepted. All pipes that fail to pass the test shall be rejected. The manufacturer shall evaluate the reasons for the failure of the test and rectify the same prior to start of production again. The regular production shall be resumed only after acceptable test result is achieved.

6.2.7.7 Reporting (New) All residual stress result shall be recorded as part of the mill report. 7


7.2

DIAMETER Pipe Body The outside diameter of pipe body, as determined by taping the circumference, shall not deviate by more than the values given below from that given in Table E-6C, Appendix E. API Spec 5L, Table 7 stands modified accordingly. Size

Tolerance

18

± 3mm

> 20 and <36 >36 GAIL (INDIA) LTD NEW DELHI

+ 3 mm, - 0.25% of specified OD ± 3mm. SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)


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Pipe Ends Diameter tolerances for the pipe ends indicated in API Spec 5L Table 8 shall be applicable on the inside diameter. The inside diameter, based on circumferential measurement over a length of 100 mm from the end shall comply with the tolerances specified in API Spec 5L. Inside diameter is defined as ID = (OD-2WT.) where ID, OD & WT are the inside diameter, specified outside diameter and specified wall thickness respectively. Out of Roundness Out of Roundness i.e., the difference between the maximum and minimum inside diameter at pipe ends shall not exceed the following: Size

Tolerance

≤36

:

0.5% of OD

>36

:

<5 mm

Out of roundness tolerance indicated in API Spec 5L, Table 8 stands deleted. Out of roundness tolerances apply to maximum and minimum diameters as measured with a bar gauge, caliper or device measuring actual maximum and minimum diameter. Each pipe shall be measured for conformance to above requirements. All dimensions and tolerances shall be measured and recorded at least 3 times per operating shift (12 hrs. maximum). 7.4

WALL THICKNESS In addition to API requirements, the wall thickness of each pipe shall be checked along the circumference at both ends and at the mid location of pipe body at 12 o'clock, 3 o’clock, 6 o'clock and 9 o'clock positions. The wall thickness tolerance shall comply with the requirements of this specification. The tolerances on specified wall thickness shall be (+) 15% and (-) 0%. API Spec 5L Table 9 stands cancelled. Wall thickness shall be measured and recorded at least 3 times per operating shift (12 hours maximum).

7.5

LENGTH All pipes shall be supplied with length between 11.5 m and 12.5 m. However pipe with GAIL (INDIA) LTD NEW DELHI



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length between 10.0mand 11.5 m can also be accepted for a max. of 5% of the ordered quantity. The minimum average length of the entire ordered quantity in any case shall be 12.0 m. API Spec 5L Table 11 shall not be applicable. Overall length tolerance shall be (-) Zero and (+) One pipe length to complete the ordered quantity. Each pipe shall be measured for conformance to above requirements and all measurements shall be recorded. 7.6

STRAIGHTNESS The deviation from a straight line for all pipe sizes shall not exceed 12 mm. Each pipe shall be checked for conformance to this requirement. Straightness shall be measured and recorded at least 3 times per operating shift (12 hours maximum).

7.7


7.8 7.8.1

WORKMANSHIP AND DEFECTS Dents Allowable dent size shall be as per API Spec 5L. Disposition of dents shall be carried out in accordance with API Spec 5L para 9.9 (c) or (d). Dents on weld and heat affected zone (HAZ) are not acceptable.

7.8.2

Offset of Plate Edges Forming and welding operations shall be conducted to minimize coil edge offset and distortion and peaking at the helical or spiral seams. The manufacturer shall provide the appropriate tooling with 'Vee’ blocks and calibrated dial indicators needed to measure the distortion and misalignment at the seam. All pipes shall be checked for offset of skelp edges. Offset shall be measured and recorded at least 3 times per operating shift (12 hours maximum). Measurements shall be taken at two locations (at a distance of one to two diameters from each end) on each pipe joint. In case of unacceptable offsets, the manufacturer shall adjust the forming and welding equipment.

7.8.3

Out-of-Line Weld Bead for Pipe with Filler Metal Welds A misalignment of weld seam exceeding 3.5 mm shall be rejected. The misalignment shall be measured on radiographic film and calculated using the formula (a+b)/2 where ‘a’ and ‘b' are the relative offsets of the outside edges of the seam (refer Figure 7.8.3 of this specification). All pipes shall be checked for out-of-line weld bead and shall be GAIL (INDIA) LTD NEW DELHI



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measured and recorded at least 3 times per operating shift (12 hours maximum). Checking of the weld seam misalignment shall also be carried out on metallographic examination specimen as stated at para 6.2.6. 7.8.4

Height of Outside and Inside Weld Beads - Submerged Arc Welds The maximum height of outside and inside weld bead shall not be more than 3.2 mm (1/8 in.) for all specified wall thickness. All pipes shall be checked for weld bead height using a template having a cut out for weld bead and shall be measured and recorded at least 3 times per operating shift (12 hours maximum).

7.8.8

Hard Spots Any hard spot having a minimum dimension greater than 2 in. (50.8 mm) in any direction and hardness greater than 248 HV10 shall be rejected. The section of pipe containing the hard spot shall be removed as a cylinder.

7.8.9

Cracks, Sweats and Leaks

:

Sections of the pipe containing cracks, sweats and leaks shall be cut off as per the requirement of API Spec 5L para 9.9 (c) or (d). 7.8.10

Laminations Any lamination or inclusion either extending into the face or bevel of the pipe or present within 25mm from pipe ends is considered defect and pipe containing such defects shall be cut back until such defects are eliminated. The acceptance limit and disposition of lamination and other type of defects on the skelp shall be as per para 9.8.5.4 of this specification.

7.8.12

Undercuts Undercutting not classified as minor shall be considered a defect. Disposition shall be as follows: 1. Undercut defects not exceeding 1/32 in. (0.8 mm) in depth and not exceeding 12½% of the specified wall thickness shall be removed by grinding in accordance with API Spec 5L para 9.9 (a) and as modified in this specification. 2. Disposition of undercuts greater in depth than 1/32 in. (0.8 mm) or 12½% of the specified wall thickness shall be in accordance with API Spec 5L para 9.9 (c) or (d).

7.8.14 Other Defects GAIL (INDIA) LTD NEW DELHI



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Any imperfection (measured from the surface) with a depth greater than 5% of the specified wall thickness of the pipe shall be considered a defect and shall be repaired in accordance with para 9.9 and as modified in this specification. 7.8.15

Peaking (New) Deviation from the circular arc at the weld seam at pipe ends shall not exceed 1.6 mm. Each pipe shall be checked for conformance to above requirement. Peaking shall be measured and recorded at least 3 times per operating shift (12 hrs. maximum). Pipes not complying to these requirements shall be disposed off as per API Spec. 5L para 9.9 (c) or (d).

7.9

PIPE ENDS

7.9.1


7.9.3

Plain Ends Unless specified otherwise, the pipe ends shall be bevelled as per API Spec. 5L. In removing the inside burrs at the pipe ends, care shall be taken not to remove excess metal and not to form an inside cavity or bevel. Removal of excess metal beyond the minimum wall thickness as indicated in para 7.3 of this specification, shall be a cause for rebevelling. In case root face of bevel is less than that specified, the pipe ends shall be rebevelled and rectification by filing or grinding shall not be done.

7.9.6

Bevel Protectors (New) Both pipe ends of each pipe shall be provided with metallic or high impact plastic bevel protectors as per Manufacturer's standard. Bevel protectors shall be of a design such that they can be re-used by coating applicator for providing on externally anticorrosion coated pipes subsequent to coating of line pipe.

9 9.2 9.2.1

Inspections and Testing TESTING OF CHEMICAL COMPOSITION Heat Analysis Where the steel mill is not a part of an integrated pipe mill, heat analysis shall be reported by the Manufacturer prior to start of pipe production.

9.2.2

Product Analysis GAIL (INDIA) LTD NEW DELHI



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9.2.2.1

Sampling Frequency Two pipes per inspection lot shall be analysed. Inspection lot shall be 100 pipes per heat. Pipes selected shall be such that one at the beginning of the heat and one at the end of the heat are also represented.

9.2.2.2

Sampling Method

9.2.2.2 2 Welded Pipe Samples used for product analysis shall be taken from finished pipes. Samples for product analysis from skelp may be used provided the traceability of samples is guaranteed. 9.3


9.3.1

Tensile Tests Tensile properties shall be determined from specimen removed from pipe which has been subjected to all mechanical and heat treatment operations.

9.3.1.2

Tensile Testing Frequency Tensile tests shall be made at the frequency of one test per inspection lot as shown in Table 13, except as modified below: Table 13 : Maximum Inspection Lot Size for Tensile Testing For Size >12¾”, Weld Tensile Tests (Column 3 of API Spec 5L) Note "a" of Table 13 shall also be applicable.

9.3.1.4

Transverse Tensile Tests The transverse tensile tests shall be carried out on flattened rectangular specimen.

9.3.1.5

Weld Tensile Tests Inside and outside weld reinforcement in excess of pipe wall thickness shall be removed from the specimen either by grinding or machining. Specimen shall be tested for ultimate tensile strength only. A cylindrical all weld tensile test shall be carried out at the time of first day production test as specified in Annexure-II of this specification to determine the yield strength, ultimate tensile strength and elongation.




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The cylindrical all weld specimen shall have gauge length, L = 5d, where; L

=

D =

gauge length (mm) diameter of the test specimen (mm)

The results of the teat shall meet the minimum requirements of the skelp with regard to yield, tensile and elongation. ” As an alternate all weld metal tensile test can be carried out at the time of first day production on the test sample as per ASME Sec.II C. This test shall be repeated in case any change in batch of wire-flux combination,” 9.3.5


9.3.5.1

Charpy Test Specimens In addition to the specimen taken from the body of the pipe, three transverse specimens with weld in middle and three transverse specimens with heat affected zone (HAZ) in the middle shall also be taken.

9.3.5.2

Charpy Testing Frequency The minimum test frequency shall be one test (a set of three specimens each for body, weld and HAZ) per heat per lot of 100 pipes per combination of pipe size and specified wall thickness.

9.4

HYDROSTATIC TESTS

9.4.1

Hydrostatic Test Requirements Test pressure shall be held for a minimum period of 15 seconds for each pipe of all sizes and grades.

9.4.2

Verification of Hydrostatic Test The pressure gauge used for hydrostatic testing shall have a minimum range of 1.5 times and maximum range of 4 times the test pressure. The pressure gauge shall be calibrated by means of a "Dead Weight" tester only and records shall be maintained.

9.4.3

Test Pressure The test pressure for all sizes and grades of pipe shall be such that hoop stress (fibre stress) generated is at least 95% of SMYS, computed based on the formula mentioned in API Spec 5L para 9.4.3 (Note 2). GAIL (INDIA) LTD NEW DELHI



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9.4.5

Burst Test

(New) Burst test shall be done on each type of pipe for each size on lowest thickness. Burst pressure & location of failure shall be recorded. Technical audit shall be carried out by OWNER / OWNER’S representative during manufacturing. Minimum Burst Test pressure shall not be less than the actual tensile stress factor computed pressure. 9.5

DIMENSIONAL TESTING The measuring equipment requiring calibration or verification under the provisions of API Spec 5L shall be calibrated with manual instruments at least once per operating shift (12 hours maximum). Such calibration records shall be furnished to Purchaser's Representative on request.

9.7

VISUAL INSPECTION All pipes shall be visually examined both externally and internally (to the extent feasible) and shall he free of defects in the finished condition.

9.8

NON DESTRUCTIVE INSPECTION The Purchaser reserves the right to depute its Representative(s) to perform inspection and witness tests in all phases of manufacturing and testing starting from steel making to finished line pipe ready for shipment. Manufacturer shall comply with the provisions regarding inspection notice: plant access, compliance and rejection mentioned in Appendix H of API Spec 5L. The Manufacturer shall give the Purchaser reasonable notice of the starting date of normal production and the work schedule. Any action or omission on part of Purchaser's Representative shall not relieve the Manufacturer of his responsibility and obligation to supply material in-strict accordance with this specification.

9.8.1

Qualification of Personnel All personnel performing NDT activities shall be qualified in the technique applied, in accordance with latest edition of ISO 9712 or ASNT No. ASNT-TCMA or equivalent. All NDT shall be performed in accordance with written procedures. These procedures shall have prior approval of the Purchaser. GAIL (INDIA) LTD NEW DELHI



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Inspector Qualification Acceptable qualification for NDT inspectors shall be as specified below: (i)

For UT - For UT, at least one level III qualified inspector shall be available to the mill for overall supervision. A level II inspector is required for shift supervision, manual weld inspection and calibration of all systems (both manual and automated).

(ii)

For alt other NDT methods Evaluation of indications

:

Level I, II, III inspector

Supervision

:

Level II or Level III inspector (in case evaluation is by Level I

inspector) 9.8.3

Methods of Inspection Location of NDT equipment in the manufacturer's facility shall be such that final inspection of weld seam shall be performed after hydro testing. Skelp Inspection The longitudinal edges of the skelp shall be 100% ultrasonically inspected over width of at least 25 mm from the trimmed skelp edge. Remaining skelp shall be ultrasonically tested for laminations using an oscillating or straight running pattern of probes, so as to provide inspection coverage of at least 20% of the skelp surface uniformly spread over the area. Alternatively, skelp UT inspection can be performed after pipe forming provided all applicable requirements as specified above are complied with. Locations showing indications above the acceptance limits may be re-examined by manual ultrasonic method. If no defects are located during re-examination the original findings may be ignored. Additional scanning may be requested by Purchaser's Representative to check questionable areas. Ends Inspection The full circumference of both ends of each pipe after bevelling shall be 100% ultrasonically tested for laminations from inside over a circumferential band of at least 25 mm width. In addition, full circumference of both ends of each pipe shall be 100 % ultrasonically tested over a circumferential width of at least 50 mm with angular probes to detect cracks, in case of non-availability of angular probes at the mill, the full circumference of both ends of each pipe shall be inspected with magnetic particle GAIL (INDIA) LTD NEW DELHI



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technique over a circumferential width of at least 50 mm to detect surface cracks. Bevel Inspection Bevel face of all pipes shall be inspected by magnetic particle method to detect defects. Weld Inspection Submerged-arc welds shall be inspected by ultrasonic methods (Refer Table-24) using automatic ultrasonic equipment in accordance with API Spec 5L para 9.8.5 and as modified in this specification. Pipe end welds shall be inspected in accordance with Para 9.8.3.1. Locations showing indications above the allowable limits during ultrasonic inspection shall be re-examined by radiography, if during production, repeated ultrasonic indications occur requiring re-inspection by radiography and it appears from radiographs that the nature of defects causing the ultrasonic indications cannot be definitely established, the Manufacturer shall prove by other inspection methods (e.g. by making some cross-sections in accordance with para 6.2.6 of this specification at locations where such indications occur near the end of the pipe) to the satisfaction of Purchaser that these are not injurious defects as stipulated in this specification. 9.8.3.1

Pipe End Weld Inspection Pipe ends not covered by automatic ultrasonic equipment shall be inspected by manual ultrasonic equipment with same sensitivity and capability as automatic equipment. Submerged-arc weld seam shall be radio graphically examined for a minimum distance of 8 in. (200 mm) from each pipe end. The results of radiographic inspection shall be recorded.

9.8.4

Radiological Inspection-Weld Seams

9.8.4.1

Radiological Inspection Equipment The homogeneity of weld seams examined by radiological methods shall be determined by means of X-rays directed through the weld material in order to create a suitable image on radiographic film. The film used for radiographic inspection of weld seam shall be class 1 or 2 as per Table-2 of ASTM E 94; with minimum density greater than 1.8 measured in connection with radiographic image of the welding and shall be suitable to allow a sensitivity of at least 1.8 percent of nominal wall thickness.




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9.8.4.2

Radiological Sensitivity Reference Standard The reference standard shall be ISO wire-type image quality indicator described in 9.8.4.4.

9.8.4.8

Defects Observed During Radiological Inspection Defects in the weld such as cracks, slag inclusions, porosity and defects in the pipe material shall be removed by cutting off the section of pipe containing these defects. The remaining defects-free section of the pipe will be acceptable provided its length is within the specified minimum length, the weld at the new pipe end contains no defects other than those permitted.

9.8.5

Ultrasonic and Electromagnetic inspection

9.8.5.1

Equipment All automatic ultrasonic equipment shall have an alarm device, which continuously monitors the effectiveness of the coupling. The equipment for the automatic inspection shall allow the localization of both longitudinal and transverse defects corresponding to the signals exceeding the acceptance limits of the reference standard. The equipment shall be fitted with a paint spray or automatic marking device and alarm device for areas giving unacceptable ultrasonic indications. All ultrasonic testing equipment shall be provided with recording device. In addition, an automatic weld tracking system shall be provided for correct positioning of the probes with respect to weld centre.

9.8.5.2

Ultrasonic and Electromagnetic Inspection Reference Standards The reference standard (calibration pipe) shall have the same specified diameter and wall thickness as specified for the production pipe being inspected and shall be of sufficient length to permit calibration of ultrasonic inspection equipment at the speed to be used in normal production. The reference standard (calibration pipe) shall also be of the same material, type and have the same surface finish and heat treatment as the pipe being inspected. The reference standard for weld UT shall contain machined notches/holes as per as per Figure 9.8.5.2 of this specification and as given below; - Two longitudinal inside notches of type N 5 at both edges of weld seam. - Two longitudinal outside notches of type N5 at both edges of weld seam. - Two longitudinal notches of type N5 at the centre of the weld seam, one outside and one inside. - Two transverse notches of type N5 across the weld seam, one outside and one inside.




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- A drilled hole in the centre of the weld seam, of diameter equal to 1.6 mm. The reference standard for skelp UT shall contain continuous machined notch of 8 mm width x ½ t depth, where “t”is the specified wall thickness. The reference standard for skelp edge UT and pipe ends shall have ¼” inch dia FBH x ½ t depth, where “t” is the specified wall thickness. The calibration shall be performed at following intervals: a. At the beginning of each operating shift (12 hours maximum). b. At least once during each operating shift (12 hours maximum). c. Every time the running of the system gives rise to doubts on its efficiency. If during the above calibration verification, it is found that the equipment has not functioned satisfactorily in the opinion of the Purchaser's Representative, all the pipes or skelp already inspected after the previous verification shall be inspected again at Manufacturer's cost. 9.8.5.4

Acceptance limits

9.8.5.4.1 Skelp Edges (New) Acceptance limit for material edge examination shall be as per criteria laid down for Acceptance Level E2 of BS 5996:1993, which is reproduced hereunder for ready reference. 1. No individual imperfection of length less than 20 mm shall be considered for population density assessment. 2. Maximum length of imperfection in any direction shall not exceed 30 mm. 3. Maximum area of individual imperfection shall not exceed 500 mm2. 4. Maximum population density (number of imperfections smaller than the maximum permissible imperfection size and longer than 20 mm per 1m length) shall not exceed 4. Disposition of any defect shall be as per API Spec L, para 9.9 (c) or (d). 9.8.5.4.2 Remaining Skelp (New) Acceptance limit for material body examination shall be as per criteria laid down for Acceptance level B4 of BS 5996: 1993 which is reproduced hereunder for ready reference: GAIL (INDIA) LTD NEW DELHI



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1. No individual imperfection that does not exceed all of the following dimensions shall be considered for population density assessment: Area: 300 mm2, Length: 35 mm, Width : 8 mm. (The length is the dimension at right angles to the scan track and the width is the dimension parallel to the scan track) 2. Maximum area of any individual discontinuity shall not exceed 1000 mm2. 3. Maximum population density of imperfections smaller than the maximum permissible imperfection size and larger than the minimum imperfection size per 1 m x 1 m square shall not exceed 10. 4. Any imperfection exceeding 100 mm in length shall not be acceptable and any planar imperfection not parallel to the skelp surface is not acceptable. Disposition of any defects shall be as per API Spec 5L para 9.9 (c) or (d). Residual Magnetism Measurement Requirements

9.8.7

The average of the four readings shall not exceed 20 gauss and no one reading shall exceed 25 gauss when measured with Hall-effect gauss meter. All residual magnetism measurements shall be recorded. 9.9

DISPOSITION OF PIPE CONTAINING DEFECTS a. Suitable tools to eliminate defects by grinding shall be used. The repaired area shall be 100% rechecked by magnetic particle or ultrasonic inspection to ensure complete removal of defects. However for repair of cosmetic type of defects, MPI may not be conducted if so directed by Purchaser's Representative on case to case basis. The pipes having a thickness less than the minimum allowed in accordance with this specification, after repair by grinding shall be treated for disposition in accordance with API Spec 5L para 9.9 (c) or (d). b. Repair welding on parent metal is not permitted. c. In addition to NTD requirement random radiography of 0.1% of the total length shall be done. The areas to be radiographed shall be at the sole discretion of Third Party Inspection Agency.

9.10

TEST METHODS

9.10.3

Guided-bend Test One face and one root guided bend weld test shall be made on samples cut from pipe. The frequency of testing shall be same as for tensile test as per para 9.3.1.2 of this specification. The dimension ‘A’ in guided bend test shall not exceed 4.0 times the thickness of the specimen.




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9.10.4 Charpy Test Individual test value for any specimen shall not be less than 80% of the required minimum average absorbed energy value as per this specification. 9.12

RETESTS

9.12.1

Recheck Analysis Modalities of recheck analysis shall be as per API Spec. 5L as applicable to the lot being tested (refer para 9.2.2.1 of this specification). However, during individual testing, each pipe shall be fully analyzed to meet the requirements of Table 2B of this specification.

9.12.7

Charpy Retests In the event that a set of Charpy test specimen fails to meet the acceptance criteria, the manufacturer may elect to replace the lot (refer para 9.3.5.2 of this specification) of material involved or alternatively to test two more lengths from that lot. If both the new tests meet the acceptance criteria, then all pipes in that lot, with the exception of the original selected length, shall be considered to meet the requirement.

9.13

REPROCESSING This para stands cancelled.

10

Marking

10.1

GENERAL Marking specified in API Paragraphs and otherwise specified in the Purchase Order shall be in English language and international system (SI) of units. Marking shall comply with Appendix-I of API Spec 5L and as modified in this specification.

11 11.1

COATING AND PROTECTION COATINGS Unless otherwise specified in the Purchase Order, the pipes shall be delivered bare, free of any trace of oil, stain, grease and paint. Varnish coating shall be applied on the marking area. Bevels shall be free of any coating.

12 12.1

Documents CERTIFICATION GAIL (INDIA) LTD NEW DELHI



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Manufacturer shall furnish to Purchaser a certificate of compliance stating that the material has been manufactured, sampled, tested, and inspected in accordance with this specification and has been found to meet the requirements. In addition all details as per Appendix F Supplementary Requirement SR 15 shall also be submitted to Purchaser/Purchaser Representative during inspection at pipe mill. 12.2

RETENTION OF RECORDS In addition to the records indicated in API Spec 5L Table 27, the Manufacturer shall retain the records of all additional tests and calibration records mentioned in this specification including the hard copy records of ultrasonic testing carried out on pipe/skelp as well as pipe ends.

12.3

PRODUCTION REPORT (New) The Manufacturer shall provide six copies of production report in English language indicating at least the following for each pipe. International system of units (SI) shall be adopted. - Pipe number - Heat number from which pipe is produced - Pipe length and weight. - Pipe grade The Manufacturer shall provide six copies of acceptance certificates which shall include the results of all tests required as per this specification and performed on delivered material giving details of, but not limited to, the following: - All test certificates as per SR 15.1. - Records of qualification of welders and procedures for repair welding. - Certified reports of dimensional, workmanship and defects inspection. - Data on test failures, rejected heats/lots, etc. - Alt other reports and results required as per this specification. The certificates shall be valid only when signed by the Purchaser's Representative. Only those pipes, which have been certified by the Purchaser's Representative, shall be dispatched from the pipe mill. In the event of small quantities of pipes supplied against this specification, like those for bends and other similar applications, as specifically called out in the Purchase Order the production report may consist of only test certificates required as per SR 15 of API Spec GAIL (INDIA) LTD NEW DELHI



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5L and other test reports/results required as per this specification. 12.4

LINE PIPE TRACEABILITY DATA

(New) The line pipe data shall be provided in MS EXCEL/MS ACCESS format in compact Disc (CD). The specific data to be recorded shall be agreed between Purchaser and the Manufacturer and shall include, but not limited to, the following: - All marking information - Data of skelp and pipe manufacture - All mechanical properties from test results - All dimensional records - All workmanship and defects inspection records - Final inspection and release date - Description and disposition of repairs - Load-out /dispatch date - Destination - Consignment details. 14

Inspection of Field Tests & Warranty (New) Purchaser shall be reimbursed by Manufacturer for any pipe furnished on this order that fails under field hydrostatic test if such failure is caused by a material/manufacturing defect in the pipe. The reimbursement cost shall include pipe, labour and equipment rental for finding, excavating, cutting out and installation of replaced pipe in position. The field hydrostatic test pressure will not exceed that value which will cause a calculated hoop stress equivalent to 95 percent of specified minimum yield strength. In case Manufacturer so desires, he will be advised at least two weeks in advance so that his Representative may witness the hydrostatic test in field, however, the testing and leak (if any) finding and repair operation shall not be postponed because of absence of the Manufacturer's Representative.




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APPENDIX B REPAIR OF DEFECTS BY WELDING (NORMATIVE) B.1.2

Weld Seam of Welded Pipe

B.I.2.1

Repaired welds shall be inspected both by X-ray and UT.

B.3

Procedure for Repair of Submerged-Arc and Gas Metal-Arc Welds

B 3.1

The defective part of the weld shall be clearly marked on the pipe so that the defect can be easily located and repaired.

B.3.2

Following requirements shall also be complied with for repair welding: a.

No repair of weld seam is permissible alter hydrostatic testing.

b.

No repair of weld seam is permissible at pipe ends up to a length of 300 mm.

c.

Cumulative length of weld seam repairs on one pipe length shall not exceed 10% of the length of pipe. Maximum two repair per pipe are allowed.

d.

Repair welding shall be executed only Purchaser Representative for each repair.

e.

No repair of a repaired weld is permitted.

f.

The repair weld shall be performed with a minimum of two passes.

after specific approval by

B.3.4 (New) The Manufacturer shall also maintain a record of repairs carried out. The records shall include repair number, pipe identification number, welding procedure applicable and NDT details.




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APPENDIX-C REPAIR WELDING PROCEDURE (NORMATIVE) C.2

Repair Welding Procedure Qualification

C.2.2

Mechanical Testing

C.2.2.3 Transverse Guided-Bend Test The radius of male member of the jig used for guided bend tests shall be RA =2.25 t, where “t” is specified wall thickness of pipe. C.2.2.5 (New) For all pipes where fracture toughness test is specified, Charpy V-Notch impact test as specified shall be included in the Repair Welding Procedure Qualification. C.2.2.6 (New) Hardness test as specified in para 6.2.6.2 of this specification shall be included in the procedure qualification. The location of the hardness measurements is to be indicated taking into account die new HAZ of the repaired area.




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PPENDIX-F SUPPLEMENTARY REQUIREMENTS (NORMATIVE) SR5 Larger

Fracture Toughness Testing (Charpy V-Notch) for Pipe of Size 4 1/2 or

SR 5.1

The Manufacturer shall perform Charpy V-notch test for determining Shear Area.

SR 5.3

The specimen shall be full sized or largest obtainable sub size in case pipeline diameter and thickness does not permit full size specimen

SR 5.4


SR 5.5

This para stands deleted.

SR 5A

Shear Area

SR 5 A.1 Three transverse specimens representing one test shall be taken from one length of pipe per heat per lot of 100 pipes per combination of pipe size and specified wall thickness. SR 5A.2

Unless specified otherwise in the Purchase Order, the specimen shall be tested at +32°F (0°C), The average shear value of the fracture appearance of the three specimen shall not be less than 75% and the all heat average for each order, per diameter, size and grade shall not be less than 80%.

Note:

The acceptance criteria of shear area as referred in API Spec. 5L para SR 5A.3 SR 5A.4 and SR 5A.5 stand modified based on above mentioned requirements. Wherever 'heat' indicated in API Spec 5L SR5A.3, SR 5A.4, SR 5A.5 and SR5A.6 shall be replaced by 'lot'. Lot shall be as per SR5A.1 as above.

SR 6


SR6.1

When required as per para 6.2.5.3 of this specification, fracture toughness for all pipe size, grades and specified wall thickness shall be determined using Drop Weight Tear Test (DWTT) by the Manufacturer in accordance with the requirements of SR 6.2 thru SR 6.8 of API Spec 5L and as modified in this specification.

SR 6.2

Two transverse specimen shall be taken from one length of pipe per heat per lot of 100 pipes per combination of pipe size and specified wall thickness. Unless specified otherwise, the test shall be conducted at +32°F (0°C).

SR 6.4

At least 80% of the heats shall exhibit a fracture appearance shear area of 75% or more for the specified test temperature.




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Note:

Acceptance criteria for retesting indicated in API Spec 5L para SR 6.5 stands modified based on above mentioned requirements. Wherever 'heat' indicated in API Spec SR6.5 shall be replaced by 'lot'. Lot shall be as per SR6.2 as above.

SR19

Additional Fracture Toughness Requirements (Transverse Charpy VNotch) for PSL 2 Pipe

SR 19.1

Except as allowed by SR 19.2 of API Spec 5L, fracture toughness testing shall be performed in accordance with the requirements of para 9.3.5.1 and 9.3.5.2 of API Spec 5L and as modified in this specification, with a test temperature of 32°F (0°C) or at a lower temperature as specified in the Purchase Order. The required minimum all-heat average full size absorbed energy value (based on a set of three specimens) for transverse body specimen shall be the greater of SR 19 (a) of API Spec 5L and SR 19.1(b). In case longitudinal specimen is applicable as per Table 14 of API Spec. 5L, the minimum average absorbed energy value shall be 13 times that applicable for transverse specimen. The required minimum average full size absorbed energy value for weld and HAZ specimen shall also be the greater of SR 19.1(a) and SR 19.1 (b) of API Spec 5L, In addition, the lowest individual absorbed energy value of the three specimens shall not be less than 80% of the value specified.




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APPENDIX- H PURCHASER INSPECTION (NORMATIVE) H.4

Rejection If Purchaser Representative rejects pipes repeatedly for any recurring cause, this shall be adequate reason to refuse final inspection of subsequent pipes until the cause has been investigated and corrective action taken by the Manufacturer.




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General

1.1

Marking shall also include Purchase Order number/item number, pipe number, heat number and weight.

1.2

Location of Markings Paint used for stencil marking shall withstand a temperature up to 250°C expected to be experienced during further external anti-corrosion coating operations of line pipe by coating applicator.

1.3

Sequence of Marking

1.3.4

Specified Dimensions: Actual pipe weight in kg shall also be marked.

1.3.5

Grades and Class: A colour code band shall be marked on inside surface of finished pipe for identification of pipes of same diameter but different wall thickness, as indicated in the Purchase Order. The colour code band shall be 50 mm wide and shall be marked at a distance of ISO mm from the pipe ends.

1.5


1.7

Die Stamping Additionally, the pipe number shall be placed by cold rolling or low stress dot marking on the outside surface of the pipe at an approximate distance of 50 mm from both ends. In case of non-availability of either cold rolling or low stress dot marking facility in pipe mill, an alternative marking scheme of a permanent nature may be proposed by the Manufacturer.




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ANNEXURE I (NEW) MANUFACTURING PROCEDURE SPECIFICATION A Manufacturing Procedure Specification (MPS) outlining the successive steps and associated inspection procedures from steel making to finished line pipe shall be prepared and submitted to Purchaser for approval prior to start of production. Manufacture of pipes shall start only after the approval of Manufacturing Procedure. The approved Manufacturing Procedure shall be strictly followed in all phases of the production of pipes. The manufacturing procedure shall as a minimum include the following information. - Steel/Plate/skelp maker and plant at which steel is produced. - Steel making process with details of secondary refining process and continuous casting process, nominal weight of each heat. - Target chemistry, range of intentionally added elements, limits on heat and product analysis to be placed on steel maker. - Skelp rolling procedure indicating number of passes, their temperature and thickness reduction in each pass required by Controlled Rolling Procedure and the finishing temperature. - Heat treatment procedure document established as per para 5.4. - Ultrasonic testing of plates/skelp and pipes using automatic and manual equipment including details of equipment, techniques, scanning pattern, probe frequency, scanning sensitivity, reference standard for calibration, dynamic calibration procedure, method of marking defects and indicating loss of coupling, inspection and recording. - Pipe making procedure including skelp edge preparation, forming and any other special process proposed. - Welding procedure specification including the details of welding process, brand name, classification, size and grade of filler metal and flux, speed of welding, number of electrodes and polarity of each electrode, welding current and voltage for each wire, edge preparation, tack welding method and spacing of tack weld, details of seam tracking system for both inside and outside welding, method of checking the setup of the system, limits of internal and external weld reinforcement etc. In addition to be WPS carried out at mill WPS & PQR shall be carried out at the pipe mill by approved welders of the EPC Contractor to establish the weldability of pipe. EPC Contractor accordingly arrange for the welders to carry out the WPS / PQR at the GAIL (INDIA) LTD NEW DELHI



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pipe mill. Establishing the WPS of pipe mill doesn’t absolve the EPC contractor of his responsibility of carrying out WPS / PWR at site. - Method of weld defect removal. - Ultrasonic testing of longitudinal weld seam of pipe using automatic equipment including details of equipment, scanning pattern, probe frequency, scanning sensitivity, calibration pipe, extent of weld length at pipe ends not covered by all probes, method of marking defect and indicating loss of coupling, inspection and records. - Full details of radiographic testing equipment including radiographic film. - Dimensional tolerances, frequency of checking, measurement and record in a tabular form including details of instruments and equipments proposed. - Detail of techniques proposed for measurement of end square ness and peaking at the welds. - Hydrostatic testing including details of testing equipment, procedure and the relevant test pressure calculations. - Marking details. - Handling, storage and shipment procedure. - Production Report Formats. - Complete details of computerized pipe tracking system. Note: In the event of small quantities of pipe ordered against this specification, the requirements of submission of manufacturing procedure details can be moderated subject to agreement between Purchaser and Manufacturer.




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ANNEXURE -II (NEW) FIRST DAY PRODUCTION TESTS Two lengths each of completely finished pipes of first day's production from two different heats (i.e. a total of four pipe lengths) shall be selected at random for testing to verify that the manufacturing procedure results in the quality of pipes which are in complete compliance with this specification. The pipes thus tested shall be considered to be the test pipes required per heat or per lot as per relevant clauses of this specification. These first day’s production tests shall be repeated upon any change in the manufacturing procedure as deemed necessary by Purchaser Representative. The first day production tests shall be carried out on pipes for each wall thickness, each diameter and each grade of steel. In addition, change of width of coil shall also call for first day production test. The Manufacturer shall submit to Purchaser a report giving the results of all tests mentioned below. The report shall be agreed and signed by Purchaser Representative, prior to start of regular production. Note: In the event of small quantities of pipes ordered against this specification, like those for bends and other similar applications, as specifically called out in the Purchase Order, the first day production test shall not be carried out. Pipes- in such case shall be accepted based on regular production tests. The various tests to be conducted on each pipe shall be as follows. The test method and acceptance values shall be as per this specification unless specified differently in this Annexure. a. Visual Examination All pipes shall be examined visually for dimensional tolerances and apparent surface defects. b. Ultrasonic Examination The weld seam of all pipes shall be examined ultrasonically by automatic ultrasonic equipment. All ultrasonic indications suggesting imperfections in the weld shall be carefully investigated against the corresponding points on the radiographs. If the ultrasonic indication cannot be fully explained from the radiograph, a cross section of the weld, at the location of the above-mentioned ultrasonic indication shall be made in such a way that the nature of the imperfection can definitely be established. GAIL (INDIA) LTD NEW DELHI



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c. Radiographic Examination The weld seam of all pipes shall be examined radio graphically for the entire length. d. Mechanical Properties The mechanical properties of all pipes shall be tested and shall meet the requirements of this specification. Purchaser Representative will select the places in pipe from where the test specimen shall be removed. The following tests shall be conducted: i.Four (4) weld guided bend test specimen transverse to the helical weld shall be removed. Of the four specimen, two specimen shall be used for the tact- bend test and two for the root bend test. ii.Tensile tests shall be conducted on: - Two (2) transverse base material specimen. - Two (2) transverse weld material specimen of the helical weld. - Two (2) cylindrical all-weld specimen of the helical weld. iii.Six (6) weld cross-section specimen, three (3) from each end of pipe joint shall be taken for metallographic examination. Two of these shall be tested for hardness at room temperature after etching. iv.Fracture toughness testing specimen shall be extracted as follows: -


-


-


The base metal specimen shall be tested at - 40, -10, 0, + 20° C for shear area and absorbed energy to produce full transition curve. The value at the test temperature specified in SR 5A and SR 19 of API Spec. 5L and duly modified in this specification for shear area and absorbed energy respectively shall be complied with. For other temperatures, the value shall be for information only. The sets of weld and HAZ specimen shall be tested for absorbed energy only at the same test temperature applicable as per SR 19 of API Spec. 5L. v.At points selected by Purchaser, twelve (12) DWTT specimens shall be removed from base metal in a transverse direction. The sets of 3 base metal specimen shall be tested at -40, -10, 0, +20°C for shear area to produce full transition curve. The GAIL (INDIA) LTD NEW DELHI



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value at the test temperature specified in SR 6 of API Spec 5L duly modified in this specification shall be complied with. For other temperatures, the value shall be for information only. (Note: This test is to be carried out only when required as per para 6.2.5.3 of this specification) vi.Hardness test shall be conducted on selected pipes as per requirement of para 6.2.6 of this specification. vii. One specimen from one pipe end shall be taken for residual stress test. e. In addition, all the tests and inspections require to be conducted as per this specification shall be conducted on all the pipes selected for testing during first day production test. f. In case of any test failure, no re-testing shall be applied and the entire first day production shall be rejected.




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ANNEXURE III (NEW) INFORMATION TO BE FURNISHED AT THE TIME OF BIDDING The following information as applicable shall be furnished at Bid stage with respect to line pipe to be supplied. -

Name(s) of proposed Manufacturer(s)

-

Authorisation letter(s) from Manufacturer(s) where applicable.

-

Authorisation letter(s) from Manufacturer(s) of skelp, in case skelp manufacturing facility is not an integral part of the Supplier’s pipe mill.

-

Record of similar supplies made earlier by the Manufacturer for both skelp and pipes, giving complete details of diameter, thickness, length, grade of skelp / pipe, service, year, name of project, name of client, and contact person. In particular, details of similar supplies made over the last five years shall be furnished.

-

Histogram for dimensional parameter, chemical analysis and tensile test indicating minimum, maximum, average and standard deviation for the previous supplies.

-

Descriptive technical catalog(s) of the proposed Manufacturer(s).

-

Copy of valid certificate of Authority to use API monogram as per clause 1.2 of this specification.

-

A clause wise list of technical deviations, if any, from the requirements of this specification shall be furnished in the Performa enclosed with the Enquiry. Deviations indicated anywhere else in the offer shall not be considered valid. In case of no deviations, Bidder shall write “NO DEVIATIONS” in the said Performa.




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FIGURE : 6.2.6.1 METALLOGRAPHIC SPECIMEN EXTRACTION PLAN




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FIGURE: 7.8.3 X-RAY FILM PROCODURE FOR MEASUREMENT OF OUT OF LINE WELD BEAD




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SPECIFICATION FOR SEAMLESS LINE PIPE (ONSHORE)


STADARD SPECIFICATION FOR SEAMLESS LINE PIPE (ONSHORE)


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CONTENTS S.No.

Description

Page No.

1

INTENT OF SPECIFICATION

2

2

SCOPE OF WORK

2

3

COVERAGE

2

4

REFERENCES

2

5

MANUFACTURING PROCESS

2

6

INSPECTION & TESTING

3

7

MARKING & DESPATCH

3




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1.0

INTENT OF SPECIFICATION

1.1

This specification establishes the minimum requirements for the manufacture of Seamless Pipes in accordance with the requirements of API (American Petroleum Institute) Specification 5L- 2000 (Forty Second Edition).

1.2

Unless modified and referred by this specification the requirements of API Spec. 5L2000 shall be valid.

2.0

SCOPE OF WORK

2.1

The scope of the tenderer includes manufacture / supply, inspection / testing , marking & packaging and despatch of seamless linepipes as indicated in the Material Requisition (MR).

2.2

All codes and standards for manufacture, testing, inspection, etc, shall be of latest edition.

2.3

Purchaser also reserves the right to delete or order additional quantities during execution of order, based on unit rates and other terms & conditions in the original order.

3.0

COVERAGE

3.1

The coverage by this specification is limited to linepipe covering non-sour hydrocarbons in liquid or gaseous phase in accordance with API Specification 5L - 2000 (PSL-1 and PSL-2 requirements, as applicable) covering seamless line pipes of sizes and grades as indicated in the MR.

4.0

REFERENCES

4.1

All pipes and their dimensions, tolerances, chemical composition, physical properties, heat treatment, hydrotest and other testing and marking requirements shall Conform to the latest codes and standards specified in the MR. Deviations, if any, shall be clearly highlighted in the offer. The latest edition of following additional references are included in this Specification: ASTM ASTM E 92: Test Method for Vickers Hardness of Metallic Materials GAIL (INDIA) LTD NEW DELHI



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ASTM E 112: Standard Test Methods for Determining Average Grain Size. BS BS 5996: Specification for the Acceptance Level for Internal Imperfection in Steel Plate, Strip and Wide Flats based on Ultrasonic Testing 5.0

MANUFACIURING PROCESS

5.1

Steel made by acid Bessemer process shall not be acceptable.

5.2

Pipes shall be supplied in double random length, i.e. pipe length between 11.5 m and 12.5 m with an average length of 12.0 m.

5.3

Seamless pipes shall not have any circumferential seam joint in a random length.

6.0


6.1

All pipes shall be hydrostatically tested. The test mill pressure shall be as follows: GROUP 1 (SEAMLESS,ERW & SPIRAL WELDED) A

S No.

CARBON STEEL

(i) (ii) (iii) (iv) (v)

MATERIAL STD ASTM A106 GR.B API 5L GR.B,SEAMLESS API 5L,E.R.W API 5L,SPIRAL ASTM A333 GR.3 & 6,SEAMLESS

(vi)

ASTM

B

S No. (i) (ii)

A333 GR.3

&

6,E.R.W

:

TEST PRESSURE

: : : : :

ASTM A 530 API 5L API 5L API 5L ASTM A530

:

ASTM A530

:

TEST PRESSURE

:

ASTM A530

:

ASTM A530

SEAMLESS ALLOY STEEL MATERIAL STD ASTM GR.P1,P12,P11,P22,P5,Pg ASTM A268 TP 405,TP410


A335



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C

S No.

SEAMLESS STAINLESS STEEL

(i)

MATERIAL STD ASTM A312 GR. TP304 ,304L ,304H, 316, 316L, 316H, 321, 347

D

SEAMLESS NICKEL ALLOY

S No. (i) (ii) (iii) (iv)

MATERIAL STD ASTM B161 UNS ASTM B165 UNS ASTM A167 UNS ASTM A407 UNS

NO2200 NO4400 NO6600 NO8800

:

TEST PRESSURE

:

ASTM A530

:

TEST PRESSURE

: : : :

ASTM B161 ASTM B165 ASTM B167 ASTM B407

6.2

Material test certificates (physical properties, chemical composition & heat treatment report) shall also be furnished for the pipes required.

6.3

Pipe with bevelled ends shall be in accordance with ASME B16.25. Weld contour shall be as per Figure-2, Type-A.

7.0

MARKING & DESPATCH

7.1

All pipes shall be marked in accordance with the applicable codes, standards & specifications. Additionally, purchase order number, item code and special conditions, if any, shall also be marked.

7.2

Paint or ink for marking shall not contain any harmful metal or metallic salts such as zinc, lead or copper which cause corrosive attack on heating.

7.3

Pipes shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind.

7.4

Pipes shall be protected from rust, corrosion & mechanical damage during transportation, shipment and storage.

7.5

Rust preventive, used on machined surfaces to be welded, shall be easily removable with a petroleum solvent and the same shall not be harmful to welding.




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7.6

Both ends of pipes (Bevelled Ends) shall be protected with wood, metal or plastic cover.

7.7

End protectors to be used on bevelled ends shall be securely and tightly attached with belt or wire.




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SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)




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CONTENTS 1

SCOPE

2

REFERENCES

5


6


7


9


10

MARKING

11


12

DOCUMENTS

14

(New) INSPECTIONS OF FIELD TESTS & WARRANTY

APPENDIX-F


SR 5

FRACTURE TOUCHNESS TESTING (CHARPY V-NOTCH) FOR PIPES OF SIZE 4½ OR LARGER

SR 6

DROP WEIGHT TEAR TESTING ON WELDED PIPE OF SIZE 20 OR LARGER, GRADE X52 OR HIGHER PIPE AND LASER

SR 17

NON DESTRUCTIVE INSPECTION OF WELDS IN ELECTRIC WELDED PIPE AND LASER WELDED PIPE

SR 19

ADDITIONAL FRACTURE TOUGHNESS REQUIREMENTS (TRANSVERSE CHARPY V-NOTCH) FOR PSL 2 PIPE

APPENDIX-H


APPENDIX-I

MARKING INSTRUCTIONS FOR API LICENSEE (NORMATIVE)

ANNEXURE-I

MANUFACTURING PROCIDURE (New)

ANNEXURE-II

FIRST DAY PRODUCTION TESTS (New)

FIGURE 6.2.6.2 LOCATIONS FOR HARDNESS MEASUREMENT FIGURE 6.2.7

REVERSE BEND TEST

FIGURE 9.8.5.2 REFERENCE STANDARD FOR UT OF LONGITUDINAL WELD SEAM




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Abbreviations: ASTM


API


ID

Inside Diameter

EW

Electric Welded

HAZ

Heat Affected Zone

NDT


NPS

Nominal Pipe Size

OD


WT





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1. Scope 1.1

PURPOSE AND COVERAGE This specification establishes the minimum requirements for the manufacture of longitudinal seam electric welded steel tine pipe in accordance with the requirements of API (American Petroleum Institute) Specification 5L Forty-Third Edition, 2004 and makes restrictive amendments to API Spec. 5L. Unless modified and or deleted by this specification, the requirements of API Spec. 5L shall remain applicable. The sections, paragraphs and appendices contained herein have the same numbering as that of API Spec SL in order to facilitate reference. Additional requirements, which are not specified in API Spec 5L, have also been numbered and marked as "(New)". The coverage by this specification is limited to line pipe to be used in onshore pipelines transporting non-sour hydrocarbons in liquid or gaseous phase. The Manufacturer shall have a valid license to use API Monogram in accordance with the requirements of API Spec 5L Forty-Third Edition, 2004 on line pipe as Product Specification Level PSL 2.

1.2

PRODUCT SPECIFICATION LEVEL (PSL) Line pipe supplied to this specification shall conform to Product Specification Level PSL 2.

1.3

GRADES This specification is applicable to PSL 2 line pipes of grade B through X70.

1.4

DIMENSIONS This specification shall be applied to line pipe of size 4 1/2 through 20 (both sizes included),

2.

References

2.1

The latest editions (edition enforce at the time of issue of enquiry) of following additional references are included in this specification: ASTM ASTM E 92

: Test Method for Vickers Hardness of Metallic Materials.

ASTM E 112 : Standard Test Methods for Determining Average Grain Size. BS BS 5996


: Specification for the Acceptance Level for Internal Imperfection in Steel Plate, Strip and Wide Flats, based on Ultrasonic Testing. SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)


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OISD –141

: Oil industry safety Directorate Standard for Design and Construction Requirements for Cross country Hydrocarbon Pipeline : Boiler & Pressure Vessel code: Welding & brazing quality. : Gas Transmission & Distribution piping system. : Recommended practice for railroad transmission of line pipe

ASME IX ASME B31.8 API RP 5 L 5


5.1

PROCESS OF MANUFACTURE Following paragraphs of API Spec 5L shall be applicable to the line pipe manufactured as per this specification: Welding Process

:

Electric Welding as per para 5.1.2.1.2.

Type of Pipe

:

Electric Welded Pipe as per para 5.1.3.3 & 5.1.3.3.2.

Type of Seam Weld

:

Electric Weld as per para 5.1 .4.1.

5.1.3.3.2 PSL 2 ELECTRIC WELDED PIPE Electric welding shall be performed with a minimum welder frequency of 200 kHz. The welding system shall have an integrated control in which following data as a minimum shall be monitored: -

Time

-

Welding speed

-

Current and Voltage

-

Heat treatment temperature

The weld seam and the entire Heat Affected Zone (HAZ) shall be heat treated so as to stimulate a normalizing heat treatment in order to control the structure so that no untempered martensite remain in the weld seam and the HAZ, and the mechanical properties of heat treated zone approximate that of the parent metal. 5.2

COLD EXPANSION Pipes furnished to this specification shall be non-expanded.

5.3

MATERIAL

5.3.3 (New) Line pipe furnished to this specification shall be made from steel produced in basic oxygen or electric arc furnace. The steel used for manufacture of pipe shall be fully killed and fine grained with a grain size of ASTM 7 or finer as per ASTM E 112. Steel shall be made by continuous casting only. GAIL (INDIA) LTD NEW DELHI



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5.4

HEAT TREATMENT The pipes shall be produced from skelp which shall be quenched and tempered or controlled rolled or combined controlled rolled and accelerated cooled to impart uniformly fine ferritic grain structure to the finished steel. Other types of heat treatment shall be agreed upon between Purchaser and Manufacturer.

6


6.1

CHEMICAL PROPERTIES

6.1.1

Chemical Composition The chemical composition of each heat of steel on product analysts shall be in accordance with Table 2B and notes given below. Table 2B of API Spec 5L is cancelled. Table - 2B: PSL 2 Chemical Requirements for Heat and Product Analyses by Percentage of Weight Element

Product Analysis (percent by weight)

C

0.16

max

Mn

1.50

max (For Grade B to X52)

1.60


0.15

min

0.45

max

S

0.01

max

P

0.02

max

Al

0.07

max

Nb

0.05

max

V

0.08

max

Ti

0.04

max (For Grade B to X60)

0.06


Cr

0.20

max

Mo

0.10

max

Cu

0.35

max

Ni

0.20

max

N

0.012

max

B

0.0005

max

Si




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Note:

g (New)

i.

V+Nb+Ti shall not exceed 0.15%.

ii.

Cu+Ni shall not exceed 0.40%.

iii.

Al/N shall be min. 2.




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Note: h (New) If alloying elements other than those specified in Table 2B above are added to the steel, the limits of the additional components shall be agreed with the Purchaser. Note: i (New) Minimum for Si is not applicable for Al killed steel. 6.1.2

Elements Analyzed For heat analysis and product analysis, all the elements listed in Table 2B of this specification shall be analyzed and reported, even if those are not purposely added but are present as residuals only.

6.1.3 6.1.3.1

Carbon Equivalent (PSL 2 Only) Calculation of Carbon Equivalent Boron content shall be considered in CE (Pcm) formula even if it is less than 0.0005%.

6.1.3.2

Maximum Carbon Equivalent For pipes of all grades, size and wall thickness, Carbon Equivalent shall comply with the following limits: CE (Pcm) ≤

0.20 %

CE (IIW) ≤

0.40 %

6.2

MECHANICAL PROPERTIES

6.2.1

Tensile Properties The finished pipe (after all heat treatment and expansion or sizing operations) shall conform to the requirements of Table 3B of API Spec 5L and as modified herein. The actual yield strength shall be as close as possible to the specified minimum yield strength (SMYS) but in no case it shall exceed the limits specified here under: API Spec 5L Grade

Permissible in excess of SMYS. psi (MPa)

Up to and including X46

19,000 (131)

X52 to X56

22,000(152)

X70

20,000(138)

The ratio of body yield strength and body ultimate tensile strength of each test pipe on which body yield strength and body ultimate tensile strength are determined, shall not exceed 0.90. The ultimate tensile strength of the weld shall be equal to or better than the specified minimum ultimate tensile strength of the base metal. The minimum elongation of base metal shall be determined in accordance with the GAIL (INDIA) LTD NEW DELHI



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formula given in the foot note (a) of Table-3B and shall comply with the minimum values of API Spec 5L Appendix D. However elongation in no case shall be less than 20%. API Spec 5L Appendix D stands modified accordingly. 6.2.2

Flattening Test Acceptance Criteria Dye penetrate testing may be used to positively confirm the presence of crack, break or opening.

6.2.5


6.2.5.2


f. (New)

For all pipe sizes and specified wall thickness, additional fracture toughness requirements as per Supplementary Requirements Appendix-F SR 19 of API Spec 5L and as modified in this specification shall be applicable for body, weld and heat affected zone.

6.2.5.3

Supplementary Fracture Toughness Tests For pipe of all grades and specified wall thickness, the Charpy V-notch Impact Test for determination of Shear Area in accordance with Supplementary Requirement SR 5 A of API Spec 5L and as modified herein shall be performed. In addition, whenever line pipes are specified for hydrocarbon service in gaseous phase and Liquefied Petroleum Gas (LPG) service in Purchase Order for pipe size 16” and larger, Drop Weight Tear Test (DWTT) in accordance with Supplementary Requirements SR 6 of API Spec 5L and as modified in this specification shall be also performed for all grades and wall thickness.

6.2.6


6.2.6.1 (New) A test specimen for metallographic & hardness examination shall be taken transverse to the longitudinal weld, from one finished pipe from each lot of 50 pipes per heat or at least once per operating shift (12 hrs maximum) which ever is occurring more frequently and whenever changes of grade, diameter or wall thickness are made and whenever significant excursions from operating heat treatment conditions are encountered. The specimen shall be suitably ground, polished and etched to reveal the macro-structure. The specimen shall be visually examined using a minimum 10X magnification to provide evidence that heat treatment of weld zone is adequate and there is no untempered martensite left. In case imperfections or defects are observed, it will become a cause for re-evaluation of welding parameters and heat treatment as deemed necessary by Purchaser's GAIL (INDIA) LTD NEW DELHI



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Representative. 6.2.6.2 (New) Vickers hardness tests shall be carried out on each specimen taken for metallographic examination in accordance with ASTM E-92, at locations indicated in Fig. 6.2.6.2 of this specification. Indentation in the Heat Affected Zone (HAZ) shall start as close to the fusion line as possible. The resulting Vickers hardness value at any point shall not exceed 248 HV10. The maximum difference in hardness between (the base metal and any reading taken on the weld or heat affected zone shall be less than 80 HV10. Modalities of retest shall be in accordance with para 9.12.2 of API Spec. 5L. 6.2.7

Reverse Bend Test

6.2.7.1 (New) Reverse bend test shall be executed with the some number of tests and retests specified for flattening test in para 9.3.2 of API Spec 5L. Ring Specimen of width 100 mm to 115 mm shall be taken from the pipe and tested in accordance with the procedure given below and Fig. 6.2.7 of this specification. 6.2.7.2

Selection of Mandrel The reverse bend test shall be carried out with a mandrel, whose radius (R), or width (A) shall be calculated for any combination of diameter, wall thickness and grade with the following formula:

Where D -

Specified outside diameter of pipe, mm

t

Specified wall thickness of pipe, mm

-

1.4 -

Peaking factor

e -

Strain

Minimum value of 'e' shall be as follows: Grade of Steel

Min ’e' value

Gr. B

0.1425

X-42

0.1375

X-46

0.1325

X-52

0.1250

X-60

0.1125




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X-65

0.1100

X-70

0.1075

6.2.7.3 (New) Procedure The mandrel shall be plunged into the specimen, with the weld in contact with the mandrel, to such a depth that the angle of engagement between mandrel and specimen reaches 60° (Ref. Fig 6.2.7 of this specification). If the combination of diameter and wall thickness of pipe and radius of mandrel is such that the angle of engagement does not reach 60° the mandrel shall be plunged into the specimen until opposite walls of the specimen meet. 6.2.7.4 (New) Acceptance Criteria A specimen which fractures completely prior to the specified engagement of mandrel and specimen, or which reveals cracks or ruptures in the weld or heat affected zone longer than 4 mm, shall be rejected. Cracks less than 6 mm long at the edges of the specimen shall not be cause for rejection. Dye penetrate testing may be used to positively confirm cracks or openings. 7


7.1

DIAMETER Pipe Body The outside diameter of pipe body, as determined by taping the circumference, shall not deviate by more than the values given below from that given in Table E-6B (for size 4 ½) and E-6 C (for size ≥ 6 5/8 ) Appendix E. API Spec 5L Table 7 stands modified accordingly. Pipe Size

Tolerance

>4 1/2 and≤18

± 0.75 % of Specified OD or ± 3 mm whichever is smaller

20

+3 mm, - 0.25% of Specified OD

Pipe Ends Diameter tolerances for the pipe ends indicated in API Spec 5L Table-8 shall be applicable on the inside diameter for pipe sizes > 14 and on outside diameter for pipe sizes ≤12”. The inside diameter, based on circumferential measurement, over a length of 100 GAIL (INDIA) LTD NEW DELHI



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mm from the end shall comply with the tolerances specified in API Spec 5L, Inside diameter is defined as ID = (OD-2WT.) where ID, OD & WT are the inside diameter, specified outside diameter and specified wall thickness respectively. Out of Roundness Out of Roundness i.e., the difference between the maximum and minimum diameter (inside for pipe size > 14 and outside for pipe size ≤ 12) at pipe ends shall comply with the following limits. Pipe size

Tolerance

≤10¾

2mm

>12¾

3 mm

Out of roundness tolerance apply to maximum and minimum diameters as measured with a bar gauge, caliper or device measuring actual maximum and minimum diameter. Out of roundness tolerance indicated in API 5L Table-8 stands deleted. Each pipe shall be measured for conformance to above requirements. All dimensions and tolerances shall be measured and recorded at least 3 times per operating shift (12 hrs maximum). 7.3

WALL THICKNESS In addition to API requirements, the wall thickness of each pipe shall be checked along the circumference at both ends and at the mid location of pipe body at 12 o'clock, 3 o'clock, 6 o'clock and 9 o'clock positions. The wall thickness tolerance shall comply with the requirements of this specification. The tolerances on specified wall thickness shall be (+)15% and (-) 0%. API Spec 5L Table 9 stands cancelled. Wall thickness shall be measured and recorded at least 3 times per operating shift (12 hours maximum).

7.5

LENGTH All pipes shall be supplied with length between 11.5 m and 12.5 m. However pipe with length between 10.0 m and 11.5 m can also be accepted for a max. of 5% of the ordered quantity. The minimum average length of the entire ordered quantity in any case shall be 12.0m. API Spec 5L Table 11 shall not be applicable. Overall length tolerance shall be (-) Zero and (+) One pipe length to complete the ordered quantity. Each pipe shall be measured for conformance to above requirements and all measurements shall be recorded. GAIL (INDIA) LTD NEW DELHI



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7.6

STRAIGHTNESS The deviation from a straight line for all pipe sizes shall not exceed 12 mm. Each pipe shall be checked for conformance to this requirement. Straightness shall be measured and recorded at least 3 times per operating shift (12 hours maximum).

7.7


7.8

WORKMANSHIP AND DEFECTS

7.8.1

Dents Allowable dent size shall be as per API Spec 5L. Disposition of dents shall be carried out in accordance with API Spec 5L para 9.9 (c) or (d). Dents on weld and heat affected zone (HAZ) are not acceptable.

7.8.2

Offset of Plate Edges All pipes shall be checked for offset of skelp edges. Offset shall be measured and recorded at least 3 times per operating shift (12 hours maximum).

7.8.5

Height of Flash of Electric Welded Pipe Each pipe shall be checked for conformance of height of flash. Height of flash shall be measured and recorded at least 3 times per operating shift (12 hours maximum).

7.8.7

Trim of Inside Flash of Electric Welded Pipe and Trim of Inside Weld Reinforcement of Laser Welded Pipe Each pipe shall be checked for conformance of depth of trim. Depth of trim shall be measured and recorded at least 3 times per operating shift (12 hours maximum).

7.8.8

Hard Spots Any hard spot having a minimum dimension greater than 2 in. (50.8 mm) in any direction and hardness greater than 248 HV10 shall be rejected. The section of pipe containing the hard spot shall be removed as a cylinder.

7.8.9

Cracks, Sweats and Leaks Sections of the pipe containing cracks, sweats and leaks shall he cut off as per the requirement of API Spec 5L para 9.9 (c) or (d).

7.8.10

Laminations




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Any lamination or inclusion either extending into the face or bevel of the pipe or present within 25 mm from pipe ends is considered defect and pipe containing such defects shall be cut back until such defects are eliminated. The acceptance limit and disposition of lamination and other type of defects on the skelp/pipe body shall be as per para 9.8.5.4 of this specification. 7.8.11

Arc Burns Arc burns produced during the manufacturing of pipes are injurious defects and shall be disposed off in accordance with the requirements of API Spec 5L para 9.9 (c) or (d). As a reference method for conforming the existence of an arc burn, the area shall be buffed with wire brush or sanding disc and etched with 5 percent nital solution. However, arc burns can be considered for acceptance, in case the same is recrystallized by seam heat treatment. In such case, the Manufacturer shall demonstrate the recrystallization to Purchaser by taking a sample as per para 6.2.6.1 (New) of this specification.

7.8.14

Other Defects Any imperfection (measured from the surface) with a depth greater than 5 % of the specified thickness of the pipe shall be considered a defect and shall be repaired in accordance with API Spec 5L para 9.9 and as modified in this specification.

7.9

PIPE ENDS

7.9.1


7.9.3

Plain Ends Unless specified otherwise, the pipe ends shall be bevelled as per API Spec.5L. In removing the inside burrs at the pipe ends, care shall be taken not to remove excess metal and not to form an inside cavity or bevel. Removal of excess metal beyond the minimum wall thickness as indicated in para 7.3 of this specification, shall be a cause for re-bevelling. In case root face of bevel is less than that specified, the pipe ends shall be re-bevelled and rectification by filing or grinding shall not be done.

7.9.6

Bevel Protectors (New) Both pipe ends of each pipe shall be provided with metallic or high impact plastic bevel protectors as per Manufacturer's standard. Bevel protectors shall be of a design such that they can be re-used by coating applicator for providing on externally anti-corrosion coated pipes subsequent to coating of line pipe.




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9

Inspection and Testing

9.2

TESTING OF CHEMICAL COMPOSITION

9.2.1

Heat Analysis Where the steel milt is not a part of an integrated pipe mill, heat analysis shall be reported by the Manufacturer prior to start of pipe production.

9.2.2

Product Analysis

9.2.2.1

Sampling Frequency Two pipes per inspection lot shall be analyzed. Inspection lot shall be 100 pipes per heat. Pipes selected shall be such that one at the beginning of the heat and one at the end of the heat arc also represented.

9.2 2.2

Sampling Method

9.2.2.22 Welded Pipe Samples used for product analysis shall be taken from finished pipes. Samples for product analysis from skelp may be used provided the traceability of samples is guaranteed. 9.3


9.3.1

Tensile Tests Tensile properties shall be determined from specimen removed from pipe which has been subjected to all mechanical and heat treatment operations.

9.3.1.2

Tensile Testing Frequency Tensile tests shall be made at the frequency of two pipes per inspection lot. Inspection lot shall be 100 pipes per heat, API spec Table 13 stands modified accordingly.

9.3.1.3

Longitudinal Tensile Tests Longitudinal tensile tests shall be carried out on a strip specimen.

9.3.1.4

Transverse Tensile Tests The transverse tensile tests shall be carried out on flattened rectangular specimen.

9.3.1.5

Weld Tensile Tests




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Inside and outside flash of weld in excess of pipe wall thickness shall be removed from the specimen either by grinding or machining. Specimen shall be tested for ultimate tensile strength only. 9.3.5


9.3.5. 1

Charpy Test Specimens In addition to the specimen taken from the body of the pipe, three transverse specimens with weld in middle and three transverse specimens with Heat Affected Zone (HAZ) in the middle shall also be taken. When either full size or sub-size transverse specimen as per API Spec 5L, Table 14 is not possible to obtain, transverse specimen of either Size 1/3 or 1/4 Size, whichever is maximum possible, may be obtained. When such sub-size specimens are used, the acceptance of the individual / average absorbed energy values shall be established as per API Spec 5L para 9.10.4 and as modified in this specification.

9.3.5.2

Charpy Testing Frequency The minimum test frequency shall be one test (a set of three specimen each for body, weld and HAZ) per heat per lot of 100 pipes per combination of pipe size and specified wall thickness.

9.4

HYDROSTATIC TESTS

9.4.1

Hydrostatic Test Requirements Test pressure shall be held for a minimum period of 15 seconds for all sizes and grades of pipes.

9.4.2

Verification of Hydrostatic Test The pressure gauge used for hydrostatic testing shall have a minimum range of 1.5 times and maximum range of 4 times the test pressure. The pressure gauge shall be calibrated by means of a "Dead Weight" tester only and record shall be maintained.

9.4.3

Test Pressure The test pressure for all sizes and grades of pipe shall be such that hoop stress (fibre stress) generated is at least 95% of SMYS, computed based on the formula mentioned in API Spec 5 L para 9.4.3 (Note 2).

9.5

DIMENSIONAL TESTING The measuring equipment requiring calibration or verification under the provisions of API Spec 5L shall be calibrated with manual instruments at least once per operating shift (12 hours maximum). Such calibration records shall be furnished to Purchaser's Representative on request. GAIL (INDIA) LTD NEW DELHI



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9.8

NON DESTRUCTIVE INSPECTION The Purchaser reserves the right to depute its Representative(s) to perform inspection and witness tests in all phases of manufacturing and testing starting from steel making to finished line pipe ready for shipment. Manufacturer shall comply with the provisions regarding inspection notice, plant access, compliance and rejection mentioned in Appendix H of API Spec 5L The Manufacturer shall give the Purchaser reasonable notice of the starting date of normal production and the work schedule. Any action or omission on part of Purchaser's Representative shall not relieve the Manufacturer of his responsibility and obligation to supply material in strict accordance with this specification.

9.8.1

Qualification of Personnel All personnel performing NDT activities shall be qualified in the technique applied, in accordance with latest edition of ISO 9712 or ASNT No. ASNT-TC-1A or equivalent. All NDT shall be performed in accordance with written procedures. These procedures shall have prior approval of the Purchaser. Inspector Qualification Acceptable qualification for NDT inspectors shall be as specified below:

For UT

(i)

For UT, at least one level III qualified inspector shall be available to the mill for overall supervision. A level II inspector is required for shift supervision, manual weld inspection and calibration of all systems (both manual and automated).

(i)

For all other NDT methods

9.8.3

Evaluation of indications

:

Supervision

:

Level I, II, III inspector Level II or Level III inspector (in case evaluation is by Level I inspector)

Methods of Inspection Location of NDT equipment in the manufacturer's facility shall be such that final inspection of Weld seam of pipe shall be performed after hydro testing.

Plate/Skelp Inspection The longitudinal edges of the plate/skelp shall be 100% ultrasonically inspected over a width of at least 25 mm from the trimmed plate/skelp edge. Remaining plate/skelp GAIL (INDIA) LTD NEW DELHI



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shall be ultrasonically tested for laminations using an oscillating or straight running pattern of probes, so as to provide inspection coverage of at least 20% of the plate/skelp surface uniformly spread over the area. Locations showing indications above the acceptance limits may be re-examined by manual ultrasonic method. If no defects are located during re-examination, the original findings may be ignored. Additional scanning may be requested by Purchaser's Representative to check questionable areas. Pipe Ends Inspection The full circumference of both ends of each pipe after beveling shall be 100% ultrasonically tested for laminations from inside over a circumferential band of at least 25 mm width. Alternatively the pipe may be tested from outside prior to bevelling, in which case a band of at least 50 mm wide shall be tested to include the eventual bevelled area. Bevel Inspection Bevel face of all pipes shall be inspected by magnetic particle method to detect defects. Weld Inspection Electric welds shall be inspected by ultrasonic methods (Refer Table 24) using automatic ultrasonic equipment in accordance with API Spec 5L para 9.8.5, API Spec 5L SR 17 (Appendix F) and as modified in this specification. Pipe end welds shall be inspected in accordance with Para 9.8.3.1. 9.8.3.1

Pipe End Weld Inspection Pipe ends not covered by automatic ultrasonic equipment shall be inspected by manual ultrasonic equipment with same sensitivity and capability as automatic equipment.

9.8.5

Ultrasonic and Electromagnetic Inspection

9.8.5.1

Equipment All automatic ultrasonic equipment shall have an alarm device, which continuously monitors the effectiveness of the coupling. The equipment for the automatic inspection shall allow the localization of both longitudinal and transverse defects corresponding to the signals exceeding the acceptance limits of the reference standard. The equipment shall be fitted with a paint spray or automatic marking device and alarm device for areas giving unacceptable ultrasonic indications. All ultrasonic testing equipment shall be provided with recording device. In addition, an automatic weld tracking system shall be provided for correct positioning of the probes with respect to weld centre.

9.8.5.2

Ultrasonic and Electromagnetic Inspection Reference Standards




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The reference standard (calibration pipe) shall have the same specified diameter and wall thickness as specified for the production pipe being inspected and shall be of sufficient length to permit calibration of ultrasonic inspection equipment at the speed to be used in normal production. The reference standard (calibration pipe) shall also be of the same material, type and have the same surface finish and heat treatment as the pipe being inspected. The reference standard for weld UT shall contain machined notches as per as per Figure 9.8.5.2 of this specification and as given below: One longitudinal inside notch of type N10 at the weld line One longitudinal outside notch of type N10 at the weld line The reference standard for skelp/pipe body UT shall contain continuous machined notch of 8 mm width x ½ t depth, where‘t’ is the specified wall thickness. The reference standard for skelp edge UT/ UT of area adjoining weld seam and pipe ends shall have 1/4 inch dia FBH x ½ t depth, where’t’ is the specified wall thickness. The calibration shall be performed at following intervals: a. At the beginning of each operating shift (12 hours maximum). b. At least once during each operating shift (12 hours maximum). c. Every time the running of the system gives rise to doubts on its efficiency. If during the above calibration verification, it is found that the equipment has not functioned satisfactorily in the opinion of the Purchaser's Representative, all the pipes or skelp already inspected after the previous verification shall be inspected again at Manufacturer's cost. 9.8.5.4

Acceptance limits

9.8.5.4.1 Skelp Edges/Area on either side of the Longitudinal Weld Seam (New) Acceptance limit for material edge examination shall be as per criteria laid down for Acceptance Level E2 of BS 5996:1993, which is reproduced hereunder for ready reference. 1. No individual imperfection of length less than 20 mm shall be considered for population density assessment. 2. Maximum length of imperfection in any direction shall not exceed 30 mm. 3. Maximum area of individual imperfection shall not exceed 500 mm2. 4. Maximum population density (number of imperfections smaller than the maximum permissible imperfection size and longer than 20 mm per 1m length) shall not exceed 4. GAIL (INDIA) LTD NEW DELHI



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Disposition of any defect shall be as per API Spec 5L para 9.9 (c) or (d). 9.8.5.4.2 Skelp/Pipe Body (New) Acceptance limit for material body examination shall be as per criteria laid down for Acceptance level B4 of BS 5996: 1993 which is reproduced hereunder for ready reference: 1. No individual imperfection that does not exceed all of the following dimensions shall be considered for population density assessment: Area: 300 mm2, Length: 35 mm, Width: 8 mm.” (The length is the dimension at right angles to the scan track and the width is the dimension parallel to the scan track.) 2. Maximum area of any individual discontinuity shall not exceed 1000 mm2. 3. Maximum population density of imperfections smaller than the maximum permissible imperfection size and larger than the minimum imperfection size per 1 m x 1 m square shall not exceed 10. 4. Any imperfection exceeding 100 mm in length shall not be acceptable and any planar imperfection not parallel to the plate surface is not acceptable. Disposition of any defects shall be as per API Spec 5L para 9.9 (c) or (d). 9.8.7 e.

9.9

Residual Magnetism Measurement Requirements The average of the four readings shall not exceed 20 gauss and no one reading shall exceed 25 gauss when measured with Hall-effect gaussmeter. All residual magnetism measurements shall be recorded. DISPOSITION OF PIPE CONTAINING DEFECTS The repaired area shall be 100% rechecked by magnetic particle or ultrasonic inspection to ensure complete removal of defects. However for repair of cosmetic type of defects, MPI may not be conducted if so directed by Purchaser's Representative on case to case basis. The pipes having a thickness less than the minimum allowed in accordance with this specification, after repair by grinding shall be treated for disposition in accordance with API Spec 5L Para 9.9 (c) or (d).

9.10

TEST METHODS

9.10.4

Charpy Test Individual test value for any specimen shall not be less than 80% of the required minimum average absorbed energy value as per this specification.




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9.12

RETESTS

9.12.1

Recheck Analysis Modalities of recheck analysis shall be as per API Spec. 5L as applicable to the lot being tested (refer para 9.2.2.1 of this specification). However, during individual testing, each pipe shall be fully analysed to meet the requirements of Table 2B of this specification.

9.12.6

Charpy Retests In the event that a set of Charpy test specimen fails to meet the acceptance criteria, the manufacturer may elect to replace the lot (refer para 9.3.5.2 of this specification) of material involved or alternatively to test two more lengths from that lot. If both the new tests meet the acceptance criteria, then all pipes in that lot, with the exception of the original selected length, shall be considered to meet the requirement.

9.13

REPROCESSING This para stands cancelled.

10

Marking

10.1

GENERAL Marking specified in AP! Paragraphs and otherwise specified in the Purchase Order shall be in English language and international System (SI) of units. Marking shall comply with Appendix I of API Spec 5L and as modified in this specification.

11

Coating and Protection

11.1

COATINGS Unless otherwise specified in the Purchase Order, the pipes shall be delivered bare, free of any trace of oil, stain, grease and paint. Varnish coating shall be applied on the marking area. Bevels shall be free of any coating.

12

Documents

12.1

CERTIFICATION Manufacturer shall furnish to Purchaser a certificate of compliance stating that the material has been manufactured, sampled, tested, and inspected in accordance with this specification and has been found to meet the requirements. In addition all details as per Appendix F Supplementary Requirement SR 15 shall also be submitted to Purchaser/Purchaser Representative during inspection at pipe mill.




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12.2

RETENTION OF RECORDS In addition to the records indicated in API Spec 5L Table 27, the Manufacturer shall retain the records of all additional tests and calibration records mentioned in this specification including the hard copy records of ultrasonic testing carried out on pipe/skelp as well as pipe ends.

12.3

PRODUCTION REPORT (New) The Manufacturer shall provide six copies of production report in English language indicating at least the following for each pipe. International System of units (SI) shall be adopted. -

Pipe number

-

Heat number from which pipe is produced

-

Pipe length and weight.

-

Pipe grade

The Manufacturer shall provide six copies of acceptance certificates which shall include the results of all tests required as per this specification and performed on delivered material giving details of, but not limited to, the following: -

All test certificates as per SR 15.1.

-

Certified reports of dimensional, workmanship and defects inspection.

-

Data on test failures, rejected heats/lots, etc.

-

All other reports and results required as per this specification.

The certificates shall be valid only when signed by the Purchaser's Representative. Only that pipes, which have been certified by the Purchaser's Representative shall be dispatched from the pipe mill. In the event of small quantities of pipes supplied against this specification, like those for bends and other similar applications, as specifically called out in the Purchase Order, the production report may consist of only test certificates required as per SR 15 of API Spec 5L and other test reports/results required as per this specification. 12.4

LINE PIPE TRACEABILITY DATA (New) The manufacturer shall establish and follow procedures for maintaining heat and lot identity of all pipes as per Supplementary Requirements SR 15.2 of API Spec. 5L.

14

Inspection of Field Tests & Warranty (New)




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Purchaser shall be reimbursed by Manufacturer for any pipe furnished on this order that fails under field hydrostatic test if such failure is caused by a material/manufacturing defect in the pipe. The reimbursement cost shall include pipe, labour and equipment rental for finding, excavating, cutting out and installation of replaced pipe in position. The field hydrostatic test pressure will not exceed that value which will cause a calculated hoop stress equivalent to 95 percent of specified minimum yield strength. In case Manufacturer so desires, he will be advised at least two weeks in advance so that his Representative may witness the hydrostatic test in field, however, the testing and leak (if any) finding and repair operation shall not he postponed because of absence of the Manufacturer's Representative.

APPENDIX-F SUPPLEMENTARY REQUIREMENTS (NORMATIVE) SR5 Fracture Toughness Testing (Charpy V-Notch) for Pipe of Size 4½ or Larger SR 5.1

The Manufacturer shall perform Charpy V-notch test for determining Shear Area.

SR 5.3

The specimen shall be fall sized or largest obtainable sub size in case pipeline diameter and thickness does not permit full size specimen. In case it is not feasible to obtain transverse specimen, a longitudinal specimen may be taken upon approval from Purchaser.

SR 5.4


SR 5.5

This para stands deleted.

SR 5A

Shear Area

SR 5A.1 Three transverse specimens representing one test shall be taken from one length of pipe per heat per lot of 100 pipes per combination of pipe size and specified wall thickness. SR 5A.2 Unless specified otherwise in the Purchase Order, the specimen shall be tested at +32°F (0°C). The average shear value of the fracture appearance of the three specimens shall not be less than 75% and the all heat average for each order, per diameter, size and grade shall not be less than 80%. Note:

The acceptance criteria of shear area as referred in API Spec. 5L para SR 5A.3 SR 5A.4 and SR 5A.5 stand modified based on above mentioned requirements. Wherever 'heat' indicated in API Spec 5L SR 5A.3, SR 5A.4, SR 5A.5 and SR 5A.6 shall be replaced by 'lot'. Lot shall be as per SR5A.1 as above.




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SR6


SR6.1

When required as per para 6.2.5.3 of this specification, fracture toughness shall be determined using Drop Weight Tear Test (DWTT) by the Manufacturer for pipe size 16” and larger. DWTT shall be carried out in accordance with the requirements of API Spec 5L para SR 6.2 thru SR 6.8 and as modified in this specification.

SR 6.2

Two transverse specimen shall be taken from one length of pipe per heat per lot of 100 pipes per combination of pipe size and specified wall thickness. Unless specified otherwise, the test shall be conducted at +32°F (0°C).

SR 6.4

At least 80% of the lot (refer para SR 6.2 of this specification) shall exhibit a fracture appearance shear area of 75% or more for the specified test temperature.

Note:-

Acceptance criteria for retesting indicated in API Spec 5L para SR 6.5 stands modified based on above mentioned requirements. Wherever 'heat' indicated in API Spec SR6.5 shall be replaced by 'lot1. Lot shall be as per SR6.2 as above.

SR17

Nondestructive Inspection of Welds in Electric Welded Pipe and Laser Welded Pipe

SR 17.1

SUPPLEMENTARY NON DESTRUCTIVE INSPECTION The weld in electric welded pipe shall be inspected full length for surface and subsurface defects and laminations by ultrasonic methods using automatic ultrasonic equipment.

SR 17.2

EQUIPMENT AND REFERENCE STANDARDS The equipment for ultrasonic inspection shall meet the requirements of para 9.8.5.1 and 9.8.5.2 of this specification. The detailed procedure shall be approved by Purchaser's Representative.

SR 17.3 ACCEPTANCE LIMITS If during production, repeated ultrasonic indications occur requiring re-inspection by other methods and it appears that the nature of defects causing ultrasonic indications can not be definitely established, the Manufacturer shall prove by other inspection methods (such as making cross-sections as per para 6.2.6.1 of this specification) that these defects are not injurious defects as stipulated in this specification. SR 17.4 DISPOSITION Disposition of defects shall be in accordance with API Spec 5L para 9.9 (c) or (d). SR19

Additional Fracture Toughness Requirements (Transverse Charpy V-Notch) for PSL 2 Pipe




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SR 19.1

Except as allowed by SR. 19.2 of API Spec 5L, fracture toughness testing shall be performed in accordance with the requirements of para 9.3.5.1 and 9.3.5.2 of API Spec 5L and as modified in this specification, with a test temperature of 32°F (0°C) or at a lower temperature as specified in the Purchase Order. The required minimum all heat average full size absorbed energy value (based on a set of three specimens) for transverse body specimen shall be the greater of SR 19.1 (a) and SR 19.1 (b) of API Spec 5L. In case longitudinal specimen is applicable as per Table 14 of API Spec. 5L, the minimum average absorbed energy value shall be 1.5 times that applicable for transverse specimen. The required minimum all heat average full size absorbed energy value for weld and HAZ specimen shall also be the greater of SR 19.1 (a) and SR 19.1 (b) of API Spec 5L. In addition, the lowest individual absorbed energy value of the three specimens shall not be less than 80% of the value specified.




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APPENDIX- H PURCHASER INSPECTION (NORMATIVE) H.4

Rejection If Purchaser Representative rejects pipes repeatedly for any recurring cause, this shall be adequate reason to refuse final inspection of subsequent pipes until the cause has been investigated and corrective action taken by the Manufacturer.




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General

1.1.1

Marking shall also include API monogram, Purchase Order number, item number, wall thickness (mm), pipe number, heat number and weight.

1.2

Location of Markings Marking shall be paint stenciled on length of the pipe at right angles to the pipe axis. Stencil marking shall be placed on the inside surface length except that on pipe size smaller than 16, marking may either be placed on inside or outside. Paint used for stencil marking shall withstand a temperature up to 2505C expected to be experienced during further external anti-corrosion coating operations of line pipe by coating applicator.

1.3

Sequence of Marking

1.3.4

SPECIFIED DIMENSIONS Actual pipe weight in kg shall also be marked.

1.35

GRADE AND CLASS A colour code band shall be marked on inside surface of finished pipe for identification of pipes of same diameter but different wall thickness, as indicated in the Purchase Order. The colour code band shall be 50 mm wide and shall be marked at a distance of 150 mm from the pipe ends.

1.5


1.7

Die Stamping Additionally, the pipe number shall be placed by cold rolling or low stress dot marking on the outside surface of the pipe at an approximate distance of 50 mm from both ends. In case of non-availability of either cold rolling or low stress dot marking facility in pipe mill, an alternative marking scheme of a permanent nature may be proposed by the Manufacturer.




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ANNEXURE I (NEW) MANUFACTURING PROCEDURE SPECIFICATION A Manufacturing Procedure Specification (MPS) outlining the successive steps and associated inspection procedures from steel making to finished line pipe shall be prepared and submitted to Purchaser for approval prior to start of production. Manufacture of pipes shall start only after the approval of Manufacturing Procedure. The approved Manufacturing Procedure shall be strictly followed in all phases of the production of pipes. The manufacturing procedure shall as a minimum include the following information. - Steel/Plate/skelp maker and plant at which steel is produced. - Steel making process with details of secondary refining process and continuous casting process, nominal weight of each heat. - Target chemistry, range of intentionally added elements, limits on heat and product analysis to be placed on steel maker. Skelp rolling procedure indicating number of passes, their temperature and thickness reduction in each pass required by Controlled Rolling Procedure and the finishing temperature. - Heat treatment procedure document established as per para 5.4. - Ultrasonic testing of plates/skelp and pipes using automatic and manual equipment including details of equipment, techniques, scanning pattern, probe frequency, scanning sensitivity, reference standard for calibration, dynamic calibration procedure, method of marking defects and indicating loss of coupling, inspection and recording. - Pipe making procedure including skelp edge preparation, forming and any other special process proposed. - Welding procedure specification including the details of welding process, brand name, classification, size and grade of filler metal and flux, speed of welding, number of electrodes and polarity of each electrode, welding current and voltage for each wire, edge preparation, tack welding method and spacing of tack weld, details of seam tracking system for both inside and outside welding, method of checking the setup of the system, limits of internal and external weld reinforcement etc. In addition to be WPS carried out at mill WPS & PQR shall be carried out at the pipe mill by approved welders of the EPC Contractor to establish the weldability of pipe. EPC Contractor accordingly arrange for the welders to carry out the WPS / PQR at the pipe mill. Establishing the WPS of pipe mill doesn’t absolve the EPC contractor of his responsibility of carrying out WPS / PWR at site. GAIL (INDIA) LTD NEW DELHI



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- Method of weld defect removal. - Ultrasonic testing of longitudinal weld seam of pipe using automatic equipment including details of equipment, scanning pattern, probe frequency, scanning sensitivity, calibration pipe, extent of weld length at pipe ends not covered by all probes, method of marking defect and indicating loss of coupling, inspection and records. - Full details of radiographic testing equipment including radiographic film. - Dimensional tolerances, frequency of checking, measurement and record in a tabular form including details of instruments and equipments proposed. - Detail of techniques proposed for measurement of end square ness and peaking at the welds. - Hydrostatic testing including details of testing equipment, procedure and the relevant test pressure calculations. - Marking details. - Handling, storage and shipment procedure. - Production Report Formats. - Complete details of computerized pipe tracking system. Note: In the event of small quantities of pipe ordered against this specification, the requirements of submission of manufacturing procedure details can be moderated subject to agreement between Purchaser and Manufacturer.




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ANNEXURE-lI (NEW) FIRST DAY PRODUCTION TESTS Two lengths each of completely finished pipes of first day's production from two different heats (i.e. a total of four pipe lengths) shall be selected at random for testing to verify that the manufacturing procedure results in the quality of pipes which are in complete compliance with this specification. The pipes thus tested shall be considered to be the test pipes required per heat or per lot as per relevant clauses of this specification. The first day's production tests shall be repeated upon any change in the manufacturing procedure as deemed necessary by Purchaser Representative. The first day production tests shall be carried out on pipes for each wall thickness, each diameter and each grade of steel, The Manufacturer shall submit to Purchaser a report giving the results of all tests mentioned below. The report shall be agreed and signed by Purchaser Representative, prior to start of regular production. Note: In the event of small quantities of pipes ordered against this specification, like those for bends and other similar applications, as specifically called out in the Purchase Order, the first day production test shall not be carried out. Pipes in such case shall be accepted based on regular production tests. The various tests to be conducted on each pipe shall be as follows. The test method and acceptance values shall be as per this specification unless specified differently in this Annexure. a. Visual Examination All pipes shall he examined visually for dimensional tolerances and apparent surface defects. b. Ultrasonic Examination The weld seam of all pipes shall be examined ultrasonically by automatic ultrasonic equipment. c. Mechanical Properties The mechanical properties of all pipes shall be tested and shall meet the requirements of this specification. Purchaser Representative will select the places in pipe from where the test specimen shall be removed. The following tests shall be conducted: i.

Two (2) flattening test specimen shall be removed; one specimen shall be tested with weld at 0° and other at 90°.

ii.

Two (2) transverse base metal specimen and two transverse weld specimen for tensile test shall be tested. In case transverse base metal specimen is not applicable as per Fig 3 of API Spec 5L, longitudinal specimen may be taken.




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iii.

Six (6) weld cross-section specimen, three (3) from each end of the pipe joint, shall be taken for metal!-'graphic examination. Two of these specimens shall be tested for hardness at room temperature after etching.

iv.

Fracture toughness testing specimen shall be extracted as follows: -


-


-


The base metal specimen shall be tested at - 40, -10, 0, + 20° C for shear area and absorbed energy to produce full transition curve. The value at the test temperature specified in SR 5A and SR 19 of API Spec. 5L and duly modified in this specification for shear area and absorbed energy respectively shall be complied with. For other temperatures, the value shall be for information only. The sets of weld and HAZ specimen shall be tested for absorbed energy only at the same test temperature applicable as per SR 19 of API Spec. 5L. v. At points selected by Purchaser, twelve (12) DWTT specimens shall be removed from base metal in a transverse direction. The sets of 3 base metal specimen shall be tested at -40. -10, 0, +20°C for shear orp« t0 produce full transition curve. The value at the test temperature specified in SR 6 of API Spec 5L duly modified in this specification shall be complied with. For other temperatures, the value shall be for information only (Note: This test is to be carried out only when required as per para 6.2.5.3 of this specification) vi. Hardness test shall be conducted on selected pipes as per requirement of para 6.2.6 of this specification. e. In addition, all the tests and inspections require to be conducted as per this specification shall be conducted on all the pipes selected for testing during first day production test.




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3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)




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CONTENTS 1.0

SCOPE

2.0

REFERENCE DOCUMENTS

3.0

PLANT SCALE AND INSTALLATION

4.0

MATERIALS

5.0

FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING

6.0

MEASUREMENT AND LOGGING

7.0

COATING PROCEDURE AND QUALIFICATION

8.0

PIPE SURFACE PREPARATION

9.0

COATING APPLICATION

10.0


11.0

HANDLING, TRANSPORTATION AND STORAGE

12.0

REPAIR OF COATING

13.0

MARKING

14.0

QUALITY ASSURANCE

ANNEXURE-I

COMBINATIONS OF COATING MATERIALS




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1.0

SCOPE This specification covers the minimum requirements for supply/arrangement of all materials, plant, equipment, plant sites, consumables, utilities and application including all labour, supervision, inspection and tests etc. for application of external anti-corrosion coating of pipes by using 3 Layer Side Extruded Polyethylene coating conforming to DIN-30670, 1991, 'Polyethylene Coating for Steel Pipes and Fittings' and the requirements of this specification.

2.0

REFERENCE DOCUMENTS Reference has also been made to the latest edition of the following standards, codes and specifications. The edition enforce at the time of floating the enquiry shall be termed as latest edition. a. ASTM D-149

: Standard Test Methods of Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Materials at Commercial Frequencies.

b. ASTM D-257

: Standard Test Methods for D-C Resistance or Conductance of Insulating Materials.

c. ASTM D-543

: Standard Method of Test for Resistance of Plastics to Chemical Reagents.

d. ASTM D-570

: Standard Method of Test for Water Absorption of Plastics.

e. ASTM D-638

: Standard Method of Test for Tensile Properties of Plastics.

f. ASTM D-792

: Standard Test Method for Density and Specific Gravity (Relative Density) of Plastics by Displacement.

g. ASTM D-1238

: Test Method for Flow Rates of Thermoplastics by Extrusion

h. ASTM D-1525

: Test Method for Vicat Softening Temperature of Plastics

i. ASTM D-1603

:

Test Method for Carbon Black in Olefin Plastics

j. ASTM D-1693

: Test Method for Environmental Stress Cracking of Ethylene Plastics

k. ASTM D-2240

: Test Method for Rubber Property Durometer Hardness

l. ASTM D-3895

:

Test Method for Oxidative-induction Time of Polyolefins by Differential Scanning Calorimetry

m. ASTM G-42

: Tentative Methods for Cathodic Disbonding of Pipeline coatings Subjected to Elevated or Cyclic Temperatures.




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n. API RP 5L1

: Recommended Practice for Railroad Transportation of Line pipe.

o. API RP 5LW

: Transportation of Line Pipe on Barges and Marine Vessels

p. DIN EN 10204

:

Metallic Products Types of Inspection Documents

q. DIN 53735

: Testing of Plastics: Determination of Melt Index of Thermoplastics.

r. ISO 8502-3

: Preparation of Steel Stubstrates before Application of Paints and Related Products -

Part 3 - Assessment of Dust on Steel Surfaces Prepared for Painting (Pressure Sensitive Tape Method) s. ISO 9002

: Quality Systems : Specification of Production and Installation

t. ISO 11124

: Preparation of Steel Substrates Before Application of Paints and Related Products

u. SIS 055900

: Preparation of Steel Substrates before Application of Paints and Related Products -Visual Assessment of Surface Cleanliness

v. API 5L

:

w. ASME B31.8

Specification for Line Pipe

: Gas Transmission and Distribution Piping Systems.

x. ASME B31.4

: Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia, and Alcohols

y. CSA Z245.20-98

: External Fusion Bond Epoxy Coating for Steel Pipe.

The CONTRACTOR shall be familiar with the requirements of these documents and shall make them readily available at the coating plant to all persons concerned with carrying out the works specified in this specification. 3.0

PLANT SCALE AND INSTALLATION

3.1

CONTRACTOR shall size coating plant(s) after evaluating the scale of work and the time schedule required for the works. Coating plant(s), both new or existing, shall be installed into a yard whose geometry and dimensions are such as to allow the execution of a continuous work schedule. For this purpose the CONTRACTOR shall ensure non-stop work execution owing to prohibitive adverse weather conditions and install requisite equipment and plant in roofed and adequately weather protected areas.




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3.2

Plant equipment, machinery and other facilities shall be in first class operating condition to at least meet the job requirements of quality and production. Worn out and improvised plants are not acceptable.

3.3

The CONTRACTOR shall, at his own responsibility and cost, provide and prepare all necessary area for the storage of bare and coated pipe and all other materials, for coating yard, stock-piling and other temporary installation. For each area, CONTRACTOR shall provide necessary agreements as required with the land owner(s) / relevant Authorities, and, on work completion, to clean and pay settlement and claims for damages, as applicable.

3.4

The CONTRACTOR shall at its own responsibility and cost, provide for water and power supply and other utilities and consumables and obtain authorization regarding access roads and other permits required for the execution of works conforming to all the requirements of the governing Authorities.

3.5

The CONTRACTOR shall at its own expense provide a fully equipped laboratory and test facilities with adequate inventory to carry out tests required for the procedure qualification and regular production. Outside testing for qualification and regular production is not acceptable to COMPANY.

3.6

The CONTRACTOR shall be fully responsible for adherence to all statutory regulations applicable for handling and disposal of the hazardous chemicals during the coating works.

3.7

The CONTRACTOR shall be responsible for obtaining all statutory approvals / clearances from relevant Authorities including Pollution Control Board, as applicable for the coating plant(s).

4.0

MATERIALS

4.1

The three layer coating system shall comprise of a powder epoxy primer, polymeric adhesive and a polyethylene top coat. Coating materials shall be suitable for the service conditions and the pipe sizes involved. The coating materials i.e. epoxy powder, adhesive and polyethylene compound shall have proven compatibility. The coating system and materials shall be pre-qualified and approved by COMPANY in accordance with provisions Annexure I of this specification. CONTRACTOR shall obtain prior approval from COMPANY for the coating system and coating materials,

4.2

The coating materials Manufacturer shall carry out tests for all properties specified in para 5.3.1 and 5.3.2 for each batch of epoxy, adhesive and polyethylene compound. In addition, the Manufacturer shall also furnish Infrared Scan for each batch of epoxy powder. The coating materials Manufacturer shall issue test certificates as per DIN EN 10204, 3.1B for each batch of materials supplied to CONTRACTOR and the same shall be submitted to COMPANY for approval prior to their use.

4.3

In addition to Manufacturer's certificate, the CONTRACTOR shall draw samples from each batch of epoxy, adhesive and polyethylene in the presence of COMPANY Representative and test for the following properties at the coating yard at least one week prior to its use, to establish compliance with the Manufacturer's test GAIL (INDIA) LTD NEW DELHI



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certificates. a. Epoxy Powder: i.

Gel Time

ii. Cure time iii. Moisture content iv. Thermal Characteristics (Tg1, Tg2 , ∆H) b. Adhesive: i. Specific Gravity ii. Melt Flow Rate iii. Vicat Softening Point c. Polyethylene: i. Melt Flow Rate ii. Specific Gravity iii. Vicat Softening Point iv. Moisture Content v. Oxidative Induction Time In case of failure of any of the above tests in a batch, that batch of material shall be tested for all other tests required as per para 5.3.1 and 5.3.2 including the tests which failed. If all tests pass, the batch shall be accepted for coating. If any of the tests fail, entire batch of material shall be rejected and shall not be used for the coating. 4.4

All materials to be used shall be supplied in sealed, damage free containers and shall be suitably marked with the following minimum information: a. Name of the Manufacturer b. Type of Material c. Batch Number d. Place and Date of Manufacture e. Shelf Life/Expiry Date (if applicable) f. Quantity All materials noted to be without above identification shall be deemed suspect and shall be rejected by COMPANY. Such materials shall not be used for coating and shall be removed from site and replaced by CONTRACTOR at his expense.

4.5

CONTRACTOR shall ensure that all coating materials are properly stored in accordance with the Manufacturer's recommendation at all times, to prevent damage and deterioration in quality prior to use.




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4.6

CONTRACTOR shall be required to use all materials on a date received rotation basis, i.e. first in- first used basis.

5.0

FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING

5.1

The coating shall be able to withstand a maximum in service operating temperature of (+)650C and shall conform to 'S’ Type of coating as per DIN 30670. In addition, in open storage the coating must be able to withstand a temperature of at least (+)80°C, without impaling its serviceability and properties specified.

5.2

The top coat polyethylene used shall be a black readymade compound, fully stabilized against Influence of ultraviolet reaction (i.e. sunlight), oxygen in air and heat (due to environmental temperature as specified above). No appreciable changes shall occur during exposure to such environments up to at least a period of 6000 hours. The CONTRACTOR shall submit certificate from Manufacturer in this regard.

5.3

Properties Properties of coating system and coating material shall comply the requirements indicated in subsequent paragraphs. In case the coating / material properties are tested as per test methods / standards other than specified herein below, the same may be accepted provided the test procedures and test conditions are same or more stringent than the specified.

5.3.1

Properties of Epoxy Powder and Adhesive CONTRACTOR shall choose such a brand of epoxy powder and adhesive that will achieve the functional requirements and properties of coating system as specified in para 5.1 and 5.3.3 of this specification respectively. Epoxy powder properties shall be as per CSA Z245.20.98. The colour of epoxy powder shall be either green or dark red or any other colour approved by COMPANY except grey colour. Copolymer grafted adhesive shall have the following properties: SI. No.

5.3.2

Properties

Unit

Requirement

Test Method

g/10 minutes

1 .0 min.

ASTM D1238

a.

Melt Flow Rate (190°C/2.16kg)

b.

Vicat Softening Point

°C

100 min.

ASTM D1525

c.

Specific Gravity

-

0.926 min.

ASTM D 792

Requirement

Test Method

Properties of Polyethylene Compound SI. No.


Properties

Unit



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a.

Tensile Strength @ + 25° C

N/mm2

17 min.

ASTM D 638

b.

Melt Flow Rate (190DC/2.16kg)

9/10 minutes

0.25 min.

ASTM D 1238 or DIN 53735

c.

Specific Gravity @ + 25°C

-

0.926 min. (MDPE) 0.941 min. (HDPE)

ASTM D 792

d.

Hardness @ + 25 °C

Shore D

50 min.

ASTM D 2240

e.

Water Absorption, 24 hours, @ + 25 °C

%

0.05 max.

ASTM D 570

f.

Volume Resistivity @ + 25°C

Ohm-cm

1016min.

ASTM D 257

g

Dielectric withstand, 1000 Volt/sec rise @ + 25°C

Volts/ mm

30,000 min.

ASTM D 149

h.

Vicat

°C

110 min.

ASTM D 1525

i.

Elongation

%

600 min.

ASTM D 638

j-

Oxidative Induction Time in Oxygen at 220°C, Aluminum pan, no screen

Minutes

10

ASTM D3895

k.

Environmental Stress Crack Resistance (ESCR) (for F 50) : -Medium DensityCondition "C” -High DensityCondition "B"

l.

5.3.3

Softening Point

Carbon Black Content

300 Hours

ASTM D1693 300

%

2 min.

ASTM D 1603

Properties of Coating System




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SI. No.

Properties

Unit

Requirement

Test Method

Bond Strength (using Type 2 Test Assembly a. i.e. Dynamometer) . @20+/-5°C . @65+/-5°C

Kg/cm

8.0 min 5.0 min

DIN 30670

Impact Strength (Min. of 30 impacts on b. body along the length. No breakdown allowed when tested at 25 Kv)

Joules per mm of coating thickness

7 min

DIN 30670

c.

Indentation Hardness @23+/-2°C @70+/-2°C

mm

0.2 max 0.3 max

DIN 30670

d.

Elongation at Failure

%

300 min.

DIN 30670

e.

Coating Resistivity (*)

Ohm - m2

10 8 min.

DIN 30670

-

Melt Flow Rate shall not deviate by more than 35% of original value

DIN 30670

Melt Flow Rate shall not deviate by more than 35% of regional value

DIN 30670

f.

Heat Ageing (*)

9-

Light Ageing (*)

-

h.

Cathodic Disbondment @ + 65° C after 30 days @ + 65°C after 48 hrs

mm radius of disbondment (**)

I

Degree of Cure of Epoxy. Percentage Cure, ∆H. ∆Tg


15 max. ASTM G42 7 max.

% C

0


95 +3/-2

CSA Z 245.20-98(***)


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(*) Test carried out in an independent laboratory of national / international recognition on PE top coat is also acceptable. (**) Disbondment shall be equivalent circle radius of total unsealed area as per ASTM G42. (***) Temperature to which the test specimens are to be heated during cyclic heating shall however be as per the recommendations of epoxy powder manufacturer. 6.0

MEASUREMENT AND LOGGING CONTRACTOR shall maintain records in computer using MS ACCESS database Software containing all the relevant data of individual pipe and pipe coating including pipe number, heat number, diameter, length, wall thickness, defects, coating number, batches of materials, sampling, testing, damages, repairs, rejects and any other information that COMPANY considers to be relevant and required for all incoming bare pipes and COMPANY approved outgoing coated pipes as applicable. CONTRACTOR'S documentation shall be designed to ensure full traceability of pipe and coating materials through all stages of coating and testing. CONTRACTOR shall submit this information in the form of a report at the agreed intervals. The above data shall also be provided in MS ACCESS format in Compact Disc (CD). CONTRACTOR shall provide one Computer Terminal to COMPANY Representative for monitoring/tracking of the above. The CONTRACTOR shall also submit the material balance details to COMPANY for information at the end of each shift.

7.0

COATING PROCEDURE AND QUALIFICATION

7.1

Upon award of the CONTRACT, the CONTRACTOR shall submit within two (2) weeks, for COMPANY approval, a detailed report in the form of bound manual outlining, but not limited to, the following:

a.

Details of plant(s), location(s), layout, capacity and production rate(s).

b.

Details of the equipment available to carry out the coating works including surface preparation, epoxy powder application and its recycling system, adhesive & polyethylene extrusion, moisture control facilities available for coating materials.

c.

Details of process control and inspection equipment required for the coating process such as temperature control, thickness control, holiday testers, etc

d.

Details of chemical pre-treatment facilities including process control and inspection equipment for phosphoric acid wash, de-ionised water wash and chromate wash.

e.

Facilities in the yard for unloading, handling, transport, production, storage, stockpiling, loading of bare and coated pipes and warehouses for storage of other coating materials.

f.

Plant Organization Chart and availability of manpower including coating specialist

g.

Details of utilities/facilities such as water, power, fuel, access roads and communication etc. GAIL (INDIA) LTD NEW DELHI



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After approval has been given by COMPANY, no change in plant set-up shall be made. However, unavoidable changes shall be executed only after obtaining written approval from COMPANY. 7.2

At least four (4) weeks prior to the commencement of production coating, a detailed procedure of the CONTRACTOR'S methods, material proposed, etc., shall be formulated by the CONTRACTOR and submitted for COMPANY approval in the form of a bound manual. The procedure shall include, but not limited to, the following information and proposals: a. Pipe inspection at the time of bare pipe receipt. b. Steel surface preparation, including preheating, removal of steel defects, method of pipe cleaning, dust removal, abrasive blast cleaning and surface profile; methods of measurements and consumables. c. Complete details of chemical pre-treatment viz phosphoric acid wash, de-ionized water wash, and chromate wash including product data sheets, health and safety sheets and manufacturer's recommended application procedure. d. Pipe heating, temperatures and control prior to epoxy application. e. Complete details of raw materials including current data sheets showing values for all the properties specified together with quality control and application procedure recommendations from manufacturer(s). f. Application of FBE powder, adhesive and polyethylene, including characteristics, temperature, line speed, application window, curing time, etc. g. Quenching and cooling, including time and temperature. h. Quality Assurance System, Quality Plan, Inspection and Test Plan and reporting formats, including instrument and equipment types, makes and uses, etc i.

Detailed method of repair of coating defects duly classified depending upon nature and magnitude of defects and repair thereof including coating stripping technique

j.

Details of instrument and equipment calibration methods including relevant standards and examples of calibration certificates.

k. Complete details and inventory of laboratory and equipment for procedure qualification and regular production l.

Pipe handling and stock piling procedure.

m. Sample of recording and reporting formats, including laboratory reports, certificates and requirement as per clause 6.0 of this specification. n. Complete details of test certificate for raw material including test methods and standard used. o. Test certificates from PE compound manufacturer for tests for thermal aging, coating resistively and aging under exposure to light. These test certificates shall not be older than three years.




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p. Health, Safety and Environment Plans. q. Storage details of coating materials and chemicals. r. Continuous temperature monitoring at various stages of coating Procedure Qualification Tests (PQT) shall be carried out only after obtaining written approval of the above procedure from COMPANY. No change in the procedure shall be made after approval has been given by the COMPANY. However, unavoidable changes shall be executed only after obtaining written approval from COMPANY. 7.3

Prior to start of production, the CONTRACTOR shall, at his expense, carry out a coating PQT for each pipe diameter on max. wall thickness, for each type of pipe, for each coating material combination, and for each plant; to prove that his plant, materials, and coating procedures result in a quality of end product conforming to the properties stated in clause 5.3, relevant standards, specifications and material manufacturer's recommendations. CONTRACTOR shall give seven (7) working days notice to witness all procedures and tests. A batch representing a normal production run, typically 15 pipes, shall be coated in accordance with the approved coating procedure and the coating operations witnessed by COMPANY Representative. Out of these pipes, at least one pipe shall be coated partly with epoxy and partly with both epoxy and adhesive layers. At least 5 (five) test pipes shall be selected by COMPANY Representative for coating procedure approval tests and shall be subjected to procedure qualification testing as described hereinafter. All tests shall be witnessed by the COMPANY Representative. Out of 5 (five) test pipes, 1 (one) pipe partly coated with epoxy and partly coated with both epoxy and adhesive layers shall be included. Remaining 4 (four) test pipes shall have all three layers. During PQT, the CONTRACTOR shall qualify various procedures forming a part of coating operations as detailed subsequently.

7.4

Qualification of Procedures

7.4.1

Epoxy Powder Application & Recycling During pre-qualification, air pressure in the epoxy spray guns, satisfactory functioning of monitoring system, line speed vs coating thickness, etc. shall be established. Dew point of air used to supply the fluidized bed, epoxy spray system and epoxy recycling system shall be recorded during the PQT. Also, the CONTRACTOR shall remove samples of reclaimed powder from the reclamation system. These samples of reclaimed powder shall be subject to a detailed visual examination, thermal analysis and moisture content tests. The properties of the reclaimed powder shall be within the range specified by the Manufacturer of epoxy powder. In case the properties of the reclaimed powder are out of the range specified by the Manufacturer, CONTRACTOR shall not use the reclaimed powder during the regular production.

7.4.2

Pipe Pre-heating The CONTRACTOR shall establish the temperature variation due to in-coming pipe




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temperature, line speed variation, wall thickness variation, emissivity, interruptions, etc. and document the same during the PQT stage. During PQT, proper functioning of pipe temperature monitoring and recording system including alarm/hooter shall be demonstrated to the COMPANY Representative. 7.4.3

Surface Preparation The procedure to clean and prepare the pipe surface shall be in accordance with the requirements of this specification. The ratio of shots to grits shall be established during procedure qualification testing, such that the resultant surface profile is not dished and rounded. The qualification shall be performed through a visual inspection, measurement of roughness and check of the presence of dust in the abrasive blast cleaned pipe surface.

7.4.4

Chemical Pre-treatment

7.4.4.1

Phosphoric Acid Wash followed by De-ionised Water Wash The procedure to apply the chemical pre-treatment viz. phosphoric acid wash followed by de-ionised water wash shall be In accordance with the recommendations of the manufacturer and shall result in intended cleaning requirements of this specification. Working solution preparation, maintaining concentration, application procedure including method of spreading, spreading rate, drying times, etc. depending upon the cleanliness/temperature of the incoming pipe and the line speed shall be established. Temperature of the chemical, pipe pre-heat temperature vs. line speed vs. dwell time, rinsing procedure, testing & control, rectificatory measures, drying procedure etc. shall be clearly established during PQT. Also the quality of the deionised water shall be established during PQT.

7.4.4.2

Chromate Treatment The procedure to apply the chromate treatment shall be in accordance with the recommendations of the manufacturer. Working solution preparation, maintaining concentration, application procedure including method of spreading, spreading rate, drying times, etc. depending upon the temperature of the incoming pipe and the line speed shall be established. Temperature of the chemical, pipe pre-heat temperature vs. line speed, pipe heating after chromating and time limit within which the pipe to be heated, testing & control, rectificatory measures, shall be clearly established during PQT.

7.4.5

Coating Application The COMPANY Representative will check the correctness of each coating application operation, values of the main parameters of each operation, preheating pipe surface temperature prior to epoxy powder application temperature, line speed, fusion bonded epoxy curing time, temperature and flow rate of co-polymer adhesive and polyethylene, etc. and the same shall be recorded. These values shall be complied with during regular production.

7.5

Qualification of Applied Coating

7.5.1

Tests on pipe coated partly with epoxy and partly with epoxy & adhesive Layers




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a. Degree of Cure Epoxy film samples (minimum 4 no.) shall be scrapped from the coated pipe and the samples shall be taken for cure test using Differential Scanning Calorimetry (DSC) procedure. Care shall be taken to remove the samples of full film thickness avoiding inclusion of steel debris. Glass transition temperature differential (∆Tg) and % cure (∆H) shall comply with the specified requirements. b. Epoxy Layer Thickness Epoxy layer thickness shall be checked at every one metre spacing at 3, 6, 9 and 12 o'clock positions. The thickness shall comply with the specified thickness requirements. c. Adhesive layer Thickness Adhesive layer thickness shall be checked at every one metre spacing at 3, 6, 9 and 12'o clock positions. The thickness shall comply with the specified thickness requirements. d. Holiday Inspection Entire pipe shall be subject to holiday inspection and the test voltage shall be set to exceed 5 v/micron of epoxy thickness specified for the portion coated only with epoxy layer. e. Adhesion Test i. Adhesion Test (24 hrs or 48 hrs) shall be carried out on the epoxy coated pipe. Test method, no. of test specimen and acceptance criteria shall comply CSA Z.245,20-98, Table 4. ii. Adhesion of FBE shall also be separately determined at ambient temperature at two locations by the "St Andrews Cross" method and the test shall comply with the specified requirements. f. 2.5° Flexibility Test 2.5° Flexibility test shall be carried out on the epoxy coated pipe at test temperature of 0°C. Test method, no. of test specimen and acceptance criteria shall comply CSA Z.245,20-98, Table 4. g. Cross-section & Interface Porosity Test Cross section porosity and interface porosity tests shall be carried out on the epoxy coated pipe. Test method, no. of test specimen and acceptance criteria shall comply CSA Z.245,20-98. Table 4. 7.5.2

Tests on pipes coated with all three layers a. Bond Strength: Three test pipes shall be selected for bond strength tests. On each of the selected pipes, three bond strength test shall be performed for each specified temperature I.e. one at each end and one in the middle of the pipe and specified




REV-0 Page 14 of 34


requirements shall be complied with, i.e. bond strength as well as mode of separation. Length of peel shall be minimum 65 mm. None of these samples shall fail. b. Impact Strength: Three test pipes shall be selected for impact strength test and the test shall meet the specified requirements. c. Indentation Hardness: Two samples for both temperatures from all pipes shall be taken. If any one of these samples fail to satisfy the specified requirements, then the test shall be repeated on four more samples. In this case, none of the samples shall fail. d. Elongation at failure: Six samples each from three coated pipes i.e. 18 samples In all shall be tested and the test shall comply the specified requirement. Only one sample per pipe may fail. e. Cathodic Disbondment Test: Two CD tests shall be carried out for the total lot of test pipes having all three layers. One test shall be carried out for 30 days duration and another test for 48 hours duration. The tests shall comply the specified requirement. Whenever Procedure Qualification is necessitated for different pipe size with same coating material combination, 48 hours test only be conducted. 30 days CD test is not mandatory in this case. f. Holiday Inspection All the pipes shall be subject to holiday inspection. The test voltage shall be as specified in para 10.4, (b). g. Coating Thickness Measurement All pipes shall be subject to coating thickness measurements. Acceptance criteria shall be as per para 10.3. h. Air Entrapment One sample each from pipe body and on weld (if applicable) shall be taken from all four coated pipes and the specified requirements shall be complied with. i. Degree of Cure Epoxy film samples (minimum 4 no., equally spaced) shall be scrapped from one coated pipe and the samples shall be taken for cure test using Differential Scanning Calorimetry (DSC) procedure. Care shall be taken to remove the samples of full film thickness avoiding inclusion of steel debris. Glass transition temperature differential (∆Tg) and % cure (∆H) shall comply with the specified requirements. 7.5.3

Inspection of all test pipes All pipes shall be subject to the following Inspections:




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a.

Surface cleanliness, surface roughness measurements and dust control immediately after second abrasive blast cleaning and salt test immediately after De-ionised water wash.

b.

pH of pipe surface before and after phosphoric acid wash.

c.

visual inspection of chromate coating.

d.

Visual inspection of finished coating, cut back dimension, internal/external cleanliness, end sealing and bevel inspection. Acceptance criteria for all inspection and testing shall be as specified in this specification.

7.6

After completion of the qualification tests and inspection as per para 7.4 and 7.5 above, the CONTRACTOR shall prepare and Issue to COMPANY for approval a detailed report of the above tests and inspection including test reports/certificates of all materials and coatings tested. Only upon written approval from COMPANY, CONTRACTOR shall commence production coating.

7.7

On successful completion of PQT, coating of all five (5) test pipes shall be removed and completely recycled as per the approved coating procedure specification, at CONTRACTOR'S expense. Remaining pipes will be accepted by COMPANY provided they meet the requirements of this specification and need not be stripped and re-cycled.

7.8

The CONTRACTOR shall re-establish the requirements of qualification and in a manner as stated before or to the extent considered necessary by COMPANY, in the event of, but not limited to, the following: 

Every time there is a change in the previously qualified procedure.



Every time there is a change in the manufacturer and change in formulation of any of the raw materials and change in location of raw material manufacture.



Every time the coating yard is shifted from one location to the other or every time the critical coating equipments (induction heater, epoxy spray system, extruder, etc) are shifted.



Any change In line speed during coating application



Any time when in COMPANY'S opinion the properties are deeded to be suspect during regular production tests.

7.9

COMPANY reserves the right to conduct any or all the test required for qualification through an independent laboratory or agency at the cost of CONTRACTOR when in COMPANY's opinion, the results are deemed suspect. COMPANY's decision shall be final.

8.0

PIPE SURFACE PREPARATION

8.1

Unless specified otherwise, the pipes shall be supplied free from mill applied oils but GAIL (INDIA) LTD NEW DELHI



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may be subject to contamination occurring during transit. 8.2

Prior to cleaning operation, CONTRACTOR shall visually examine the pipes and shall ensure that all defects, flats and other damages have been repaired or removed. The CONTRACTOR shall also remove marking stickers, if any, present within the pipe. Record shall be kept of such marking on the stickers to ensure traceability of pipe after coating.

8.3

Any oil, grease, salt or other contaminants detrimental to the formation of a good coating bond or coating quality shall be removed prior to coating application. Contaminants may be removed by the use of non-oily solvents. Gasoline or kerosene shall not be used for this purpose. Visible oil and grease spots shall be removed by solvent wiping. Solvent cleaning shall be in accordance with SSPC-SP1. Steel surface shall be allowed to dry before abrasive cleaning.

8.4

All pipes shall be preheated to a temperature of 65°C to 85°C prior to abrasive blast cleaning. The external surface of the pipe shall be cleaned using 2 no. dry abrasive blast cleaning units to achieve the specified surface cleanliness and profile. After first abrasive blast cleaning, chemical pre-treatment with phosphoric acid solution as per para 8.6 shall be carried out prior to second abrasive blast cleaning. However at the option of CONTRACTOR, chemical pre-treatment with phosphoric acid solution as per para 8.6 may be carried out after the second abrasive blaster. The abrasive blast cleaning units shall have an effective dust collection system to ensure total removal of dust generated during blast cleaning from the pipe surface. The equipment used for abrasive blast cleaning shall meet the specified requirements and shall be free from oil, water soluble salts and other forms of contamination to ensure that the cleaning process is not impaired. Traps, separators and filters shall be checked for condensed water and oil at the start of each shift and emptied and cleaned regularly. During abrasive blast cleaning, the metallic abrasive shall be continuously sieved to remove "fines" and "contaminants" and the quality checked at every four hours. Abrasives used for blast cleaning shall comply ISO11124

8.5

Suitable plugs shall be provided at both pipe ends to prevent entry of any shot/grit into the pipe during blast cleaning operations. These plugs shall be removed after blast cleaning. Alternatively the CONTRACTOR may link the pipes suitably together to prevent the entry of any shot/grit into the pipe.

8.6

Chemical Pre-treatment with Phosphoric Acid Solution

8.6.1

All pipes shall be provided chemical pre-treatment with phosphoric acid solution. 10% solution of phosphoric acid, Oakite 31 / 33 or equivalent, shall be used to remove all soluble salts and other soluble contaminants. The CONTRACTOR shall provide data sheets and supporting documentation for the phosphoric acid to be used. The documentation shall verify that the phosphoric acid is suitable for the treatment of line pipe prior to the application of the specific fusion bonded epoxy powder being applied and the final coating will meet fully the requirements of this specification.




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8.6.2.1

The pipe temperature immediately prior to the phosphoric acid treatment shall be in the range of 450 to 750C. Phosphoric acid treatment shall be followed immediately by washing with de-ionised water. Deionised water used shall conform to the following requirements:

SI.No.

Properties

Unit

Requirement

a.

Turbidity

NTU

1 max.

b.

Conductivity

μmho/cm

5 max.

C

Hardness

d.

Total Alkalinity as CaC03

mg/l

2 to 3

e.

Chloride as CI"

mg/l

1 max.

f.

Sulphate as SO4

mg/i

1 max.

g.

pH

-

-

Nil

6.5 to 7.5

Tests to determine the above properties shall be carried out in accordance with "Standard Methods for the Examination of Water and Wastewater" published jointly by American Public Health Association, American Water Works Association and Water Pollution Control Federation. Quality of the deionised water shall be monitored at the start of each shift and at every four hours interval. Non-compliance of deionised water wrt the above requirements shall cause for stoppage of the operations. 8.6.3

The pH of the pipe surface shall be determined both before and after the de-ionised water rinse initially on each pipe and in case of consistent results, the frequency may be relaxed to once per hour at the discretion of COMPANY Representative. The measured pH shall be as follows: Before de-ionised water wash :

1 to 2

After de-ionised water wash

6 to 7

:

8.6.4

After the deionised water wash, the pipe shall be dried with dry air and preheated to a temperature of 65°C to 85°C.

8.6.5

The salt tests shall be carried out after deionised water rinse. One test shall be carried out at one end of each pipe. The acceptance criteria shall be 2g/cm2. An approved salt meter (SCM 400 or equivalent) shall be used to carry out salt tests and shall be calibrated in accordance with the equipment manufacturer's recommendations.

8.7

Abrasive cleaning carried out shall be such that the resultant surface profile Is not dished and rounded when viewed with 30X magnification. The standard of finish for GAIL (INDIA) LTD NEW DELHI



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cleaned pipe shall conform to near white metal finish to Sa 2 ½ of Swedish Standard SIS 055900 latest edition. Surface of pipe after abrasive blast cleaning shall have an anchor pattern of 50 to 70 microns (Rz), This shall be measured for each pipe by a suitable instrument such as surface profile depth gauge. In addition the pipe surface after blast cleaning shall be checked for the degree of cleanliness (Sa 2 ½), degree of dust and shape of profile. Degree of dust shall comply the requirements of ISO 8502 - 3. Acceptance limit shall be either quality rating 2 or Class 2. 8.8

All pipes shall be visually examined for presence of any shot/grit/loose material left inside the pipe during blast cleaning. Suitable mechanical means (stiff brush) shall be employed to remove the same before the pipes are processed further. In addition, inside surface of the pipe shall also be visually inspected for presence of any foreign material or shots and grit (free or embedded/sticking to pipe inside surface). The pipe inside surface shall be examined using sharp floodlight focused at the middle of the pipe at one end while inspection is carried out visually from other end. Any foreign material or shots/grit present in the pipe shall be completely removed by mechanical brush, high pressure air jets, by tilting of pipe, etc.

8.9

At no time shall the blast cleaning be performed when the relative humidity exceeds 85%. The CONTRACTOR shall measure the ambient conditions at regular intervals during blast cleaning and coating operations and keep records of prevailing temperature, humidity and dew point.

8.10

The blast cleaned surface shall not be contaminated with dirt, dust, metal particles, oil, water or any other foreign material, nor shall the surface or its anchor pattern be scarred or burnished. All blast cleaned pipe surface shall be kept in dust free enclosure prior to coating. After blast cleaning, all surfaces shall be thoroughly inspected under adequate lighting to determine anchor pattern, quality of blasting and identify any surface defects prior to coating application. All surface defects such as slivers, scab, burns, laminations, welds spatters, gouges, scores, indentations, slugs or any other defects considered Injurious to the coating Integrity made visible during blast cleaning shall be reported to the COMPANY Representative and on permission from COMPANY Representative, such defects shall be removed by filing or grinding. After any grinding or mechanical repairs, the remaining wall thickness shall be checked and compared with specified thickness. Any pipes having thickness less than 95% of specified thickness shall be kept aside and disposed off as per the instructions of COMPANY Representative. The method employed to remove surface defects shall not burnish or destroy the anchor pattern or contaminate the surface. Pneumatic tools shall not be used unless they are fitted with effective air/oil and water traps. Where burnishing results in destruction of anchor pattern, the anchor pattern shall be restored by suitable means. Pipes which have damages repaired by grinding and have ground areas more than 50mm in diameter shall be re-blasted. Any dust or loose residues that have been accumulated during blasting and/or during filing/grinding operations shall be removed by vacuum cleaning. If contamination of surface occurs, the quality of blast cleaning method and process shall be examined. If the surface roughness is outside the specified limit, the blast cleaning material shall be checked and replaced.




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8.11

Upon Completion of the blasting operations, the quality control supervisor shall accept the pipe for further processing or return for re-blasting after removal of defects/imperfections. In case imperfections are considered detrimental to the coating quality, the same shall be reported to COMPANY'S Representative for final decision on rejection or re-blasting / removal of defects. Re-blasting / removal of defects or returning pipe to the yard shall be at the CONTRACTOR'S cost. COMPANY'S Representative, in additions, reserves the right to initiate any of the above actions during periodic inspections for oil, dust, salt, imperfections, surface defects, lack of white metal finish, etc.

8.12

In order to ensure that pipe with defects are not processed further, provisions shall be available to lift the pipes from inspection stand.

8.13

Chemical Pre-treatment with Chromate Solution

8.13.1

Following completion of abrasive blast cleaning, all pipe surface shall be chemically pre-treated with a10% strength chromate solution.

8.13.2

The CONTRACTOR shall provide data sheets and supporting documentation for the chemical to be used. The documentation shall verify that the chemical is suitable for the treatment of line pipe prior to the application of the specific fusion bonded epoxy powder being applied and the final coating will meet fully the requirements of this specification.

8.13.3

The chemical pre-treatment shall be applied fully in accordance with the chemical suppliers' Instructions and in a manner that ensures 100% uniform coverage of the pipe surface without introducing surface contamination.

8.13.4 The CONTRACTOR shall check that the concentration of the chemical pre- treatment solution remains within the range recommended by the chemical manufacturer for the pipe coating process. The concentration shall be checked at the make up of each fresh solution and once per hour, using a method approved by the chemical manufacturer. The CONTRACTOR shall also ensure that the chemical pre-treatment solution remains free from contamination at all times. Recycling of chemical pretreatment solution is not permitted. 8.13.5

The CONTRACTOR shall ensure that the temperature of the substrate is maintained between 40°C and 80°C and the chromate solution temperature does not exceed 60°C or as recommended by the manufacturer.

8.13.6

The chromate coating shall be smooth, even, free from runs, drips or excessive application and lightly adherent with no flaking of the coating. The chromate coated steel must be thoroughly dried immediately after application and shall be achieved by boiling off any residual solution on the surface.

8.14

The total allowable elapsed time between completion of the blasting operations and commencement of the pre-coating and heating operations shall be such that no detectable oxidation of the surface occurs. Relative humidity readings shall be recorded every half an hour during the blasting operations in the immediate vicinity of the operations. The maximum elapsed time shall not exceed the duration given




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below:

Relative Humidity %

Maximum elapsed time

>80

2 hours

70 to 80

3 hours

<70

4 hours

Any pipe not processed within the above time-humidity requirement shall be completely re-blasted. Any pipe showing flash rusting shall be re-blasted even if the above conditions have not been exceeded. 8.15

Pipe handling between abrasive blasting and pipe coating shall not damage the surface profile achieved during blasting. Any pipe affected by the damage to the surface exceeding 200mm2 in area and/or having contamination of steel surface shall be rejected and sent for re-blasting.

9.0

COATING APPLICATION The external surface of the cleaned pipe conforming to clause 8.0 of this specification shall be immediately coated with 3-layer extruded polyethylene coating in accordance with the procedures approved by COMPANY, relevant standards and this specification. In general the procedure shall be as follows:

9.1

Pipe Heating

9 1.1

Immediately prior to heating of pipe, all dust and grit shall be removed from inside of the pipe by a combination of air blast, brushing and vacuum cleaning. Suitable arrangement shall be made to protect the bevel ends from getting damaged during the coating operation.

9.1.2

Induction heater or gas fired heating shall be used for heating the pipe. The method shall be capable of maintaining uniform temperature along the total length of the pipe, and shall be such that it shall not contaminate the surface to be coated. In case of induction heating, appropriate frequency shall be used to ensure 'deep heating' and intense skin heating is avoided. Gas fired heating system shall be well adjusted so that no combustion products are deposited on the steel surface. This shall be demonstrated on bare pipes prior to start of PQT. Oxidation of the cleaned pipe surfaces prior to coating (In the form of blueing or other apparent oxide formation) is not acceptable.

9.1.3

External surface of the pipe shall be heated to about 190°Cor within a temperature range (min. to max.) as recommended by the powder manufacturer. Required pipe temperature shall be maintained as it enters the coating chamber.

9.1.4

Temperature of the pipe surface shall be continuously monitored & recorded by using suitable Instruments such as infrared sensors, contact thermometers,




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thermocouples etc. The recording method shall allow to correlate each line pipe. The monitoring instrument shall be able to raise an alarm/activate audio system (hooter) in the event of tripping of induction heater/gas fired heater or in the event of pipe temperature being outside the range recommended by the manufacturer. Any deviation from the application temperature range recommended by manufacturer shall be rectified. If immediate rectification is not feasible, the production shall be stopped until cause of deviation has been removed. Any pipe coated during the duration of temperature deviation shall be identified by marking and rejected. Such rejected pipes shall be stripped, re-cleaned and recoated. 9.1.5

Temperature measuring & monitoring equipment shall be calibrated twice every shift and/or as per COMPANY Representative's instruction.

9.1.6

CONTRACTOR shall ensure that pipe surface emissivity variations are minimized during pipe heating. To avoid significant variance, more than once blasted joints should be coated at the same time and not mixed with joints blasted only once.

9.2

Pipe Coating

9.2.1

Subsequent to pipe heating, coating consisting of following layers shall be applied onto the pipe. i.

Electrostatic application of epoxy powder of minimum dry film thickness 0.150 mm, unless otherwise specified. The maximum thickness shall not exceed the epoxy thickness specified by epoxy powder manufacturer.

ii.

Grafted co-polymer adhesive application by extrusion, minimum thickness 0.200 mm.

iii.

Polyethylene application by extrusion.

The coated pipe shall be subsequently quenched and cooled in water for a period that shall sufficiently lower the temperature of pipe coating to permit handling and inspection. 9.2.2

Minimum total thickness of finished coating shall be as under: Pipe Size (Specified Outside Diameter)

Minimum Coating Thickness (mm)(*) Normal Type (n)

Reinforced Type (v)

Up to 10 ¾ " (273.1 mm)

2.0

2.7

Over l0 ¾ (273.1 mm) to below 20" (508.0 mm)

2.2

2.9

From 20" (508.0mm) to below 32" (813.0 mm)

2.5

3.2




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From 32" (813.0 mm) and above

3.0

3.7

(*) In case HDPE material is used as top coat, 10% reduction in minimum coating thickness specified is permissible. Required coating thickness shall be Normal Type (n), unless otherwise specified. 9.2.3

Coating materials shall be inspected in accordance with the manufacturer's recommendation prior to coating application and it shall be ensured that the materials are moisture free. In case the relative humidity exceeds 80%, the adhesive and polyethylene material shall be dried using hot dry air as per the directions of COMPANY Representative.

9.2.4

Prior to starting the application of fusion bonded epoxy powder, the recovery system shall be thoroughly cleaned to remove any unused powder remaining from a previous line pipe coating application. The use of recycled powder shall be permitted subject to: a. Satisfactory qualification of the reclaimed system during PQT stage b. The proportion of the reclaimed powder in the working mix does not exceed 20% at any one time. c. The quality of the recycled powder being routinely checked during production, at a minimum frequency of once per shift and consistently meets the requirements stated at para 5.3.1

9.2.5

Dry air, free of oil and moisture shall be used in the coating chamber and spraying system and filters, dehumidifier/dryer as required along with control & monitoring system shall be provided for this purpose. Dew point of air used to supply the fluidized bed, epoxy spray system and epoxy recycling system shall be at least (-) 40°C and this shall be monitored during the regular production.

9.2.6

Air pressure in the epoxy spray guns shall be controlled, continuously monitored and recorded by using suitable instruments. The air pressure shall be controlled within the limits established during coating procedure qualification. The monitoring system shall be capable of rising an alarm activate audio system (hooter) in the event of change in air pressure beyond the set limits. Any deviation from the pre-set limits shall be rectified, if immediate rectification is not feasible, the production shall be stopped until cause of deviation has been removed. Any pipe coated during the duration of air pressure deviation shall be identified by suitable marking and rejected. Such rejected pipes shall be stripped and recoated.

9.2.7

Extruded adhesive layer shall be applied before gel time of the epoxy coating has elapsed and within the window recommended by the manufacturer. The CONTRACTOR shall establish, to the satisfaction of the COMPANY Representative, that the adhesive is applied within the gel time window of epoxy and at the temperature recommended by the adhesive manufacturer. The CONTRACTOR shall state the minimum and maximum time interval between epoxy and adhesive application at the proposed pre-heat temperature and line speed.




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9.2.8

Extruded polyethylene layer shall be applied over the adhesive layer within the time limit established during PQT stage and within the time/temperature range recommended by the manufacturer. The extrusion temperatures of the adhesive and polyethylene shall be continuously recorded. The monitoring instruments shall be independent of the temperature control equipment. The instruments shall be calibrated prior to start of each shift.

9.2.9

CONTRACTOR shall ensure that there is no entrapment of air or void formation along the seam weld (where applicable) during application of coating. Air entrapment below the coating and also along the coating overlap shall be prevented by forcing the coating on to the pipe using high pressure roller of suitable design during coating application. In case it is not adequately achieved, CONTRACTOR shall supplement by other methods to avoid air entrapment. The methods used shall be witnessed and approved by COMPANY.

9.2.10

Resultant coating shall have a uniform gloss and appearance and shall be free from air bubbles, wrinkles, holidays, irregularities, discontinuities, separation between layers of polyethylene & adhesive, etc.

9.2.11

Coating and/or adhesive shall terminate 150 mm (+) 20 / (-) 0 mm from pipe end. The adhesive shall seal the end of applied coating. CONTRACTOR shall adopt mechanical brushing for termination of the coating at pipe ends. Edge of the coating shall be shaped to form a bevel angle of 30° to 45°.

9.2.12

Failure to comply with any of the above applicable requirement and of the approved procedure shall be cause for the rejection of the coating and such coating shall be removed in a manner approved by COMPANY at CONTRACTOR's expense.

10.0


10.1

General The CONTRACTOR shall establish and maintain such quality assurance system as are necessary to ensure that goods or services supplied comply in all respects with the requirements of this specification. The minimum inspection and testing to be performed shall be as indicated subsequently herein.

10.2

Visual Inspection Immediately following the coating, each coated pipe shall be visually checked for imperfections and irregularities of the coating. The coating shall be of natural colour and gloss, smooth and uniform and shall be blemish free with no dust or other particulate inclusions. The coating shall not show any defects such as blisters, pinholes, scratches, wrinkles, engravings, cuts, swellings, disbonded zones, air inclusions, tears, voids or any other irregularities. Special attention shall be paid to the areas adjacent to the longitudinal weld (if applicable), adjacent to the cut-back at each end of pipe and within the body of the pipe.




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In addition inside surface of the pipe shall also be visually inspected for presence of any foreign material or shots and grit (free or embedded/sticking to pipe inside surface). The pipe inside surface shall be examined using sharp floodlight focused at the middle of the pipe at one end while inspection is carried out visually from other end. 10.3

Coating Thickness a. The coating thickness shall be determined by taking at least 10 measurements at locations uniformly distributed over the length and periphery of each pipe. In case of welded pipes, five of the above readings shall be made at the apex of the weld seam, uniformly distributed over the length of the coated pipe. All readings must meet the minimum requirements. However, localized coating thickness of less than the permissible minimum thickness can be tolerated on the condition that it does not attain a total extent of more than 5 cm2 per meter length of coated pipe, and the actual coating thickness does not drop more than 10% below the permissible minimum coating thickness at these locations. The frequency of thickness measurement as stated above shall be initially on every pipe, but may be reduced depending upon consistency of results, at the sole discretion of COMPANY Representative. Results of all measurements shall be recorded. b. Thickness of epoxy and adhesive shall be measured at the beginning of each shift and whenever the plant re-starts after any stoppage for compliance. Coating of epoxy and adhesive on portion of pipe required for this purpose, stripping and recoating of such partly coated pipes shall be at CONTRACTOR's expense. c. Coated pipes not meeting the above requirements shall be rejected. Rejected coated pipes shall be stripped and re-coated in accordance with approved procedure, at CONTRACTOR's expense.

10.4

Holiday Detection a. Each coated pipe length shall be checked over 100% of coated surface by means of a "holiday detector" of a type approved by COMPANY for detecting holidays in the finished coating. b. The holiday detector shall be a low pulse D.C. full circle electronic detector with audible alarm and precise voltage control complying with DIN VDE 0433 Part 2. The set voltage for inspection shall be minimum 25 kV. Travel speed shall not exceed 300 mm/s. c. CONTRACTOR shall calibrate the holiday detector at least once every 4 hours of production. CONTRACTOR shall have necessary instruments or devices for calibrating the holiday detector. d. Any pipe coating shall be rejected if more than 1(one) holiday & area more than 100 cm2 in size are detected in its length attributable to coating process.




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e. Holidays which are lesser in size than those mentioned in (d) above, shall be repaired in accordance with an approved procedure and shall be at CONTRACTOR's expense. 10.5

Bond Strength Test a. CONTRACTOR shall conduct bond strength test for composite coating as per Clause 5.3.3(a) of this specification. A minimum of 65 mm length shall be peeled. First 20 mm and last 20 mm shall not be counted for assessment of bond strength. b. The frequency of test for cut back portions shall be one pipe in every fifteen (15) pipes coated and for middle of pipe shall be one pipe in every sixty (60) pipes coated or one pipe per shift whichever is higher. On each selected pipe, bond strength shall be performed for each specified temperature. Test shall be performed at each cut back portion and one in the middle of pipe. The system shall disbond /separate cohesively either in adhesive layer or in polyethylene layer. Majority of the peeled off area on the pipe shall show presence of adhesive. Disbondment / separation at epoxy to steel interface or epoxy / adhesive interface or adhesive / polyethylene interface shall not be permitted. The failure mode shall be recorded for each test. c. In case the test fails to comply with the specified requirement, the CONTRACTOR shall test the preceding and succeeding coated pipe. If both pipes pass the test, then the remainder of the pipe joints in that shift shall be deemed satisfactory. If either pipe fails to meet the specified requirements, all pipes coated during that shift shall be tested until the coating is proved acceptable. Rejected coated pipes shall be stripped and re-coated in accordance with approved procedure, at CONTRACTOR'S expense. d. The frequency of bond strength test as per para 10.5 (b) for cut back portion may be reduced depending upon the consistency of result to one pipe in every twenty five (25) instead of every fifteen pipes, at the sole discretion of the COMPANY Representative.

10.6

Impact Strength a. Impact strength test shall be conducted as per clause 5.3.3(b) of this specification. Initially the frequency of test shall be two (2) coated pipes per shift that may be further reduced to one coated pipe per 2 weeks depending upon consistently acceptable results at the sole discretion of COMPANY'S Representative. b. Minimum thirty (30) impacts located equidistant along the length of coated pipe shall be performed. c. Immediately after testing, the test area shall be subjected to holiday detection at the same voltage as used prior to impact strength test. The pipe shall be rejected if any holiday is noted in the test area. d. In case of test failure, retesting and disposal of coated pipe shall be as per para 10.5 (c) above.

10.7

Indentation Hardness a. Indentation hardness test shall be as per clause 5.3.3 (c) of this specification. The frequency of test shall be initially 2 (two) coated pipes per shift which shall be further




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reduced to one test each on 2 coated pipes per week at random after 1 week of consistently acceptable results. Two samples for each temperature shall be taken from the cut back portion of coated pipe and one in the middle of the pipe for this test. b. In case of test failure, retesting and disposal of coated pipe shall be as per para 10.5 (c) above. 10.8

Air Entrapment Test a. Strips from bond strength tests or coated pipe may be used to help determine the porosity of the finished coating. Strip shall be also cut from longitudinal weld (if applicable) at cut back portion and examined for the presence of voids. b. Bond strength strip shall be viewed from the side and at the failure interface. At the pipe bond strength test location, utility knife shall be used to cut the edge of the coating to a 45° angle and view with a microscope. Similar examination shall be done in the coating cut back area. c. One sample each either on the bond strength strip or coated pipe and strip cut from the longitudinal weld (if applicable) shall be examined for air entrapment per shift. Strips shall be viewed from the side. d. All examination shall done using a 30X magnification hand-held microscope. The polyethylene and adhesive layers shall have no more than 10% of the observed area taken up with air entrapment (porosity or bubbles). Air entrapment shall not occupy more than 10% of the thickness in each case. Bubbles shall not link together to provide a moisture path to the epoxy layer. e. In case of test failure, retesting and disposal of coated pipe shall be as per para 10.5 (c) above.

10.9

Degree of Cure Epoxy film samples shall be removed from cut back portion of the coated pipe using hammer and cold chisel and the samples shall be taken for cure test using DSC procedure. Care shall be taken to remove the samples of full film thickness avoiding inclusion of steel debris. Glass transition temperature differential (∆Tg) and % cure (∆H) shall comply with the specified requirements. a. Frequency of this test shall be once per shift. Pipe shall be selected randomly by COMPANY Representative during the middle of a shift. Suitable provisions / arrangements as per the instructions of COMPANY Representative shall be made by the CONTRACTOR for this purpose b. In case of test failure, production carried out during the entire shift shall be rejected, unless the CONTRACTOR proposes a method to establish the compliance with the degree of cure requirements of all pipes coated during that shift.

10.10

Epoxy Layer Adhesion Test




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a. Adhesion of epoxy layer shall be determined at ambient temperature by the "St Andrews Cross" method i.e. by cutting two straight lines through the epoxy layer with a sharp knife. The incisions shall intersect at an angle of 30V1500. The epoxy coating shall resist disbondment from the steel when attempts are made to flick/lift the coating from the 30° angle with a sharp knife. b. Frequency of this test shall be once per shift. The test shall be carried out at the cut hack portion on the pipe from which the Degree of Cure test has been carried out as per para 10.9 above. c. In case of test failure, retesting and disposal of coated pipe shall be as per para 10.9 (c) above. 10.11

Cathodic Dlsbondment Test a. 48 hours CD test shall be conducted as per clause 5.3.3 (h) of this specification. b. The frequency of this test shall be once in every two weeks or one test representing each batch of epoxy powder used, whichever is more frequent. c. In case the test fails to conform to the specified requirement, at the option of the CONTRACTOR, all pipes coated after the previous acceptable test and prior to next acceptable test shall be rejected or the test shall be repeated using two additional samples taken from the same end of the affected pipe. When both retests conform to the specified requirement, the lot of pipes shall be accepted. When one or both the retests fail to conform to the specified requirement, all coated pipes after previous acceptable test and prior to next acceptable shall be rejected. All rejected pipes shall be stripped, re-cleaned and re-coated. COMPANY may consider a further retest program to determine whether any of the affected pipe meet the criteria for acceptance upon written request by the CONTRACTOR.

10.12. Damages occurring to pipe coating during above tests shall be repaired in accordance with approved coating repair procedure. 10.13

Repairs occurring on account of the production tests are however excluded from above mentioned limitations at para 10.4 (d) above.

10.14

COMPANY reserve the right to perform inspection and witness tests on all activities concerning the pipe coating operations starting from bare pipe to finished coated pipe ready for dispatch and also testing of raw materials. CONTRACTOR shall give reasonable notice of time and shall provide without charge reasonable access and facilities required for inspection to the COMPANY's representative. Inspection and tests performed or witnessed by COMPANY's representative shall in no way relieve the contractor’s obligation to perform the required inspection and tests.

10.15

In case rate of defective or rejected pipes and/or samples tests are 10% or more for a single shift (typically 8 hours), CONTRACTOR shall be required to stop production and carry out a full and detailed investigation and shall submit findings to COMPANY for approval. CONTRACTOR shall recommence the production only after getting the written permission from COMPANY. Under no circumstances any action or omission of the COMPANY'S Representative shall relieve the CONTRACTOR of his responsibility for material and quality of




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coating produced. No pipes shall be transported from the coating plant unless authorized by COMPANY in writing. 11.0


11.1

The CONTRACTOR shall be fully responsible for the pipe and for the pipe identification marking from the time of "taking over" of bare pipe from COMPANY until such time that the coated line pipes are 'handed over’ and/or installed in the permanent installation as the case may be according to the provisions of the CONTRACT. At the time of "taking over" of bare pipes CONTRACTOR shall inspect and record all the relevant details referred above including pipe defects in the presence of COMPANY. All pipes shall be checked for bevel damages, weld seam height, dents, gouges, corrosion and other damages. COMPANY Representative shall decide whether pipe defects / damages are suitable for repair. Damage to the pipes that occur after the CONTRACTOR has taken delivery such as dents, flats, or damage to the weld ends shall be cut off or removed and pipes re-bevelled and repaired again as necessary. The cost of this work, as well as that of the pipe lost in cutting and repair shall be to the CONTRACTOR'S account. All such works shall be carried out after written approval of the COMPANY. Any reduction in length shall he indicated In the CONTRACTOR'S pipe tracking system.

11.2

The CONTRACTOR shall unload, load, stockpile and transport the bare pipes within the coating plant(s) using suitable means and in a manner to avoid damage to pipes. The CONTRACTOR shall stockpile the bare pipes at the storage area of the coating plant. The CONTRACTOR shall prepare and furnish to COMPANY a procedure/calculation generally in compliance with API RP-5L1 for stacking of pipes of individual sizes, which shall be approved by COMPANY prior to commencement.

11.3

The CONTRACTOR shall load, unload, transport and stockpile the coated pipes within the coating plant using approved suitable means and in a manner to avoid damage to the pipe and coating. The COMPANY shall approve such procedure prior to commencement of work.

11.4

Coated pipes may be handled by means of slings and belts of proper width (minimum 60 mm) made of non- abrasive/non-metallic materials, in this case, pipes to be stacked shall be separated row by row to avoid damages by rubbing the coated surface in the process of taking off the slings. Use of round sectional slings is prohibited. Fork lifts may be used provided that the arms of the forklift are covered with suitable pads, preferably rubber.

11.5

Bare/ coated pipes at all times shall be stacked completely clear from the ground, at least 300 mm, so that the bottom row of pipes remain free from any surface water. The pipes shall be stacked at a slope so that driving rain does not collect inside the pipe. Bare / coated pipes may be stacked by placing them on ridges of sand free from stones and covered with a plastic film or on wooden supports provided with suitable cover. This cover can be of dry, germ free straw covered with plastic film, otherwise foam rubber may be used. The supports shall be spaced in such a manner as to avoid permanent bending of the pipes.




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Stacks shall consist of limited number of layers such that the pressure exercised by the pipe's own weight does not cause damages to the coating. CONTRACTOR shall submit calculations for COMPANY approval in this regard. Each pipe section shall be separated by means of spacers suitably spaced for this purpose. Stacks shall be suitably secured against falling down and shall consist of pipe sections having the same diameter and wall thickness. The weld seam of pipes shall be positioned always in a manner so as not to touch the adjacent pipes. The ends of the pipes during handling and stacking shall always be protected with bevel protectors. 11.6

The lorries used for transportation shall be equipped with adequate pipe supports having as many round hollow beds as there are pipes to be placed on the bottom of the lorry bed. Total width of the supports shall be at least 5% of the pipe length and min. 3 no. support shall be provided. These supports shall be lined with a rubber protection and shall be spaced in a manner as to support equal load from the pipes. The rubber protection must be free from all nails and staples where pipes are in contact. The second layer and all following layers shall be separated from the other with adequate number of separating layers of protective material such as straw in plastic covers or mineral wool strips or equivalent, to avoid direct touch between the coated pipes. All stanchions of lorries used for transportation shall be covered by non-abrasive material like rubber belts or equivalent. Care shall be exercised to properly cover the top of the stanchions and other positions such as reinforcement of the truck body, rivets, etc. to prevent damage to the coated surface. Slings or non-metallic straps shall be used for securing loads during transportation. They shall be suitably padded at the contact points with the pipe

11.7

Materials other than pipes and which are susceptible of deteriorating or suffering from damages especially due to humidity, exposure to high thermal excursions or other adverse weather conditions, shall be suitably stored and protected. Deteriorated materials shall not be used and shall be replaced at CONTRACTOR's expenses. These materials shall always be handled during loading, unloading and storage in a manner so as to prevent any damage, alteration and dispersion. When supplied in containers and envelopes, they shall not be dropped or thrown, or removed by means of hooks, both during the handling operations till their complete use. During unloading, transport and utilization, any contact with water, earth, crushed stone and any other foreign material shall be carefully avoided. CONTRACTOR shall strictly follow Manufacturer's instructions regarding storage temperature and methods for volatile materials that are susceptible to change in properties and characteristics due to unsuitable storage. If necessary the CONTRACTOR shall provide for a proper conditioning.

11.8

In case of any marine transportation of bare/coated line pipes involved, the same shall be carried out in compliance with API RP 5LW. CONTRACTOR shall furnish all details pertaining to marine transportation including drawings of cargo barges, storing/stacking, sea fastening of pipes on the barges/marine vessels to the company for approval prior to undertaking such transportation works. In addition




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contractor shall also carry out requisite analyses considering the proposed transportation scheme and establish the same is safe and stable. On-deck overseas shipment shall not be allowed. 12.0

REPAIR OF COATING CONTRACTOR shall submit to COMPANY, its methods and materials proposed to be used for executing a coating repair and shall receive approval from COMPANY prior to use. In open storage the repair coating materials must be able to withstand a temperature of at least (+)80°C without impairing its serviceability and properties. CONTRACTOR shall furnish manufacturer's test certificates for the repair materials clearly establishing the compliance of the repair materials with the applicable coating requirements indicated in this specification. All pipes leaving coating plant shall have sound external coating with no holiday or porosity on 100% of the surface. Defects, repairs and acceptability criteria shall be as follows: -

Pipes showing porosities or very small damage not picked up during holiday test and having a surface less than 0.5 cm3 or linear damage (cut) of less than 3 cm shall be repaired by stick using material of same quality.

-

Damages caused to coating by handling such as scratches, cuts, dents, gouges, not picked up during holiday test, having a total reduced thickness on damaged portion not less than 2 mm and an area not exceeding 20 cm2 shall be rebuild by heat shrink patch only and without exposing to bare metal.

-

Defects of size exceeding above mentioned area or holidays of width less than 300 mm shall be repaired with heat shrink repair patch by exposing the bare metal surface.

-

Defects exceeding the above and in number not exceeding 2 per pipe and linear length not exceeding 500 mm shall be repaired using heat shrinkable sleeves of HTLP 80 or equivalent.

-

Pipes with bigger damage shall be stripped and recoated.

-

In case of coating defect close to coating cut back, CONTRACTOR shall remove the coating throughout the entire circumference of the pipe down to the steel surface and increase the coating cut back length. Now if the coating cut back exceeds 170 mm of linear length of pipe then the coating shall be repaired by the use of heat shrink sleeves thereby making up the coating cut back length of 150 mm.

Not withstanding the above, under no circumstances, if the defect exceeds 70 mm from the original coating cut back length, the entire coating shall be removed and the pipe shall be recycled through the entire coating procedure. Irrespective of type of repair, the maximum numbers of repair of coating shall be as follows:




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-

Holiday repair of size <100 cm2 attributable to process of coating application shall be maximum one number per pipe.

-

In addition to the above, defects to be repaired by heat shrink patch/sleeve shall be maximum 2 (two) per pipe.

Defects exceeding the above limits shall cause pipe coating rejection, stripping and recoating. The above is exclusive of the repairs warranted due to testing as per this specification. All repairs carried out to coating for whatever reason shall be to the account of CONTRACTOR. Cosmetic damages occurring in the polyethylene layer only need not be repaired by exposing up to steel surface, as deemed fit by the COMPANY Representative. In any case the CONTRACTOR shall establish his material, methods and procedure of repair that result in an acceptable quality of product by testing and shall receive approval from COMPANY prior to use. Testing of repairs shall be in the same form as testing coating. All repairs shall result in a coating thickness no less than the parent coating thickness. CONTRACTOR shall test repairs to coating as and when required by COMPANY. 13.0

MARKING CONTRACTOR shall place marking on the outside surface of the coating at one end of the coated pipe, and marking snail indicate, but not limited to the following information: a. Pipe number, Heat number b. Diameter & Wall thickness c. Coated pipe number d. Colour band e. Any other information considered relevant by COMPANY. f. Pipe Manufacturer Name g. Inspection Mark/Punch CONTRACTOR shall obtain prior approval on marking procedure to be adopted from the COMPANY.

14.0

QUALITY ASSURANCE

14.1

The CONTRACTOR shall have established within his organization and, shall operate for the contract, a documented Quality System that ensures that the requirements of this specification are met in all aspects. The Quality System shall be based upon ISO 9001/2 or equivalent.

14.2

The CONTRACTOR shall have established a Quality Assurance Group within its




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organization that shall be responsible for reviewing the Quality System and ensuring that it is implemented. 14.3

The CONTRACTOR shall submit the procedures that comprise the Quality System to the COMPANY for agreement.

14.4

The CONTRACTOR'S Quality System shall pay particular attention to the control of Suppliers and Sub-contractors and shall ensure that the requirements of this specification are satisfied by the Suppliers and Sub contractors operating Quality system in their organization.

14.5

The CONTRACTOR shall, prior to the commencement of work, prepare and issue a Quality Plan for all of the activities required to satisfy the requirements of this specification. The plan shall include any sub-contracted work, for which the subcontractors Quality Plans shall be submitted. The plan shall be sufficiently detailed to indicate sequentially for each discipline the requisite quality control, inspection, testing and certification activities with reference to the relevant procedures and the acceptance standards.

14.6

The CONTRACTOR'S Quality system and associated procedures may, with due notice, be subject to formal audits. The application of quality control by the CONTRACTOR will be monitored by the COMPANY Representatives who will witness and accept the inspection, testing and associated work required by this specification.




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ANNEXURE-I LIST OF ACCEPTABLE COMBINATIONS OF COATING MATERIALS The following combinations of coating materials are considered acceptable. In the event of award of contract, CONTRACTOR shall furnish the combination(s) proposed and re-confirmation of compatibility & properties of the proposed combination (s) from the raw materials Manufacturers & system properties. Epoxy Powder (Manufacturer)

Adhesive (Manufacturer)

PE Compound (Manufacturer)

CORRO-COAT EP-F2001 (JOTUN)

FUSABOND158D (DUPONT)

SCLAIR 35 BP HDPE (NOVACOR)

PE 50-8190/8191 (BASF) or CORRO-COAT EP-F 2001 (JOTUN)

LUCALEN G3510H (BASF)

LUPOLEN 3652 D SW 00413 (BASF)

PE 50-6109 (BASF) or CORRO-COAT EP-F

ME 0420 (BORALIS)

HE 3450 (BOREALIS)

CORRO-COAT EP-F 2001 (JOTUN)

LE-149 V (S K CORPORATION)

ET 509 B (S K CORPORATION)

SCOTCHKOTE 226N (3M)

ME 0420 (BOREALIS)

PB 48A004

2001/2002HW (JOTUN) or SCOTCHKOTE 226N (3M)

(GAIL)

Although the above combinations would be acceptable to COMPANY, the responsibility of suitability for application, performance, properties and compliance to the coating system requirements shall unconditionally lie with the CONTRACTOR.




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SPECIFICATION FOR INTERNAL EPOXY COATING FOR LINE PIPES


SPECIFICATION FOR INTERNAL EPOXY COATING OF LINE PIPES


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CONTENTS 1 2 3 4 5 6 7 8 9

SCOPE DEFINITIONS ABBREVIATIONS INTERNAL LIQUID EPOXY COATING COATING MATERIAL APPLICATION OF THE COATING MATERIAL PRODUCTION CONTROL REPAIRS HANDLING, TRANSPORTATION AND STORAGE

ANNEX A :

(NORMATIVE) DETERMINATION OF ASH (REFER TO SUB CLAUSE 5.2.5)

ANNEX B :

(NORMATIVE) DRY FILM THICKNESS (REFER TO SUB CLAUSE 5.3.3 AND 7.1.2)

ANNEX C :

(NORMATIVE) RESISTANCE TO GAS PRESSURE VARIATION (REFER TO SUB CLAUSE 5.3.9)

ANNEX D :

(NORMATIVE) HYDRAULIC- PRESSURE BLISTERING (REFER TO SUB CLAUSE 5.3.12)

ANNEX E :

(NORMATIVE) POROSITY OF A FILM OF THE COATING MATERIAL ON A GLASS PANEL (REFER TO SUB CLAUSE 7.2.6)

ANNEX F : ANNEX G :


(NORMATIVE) CURING TEST (REFER TO SUB CLAUSE 7.2.5) (NORMATIVE) WET-SPONGE TEST (REFER TO SUB CLAUSE 7.2.6)



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1. SCOPE The intent of this specification is to set forth the minimum requirements for supply / arrangement of all materials, plant, equipments, plant sites consumables, utilities and application including all labour, supervision, inspection & test etc for application of internal epoxy coating. 2. DEFINITIONS OWNER means the GAIL (INDIA) LIMITED The COATING CONTRACTOR is the party, who will do coating, supplies equipment and services to perform the duties specified by the contractor CONTRACTOR / VENDOR means the person(s) named as contractor in the FORM OF AGREEMENT and the legal successors in title to this person (s). The word shall indicates a requirement The word should indicates a recommendation 3. ABBREVIATIONS ASTM - American Society for Testing and Materials BS DIN

- British Standards - Deutsche Industries Normen

FBE

- Fusion Bonded Epoxy

ISO

- International Organisation of Standardisation

NACE

- National Association of Corrosion Engineers

SSPC - Steel Structures Painting Council 3.1.

Codes, Regulations and Standards The latest edition of the following codes and standards shall establish the minimum standards for the work. VENDOR may use alternate standards that meet or exceed those if approved by OWNER. American Society for Testing and Materials (ASTM) - ASTM D 638 Test Methods for Tensile Properties of Plastics




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- ASTM G95

Test Method for Cathodic Disbonding of Pipeline Coatings.

International Standards Organization (ISO) - ISO 9002 Quality System – Quality Assurance in Production, Installation and Servicing - ISO 8501-1 Preparation of Steel Substrates before Application of (Part I) Paints and Related Products – Visual Assessment of Surface Cleanliness - ISO 8503-1 Preparation of Steel Substrates before Application of (Part 1) Paints and Related Products – Visual Assessment of Surface Cleanliness - ISO 15741 Paints and Varnishes – Friction-reduction coatings for the interior of onshore – and offshore steel pipeline for non-corrosive gases. British Standards (BS) - BS 5750

: Specification for Final Inspection and Testing (Part 3)

Deutsche Institute Fur Normung (DIN) - DIN 30670 - DIN 50049 3.4.

: Polyethylene Coatings for Steel Pipes and Fittings : Inspection Documents for the Delivery of Metallic Products.

Document Precedence

The VENDOR shall notify OWNER / CONSULTANT of any conflict between this specification, the related data sheets, the Codes and Standards and any other specifications noted herein. Resolution and / or interpretation precedence shall be obtained from OWNER / CONSULTANT in writing before proceeding with the design & manufacture. In case of conflict, the order of precedence shall be: • • • •

Coating Data Sheets Coating Narrative Specification Design General Specification and Standards Industry Codes and Standards

4. INTERNAL LIQUID EPOXY COATING Each pipeline shall be provided with an internal liquid epoxy coating by the Vendor. The internal coating shall be as per ISO 15741 – 2001 (E). 5. COATING MATERIAL




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5.1. General The coating material shall typically be a two-pack epoxy paint. It shall not contain any substances which will be released from the paint film after it has cured and are proven to be detrimental to the operation of the pipeline and the quality of the gas. Unless otherwise agreed, the coating material shall be qualified in accordance with 5.2 and 5.3 and shall not be changed after qualification. The manufacturer of the coating material shall provide on request infrared spectrograms of the base component and the curing agent component (see 5.2.8) In addition, the manufacturer shall provide a product data sheet (see 5.6), a health and safety data sheet and a certificate stating the test results obtained in accordance with 5.2 and 5.3 respectively and, if applicable, deviating test conditions. The manufacturer shall also provide with every batch of the coating material a batch test certificate stating the information as given in 5.8. Unless otherwise agreed, the applied coating shall provide corrosion protection during storage and transport for a minimum period of one year without significant breakdown of the coating. The typical operating-temperature range for this type of coating is between -200C and 110 0C. Where, subsequently, external coatings have to be applied, care shall be taken not to allow the internal coating to be damaged by the elevated temperatures which may occur. 5.2.

Particular requirement for qualification of the coating material

5.2.1. General The following sub clauses describe the laboratory test methods which are required for qualification of the coating material. 5.2.2. Non-volatile matter (by mass) When determined in accordance with ISO 3251, the non-volatile matter (by mass) of the coating material shall comply with the value specified by the coating material manufacturer in the qualification certificate (Table- 2) 5.2.3. Non-volatile matter (by volume)




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When determined in accordance with ISO 3233, the non-volatile matter (by volume) of the coating material shall comply with the value specified by the coating material manufacturer in the product data sheet (Table-1) 5.2.4. Viscosity When determined by the method specified by the manufacturer, the viscosity of the ready-mixed coating material shall comply with the value specified by the coating material manufacturer in the qualification certificate (Table 2) The viscosity should preferably be measured with ISO 2431 5.2.5. Density When determined in accordance with one of the parts of ISO 2811, the density of the coating material shall comply with the value specified by the coating material manufacturer in the product data sheet (Table 1) 5.2.6. Ash (residue on ignition) When determined in accordance with the method described in annex A, the ash (residue on ignition) of the coating material shall comply with the value specified by the coating material manufacturer in the qualification certificates (Table 2) 5.2.7. Pot life The pot life is considered to be the time taken by the ready-mixed coating material to reach a condition at which it can no longer be applied satisfactorily. The pot life shall be specified in the product data sheet (see 5.6) 5.2.8. Infrared spectrograms Infrared spectrograms of the base component and the curing agent component shall be submitted on request. 5.2.9. Appearance The appearance and continuity of the coating shall be inspected visually without any magnification. 5.3.

Particular requirement for qualifications of the cured paint film

5.3.1. Preparation of test panels




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Perform the tests specified in 5.3.3 to 5.3.12 on coatings applied to the required dry film thickness specified in 5.3.3 by spraying on to test panels (steel or glass). Prepare steel test panels as specified in 6.2 and glass panels as specified each test at least in duplicate. 5.3.2. Conditions of test panels If specified, condition the coated test panels using one of the following cycles, depending on the substrate and on the individuals test. Cycle B and cycle C are optional and the choice of the conditioning cycle depends on the time available to perform the test procedure. Cycle A Substrate: Steel or Glass - Condition at 18 0C to 25 0C and ≤ 80% relative humidity until the coating is at least tack-free. - Dry for 30 minutes in a circulating-air oven at (75+2)0C - Condition for a minimum of 30 minutes at 180C to 250C and ≤ 80% relative humidity before testing. Cycle B Substrate: Steel or Glass - condition at 180C to 250C and ≤ 80% relative humidity until the coating is at least tack-free. - Dry for 30 minutes in a circulating-air oven at (150+2)0C - Condition for a minimum of 30 minutes at 18OC to 25OC and ≤ 80% relative humidity before testing. Cycle C Substrate: Steel or Glass - condition at 18OC to 25OC and ≤ 80% relative humidity until the coating is at least tack-free. - Dry for 30 minutes in a circulating-air oven at (40+2) OC. - Condition for a minimum of 30 minutes at 18OC to 25OC and ≤ 80% relative humidity before testing.




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5.3.3.

Dry film thickness Unless otherwise agreed, the dry film thickness of the coating, applied on a glass or steel panel, shall be between 60 µm and 100 µm except for the test described in 5.3.6 (resistance to neutral salt spray). Unless otherwise agreed, the dry film thickness shall be measured in accordance with ISO 2808: 1997, Method No. 2 for glass and Method No. 10 for blast-cleaned steel, following the procedure given in annex B.

5.3.4. Adhesion When determined in accordance with ISO 2409, the cross-cut classification of the coating applied on steel panels and conditioned using cycle B or C (see 5.3.2) shall be equal to or lower than 1. 53.5. Buchholz hardness When determined in accordance with ISO 2815, the Buchholz hardness of the coating, applied on glass or steel panels and conditioned using cycle B or C (see 5.3.2) shall have a value of 94 or more. 5.3.6. Resistance to neutral salt spray The coating, applied on steel panels with a dry film thickness of 60 µm to 75 µm, conditioned using cycle B or C (see 5.3.2), and with an X-cut down to the substrate at least 20 mm from any edge, shall be tested in accordance with ISO 7253 for 480 h. After the test, allow the test panels to dry for at least 30 min at 18OC to 25OC and ≤ 80% relative humidity. The coating shall be free from any signs of deterioration, for example blistering (except in the area within 2.0 mm from the X-cut), cracking and staining. Any corrosion shall extend not more than 2.0 mm at the most from the X-cut. It shall not be possible to remove by means of clear plastic tape more than 3.0 mm of the coating in any direction from the area around the X-cut. 5.3.7. Resistance to artificial ageing Prepare two different sets of coated test panels, each set consisting of 3 steel panels. The dimensions of the panels shall be approx. 100 mm X 50 mm X 0.8 mm. Carry out the following procedure: - Condition set 1 using cycle C (see 5.3.2)




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- Condition set 2 using cycle C (see 5.3.2) and then age the panel 80OC in a circulatingair oven for 100 h followed by conditioning for 24 h at 18OC to 25OC and ≤ 80% relative humidity. - After ageing, subject the test panels to a bend test in accordance with 5.3.8 The result of the bend test shall comply with the requirement specified in 5.3.8. 5.3.8. Bend test (conical mandrel) Prepare steel panels and condition them using cycle B or C (see 5.3.2). When the panel are tested in accordance with ISO 6860, the maximum extent of cracking along the panel from the small and of the mandrel shall be less than or equal to 13 mm, and there shall be no loss of adhesion. 5.3.9. Resistance to gas pressure variations Prepare steel panels and condition them using cycle B or C (see 5.3.2). When the panels are tested with annex C, they shall have a generally good appearance when examined in accordance with 5.2.9 and shall not show any blistering. The adhesion value shall fulfill the requirements given in 5.3.4 after conditioning for 24 h and 40 h at 18 OC to 25OC and ≤ 80% relative humidity. 5.3.10. Resistance to water immersion Prepare steel panels and conditions them using cycle B or C (see 5.3.2). When the panels are tested in accordance with ISO 2812 – 2 for 480 h, the coating shall not show any blistering or appreciable softening. The examination shall be carried out 3 min after the panels have been removed from the test liquid. 5.3.11. Resistance to chemicals Prepare steel panels and condition then using cycle B or C (see 5.3.2). When the panels are tested in accordance with ISO 2812-1:1993, Method No. 1, Procedure a, for 168 h, the coating shall not show any blistering or appreciable softening. Use the following test liquid: cyclo hexane; 95% by volume di-ethylene glycol solution in water; hexane; methanol; toluene and lubricating oil (e.g. compressor shall oil in accordance with ISO 6743-4). The test panels shall be completely immersed in the test liquid. The examination shall be carried out at 18 0C to 25 0C and ≤ 80% relative humidity 3 min after the panels have been removed from the test liquid. After conditioning for 24 h at 18 0C to 25 0C and ≤ 80% relative humidity, the adhesion value shall fulfill the requirements given in 4.3.4. A change in the colour of the coating shall not be GAIL (INDIA) LTD NEW DELHI



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considered as an indication of inferior coating quality. 5.3.12 Resistance to hydraulic blistering Prepare steel panels and condition them using cycle B or C (see 5.3.2). When the panels are tested in accordance with annex D, the coating shall not show any blistering. The examination shall be carried out at 18 0C to 25 0C and ≤ 80% relative humidity 3 min after the panels have been removed from the test liquid. The adhesion value shall fulfil the requirements given in 5.3.4 after conditioning at 18 0 C to 25 0C and ≤ 80% relative humidity for 24 h. 5.4.

Packaging, labeling and storing All coating materials and solvents shall be stored in the original container bearing the manufacturer’s label and instruction. At least the following information shall be shown on the label: - The name of the coating material; - The name of the manufacturer of the coating material; - The colour of the coating material; - The batch number; - Instructions and warnings regarding health, safety and environmental protection; - a reference to the relevant product data sheet;

5.5.

Quality Assurance It necessary to ensure that the goods or services supplied comply in all respects with the requirements of this International Standard. The coater shall therefore set up and maintain a quality assurance system as, for example, detailed in ISO 9001. The purchaser shall have the right to undertake inspection and testing of the coated goods during any stage of coating at which the quality of the finished goods may be affected and to undertake inspection or testing of coating materials, or other materials used, to ensure compliance with the requirement given in 5.2 and 5.3.

5.6.

Product data sheet




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The coating material manufacturer’s product data sheet give information regarding at least the items listed in Table 1. Table 1 – Minimum information to be included in product data sheet Date of issue Name of coating material Name of coating material manufacturer Colour of coating material Type of coating material Shelf life Non-volatile matter by volume a method used (see5.3.2)

Test

Density b Test method used (see 5.2.5) Pot life a (see 5.2.7) Flash point c Time to complete curing Recommended thinner Maximum allowed quantity of thinner, in % Recommended surface preparation grade Recommended method of application Recommended maximum / minimum dry film thickness of the applied coating Recommended cleaning solvent (for the application equivalent)




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Recommended application conditions (air and steel temperature and relative humidity) Recommended minimum curing conditions Recommended maximum / minimum service temperature Recommended storage conditions Reference to instruction and warnings regarding health, safety and environmental protection Theoretical spreading rate (l/m2 or kg/m2) for a given dry film thickness. a. Only for the mixed coating material. b. Give separately for base component and curing agent component (if pigmented) c. Give separately for base component, curing agent component and mixed coating material. 5.7.

Qualification certificate The qualification certificate shall give, as a minimum, the values of the properties listed in Table 2. Table 2 – Minimum information to be included in qualification certificate Date of issue Name of coating material Name of coating material manufacturer Authority of issue Property

Test method

Non-volatile matter by mass a Ash b

ISO 3251 Annex A

Viscosity c GAIL (INDIA) LTD NEW DELHI

Sub clause See 5.2.2 See 5.2.6 See 5.2.4



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Adhesion

ISO 2409

See 5.3.4

Buchholz hardness

ISO 2815

See 5.3.5

ISO 7253

See 5.3.6

Resistance to neutral salt spray Resistance to artificial ageing

See 5.3.7

Bend test (conical mandrel)

ISO 6860

See 5.3.8

Resistance to gas pressure variations

Annex C

See 5.3.9

Resistance to water immersion

ISO 2812-2

See 5.3.10

Resistance to chemicals - Resistance to cyclohexane - Resistance to 95% by volume diethylene glycol solution in water - Resistance to hexane ISO 2812-1 5.3.11 - Resistance to methanol - Resistance to toluene - Resistance to lubricating oil (e.g. compressed seal oil) material Resistance to hydraulic blistering Annex D See 5.3.12

See

a. Separate for base component, curing agent component and mixed coating material. b. Separate for base component and curing agent component (if pigmented). c. Only for the mixed coating 5.8.

Batch test certificate The batch test certificate shall give, as a minimum, the information and test results for the items listed in Table 3




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Table 3 – Minimum information to be included in batch test certificate Item

Test method

Information from the coating material manufacturer

Test result

Date of issue Batch number Name of coating material Name of coating material manufacturer Production date

Expiry date for use Non-volatile matter by mass base component

See 5.2.2

Non-volatile matter by mass Curing agent component a Viscosity – base component

See 5.2.2

Viscosity – curing agent component

b

Density – base component Density –curing agent component Ash –base component c Ash- curing agent component c, d

See 5.2.5 See 5.2.5


b

See 5.2.6 See 5.2.6



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Infrared spectrogram d, e See 5.2.8 a. The non-volatile matter by mass of the curing agent component shall not be used for any purposes other than batch consistency checks. b. As specified by the coating material manufacturer. c. If required. d. If pigmented. e. Separately for base component and curing agent component.

6.

APPLICATION OF THE COATING MATERIAL

6.1 6.2

General During application of the coating material, all steps in the coating process shall be assessed and recorded. The parameters listed in Table 4 shall be included.

Table 4 – Minimum items to be checked and recorded during the coating process Items

Method

Frequency

Coating material Name of product Name of manufacturer Batch number

Visual examination

At every change of shift

Acceptance criteria As specified specified

Surface condition prior to surface preparation

Visual examination

Every pipe

As specified

ISO 8501-1 ISO 8503-2

Twice per shift Twice per shift

As specified As specified

Visual examination

Every pipe

Subject to agreement

Surface condition after surface preparation Surface cleanliness Surface profile Surface imperfections E.g. dents, laps GAIL (INDIA) LTD NEW DELHI



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Wet paint (mixed) Viscosity and temperature

As specified

Every time paint is mixed and every time painting is interrupted

Environmental conditions in the painting area Ambient temperature Steel temperature Relative humidity Flash point

Instrumental Instrumental Instrumental instrumental

Cured paint film on pipes Appearance and continuity Dry film thickness Porosity (pinholes)

Visual examination ISO 2808:1997, Method 10 Wet-sponge test (annex G)

Spot test Twice per shift (a)

Cured paint film on steel test panels As described in Table 5

See table 5

Twice per shift

Paint film on glass test panels Porosity (pinholes)

Annex E

As specified


As specified

No sagging As specified As required

As specified in Table-5


Max. 5 pores

a. The wet sponge test shall be carried out only if the porosity test on glass panels constitutes a failure

6.2.

Surface preparation First check that the surface are free from any foreign matter such as welding flux, welding spatter, salts, oil or grease. If necessary, wash the surfaces with a highpressure jet of fresh water. Removed organic contaminants using detergents or suitable organic solvents. Then blast-clean the surfaces to surface preparation grade Sa 1/2 in accordance with




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ISO8501-1. Removed, using suitable methods, any surface irregularities or imperfections which may have become visible. Check the surface profile. Unless otherwise agreed, it shall be such that R γ5 (see ISO 8503-1) is between 25 μm and 60 μm. During and after blast-cleaning and prior to application of the coating material, the temperature of the steel surface shall be at least 30C above the dew point or the minimum curing temperature given by the coating material manufacturer, whichever is the higher. 6.3.

Paint preparation Before removing each component from its container, stir or agitate it until it is homogeneous, using equipment which is capable of homogenizing the entire contents of the container without excessively entraining air into the material. Mix the two components (base component and curing agent component) thoroughly and, if necessary, dilute in accordance with the coating material manufacturer’s instructions. After the material has been homogenized, it shall be continuously mixed at a slow speed. The mixed paint shall be free of any lumps and pieces of skin. Measure the viscosity in accordance with the method recommended by the manufacturer and record it. Check whether it complies with the value specified by the manufacturer and keep it constant during application procedure.

6.4.

Paint application Check the surface to be coated to see whether it still complies with the specified surface preparation grade and profile (see 6.2) Apply the paint in a covered or enclosed space, shielded from wind, blowing dust and inclement weather, using the application parameters recommended by the coating material manufacturer and approved by the coater. The ambient temperature and relative humidity and the temperature of the steel surface application and subsequent drying/ curing shall be in accordance with the recommendations of the manufacturer of the coating material. The temperature of the steel shall be at least 30C above the dew point. In the case of accelerated curing, the temperature shall be as agreed between the coating material manufacturer and the coater. Spray the paint continuously and uniformly on to the whole surface to be coated. The coating shall be uniform, and particular attention shall be given to achieving the




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specified dry film thickness. Unless otherwise specified or agreed, maintain a cutback length of (20 + 5) mm. 6.5.

Health and safety and protection of the environment It is the duty of clients, specifiers, contractors, coating material manufacturers, inspectors and all other personnel involved in the undertaking to carry out the work for which they are responsible in such a manner that they do not endanger the health and safety of themselves or others. In pursuance of this duty, each person shall ensure that all the statutory requirement of the country in which their work, or any part of the work, is carried out are complied with.

7.

PRODUCTION CONTROL

7.1.

Assessment of the coating on the pipes

7.1.1. Appearance Inspect the coating visually for uniformity of colour, smoothness and freedom from runs, holidays and other defects that could be detrimental to its quality. 7.1.2. Dry film thickness Unless otherwise specified or agreed, the minimum dry film thickness of the coating shall be 60 µm above the peaks in the profile of the substrate and shall be determined in accordance with Annexure B. 7.2. 7.2.1.

Assessment of the coating on steel panels Preparation of test panels Perform the tests specified in 7.2.2 to 7.2.5 on coating applied by spraying on to steel test panels, to give dry film thickness specified in 5.3.3. Prepare the test panels as specified in 6.2 and apply the paint in accordance with the instructions of the coating material manufacturer. Use conditioning cycle B or C (see 5.3.2). Perform each test at least in duplicate. Table 5 shows the required frequency of the tests specified in 7.2.2 to 7.2.5

7.2.2. Adhesion When determined in accordance with ISO 2409, the cross-cut classification of the GAIL (INDIA) LTD NEW DELHI



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coating shall be equal to or lower than 1. 7.2.3. Buchholz hardness When determined in accordance with ISO 2815, the Buchholz hardness of the coating shall be at least 94. 7.2.4. Bend test When determined in accordance with ISO 6860, the maximum extent of cracking along the panel from the small end of the mandrel shall be less than or equal to 13 mm, and there shall be no loss adhesion. 7.2.5.

Curing test When tested in accordance with annex F, the coating shall not show any softening, wrinkling or blistering.

7.2.6.

Porosity test The porosity of both the wet and the dry film shall be checked on glass panels by the method given in Annex E. Porosity is considered to be any coating defect (pinhole) through which light can pass directly. More than 5 pinholes shall constitute a failure. If the porosity test on a glass panel is deemed a failure, the wet-sponge test given in Annex G shall be carried out on the surfaces painted with the coating material which failed the glass –panel test, testing at least ten areas, excluding welds. The coating on these surfaces shall not have more than 1 pinhole per 100 cm2 Table 5 – Required frequency of, and acceptance criteria for, the production –control tests specified in 7.2.2.to 7.2.5 Test

Method

Frequency

Adhesion

ISO 2409

Bend test

ISO 6860

Buchholz hardness

ISO 2815

Twice shift Twice shift Twice shift

Curing test

Annex F


Acceptance criteria

per Classification ≤ 1 per No loss of Adhesion per Hardness ≥ 94

Twice per shift


No softening, wrinkling or blistering


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8.

REPAIRS Defective coating, or areas with insufficient dry film thickness, shall be repaired in accordance with the coating material manufacturer’s recommendations.

9.


9.1.

Handling Coated pipes shall be handled in such a way that no damaged is caused to the coating.

9.2 . Transportation to the storage area During transportation to the storage area at the coater’s workshop, the coater shall take all relevant precautions to avoid damaged to the coating. 9.3.

Storage Coated pipes shall be stored in such a way that the quality of the coating will not be affected.

9.4.

Loading coated pipes for transportation When loading pipes at the workshop or in the field, all relevant precautions shall be taken to avoid the possibility of damage to the pipes or to the coating during transportation. The coater is responsible for ensuring that all pipes delivered to the purchaser are correctly coated and the coating is properly cured.




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ANNEX A : A.1

(NORMATIVE) DETERMINATION OF ASH (REFER TO SUB CLAUSE 5.2.5)

General This annex describes a method for determining the ash residue from a coating.

A.2

Apparatus

Ordinary laboratory apparatus, together with following: A.2.1 Porcelain crucible A.2.2

Muffle furnace

A2.3

Desiccator, containing an active desiccant

A2.4

Analytical balance, capable of weighing to 1 mg

A.3.

Procedure Weigh, to the nearest 1 mg, between 3g and 5 g of the product into a porcelain crucible (A.2.1). Place the crucible in a hood and heat with a low flame until the contents of the crucible are a dry, charred mass. Transfer to the muffle furnace (A.2.2) and ignite the residue at red heat (not exceeding 6000C) until the ash is free of carbon. Cool in the desiccator (A.2.3) and weigh. Repeat the igniting, cooling and weighing until the difference between successive weighing does not exceed 1 mg.

A.4.

Expression of results Calculate the ash WA, as a percentage by mass, using the following equation: WA ═ (m1/m0) X 100

(A.1)

Where m1 is the mass, in grams, of the residue after ignition. m0 is the mass, in grams, of the test portion. GAIL (INDIA) LTD NEW DELHI



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B.1.

General

ANNEX B : (NORMATIVE) DRY FILM THICKNESS (REFER TO SUB CLAUSE 5.3.3 AND 7.1.2)

This annex describes the measurement of the dry film thickness of a coating on a blastcleaned steel surface using an instrument based on the permanent-magnet principle or the inductive-magnet principle. If a coating has been applied to a blast-cleaned steel substrate, the measurement of the dry film thickness is more complicated than for smooth, flat surfaces. The effect of a surface roughness on the result increase with profile depth also related to the design of the measurement probe and the thickness of the coating. B.2.

Apparatus Unless otherwise specified or agreed, the minimum dry film thickness of the coating shall be determined in accordance with ISO 2808:1997, Method No.10, using a singlepole instrument of the permanent-magnet or inductive-magnet type.

B.3.

Procedure Before use, ascertain that the instrument is in good working order (see manufacturers) Calibrate the instrument on a smooth, flat, level steel plate, using ISO 2808:1997, Method No.10. It will then be necessary to determine a “correction factor” by taking a series of readings on the unpainted blast-cleaned surface and calculating the average. All readings subsequently taken on the painted surface are then reduced by the “correction factor” to give the true value of the thickness above the peaks. Check the calibration at frequent intervals. For each pipe or fitting tested, at least 8 values shall be recorded. Each value shall be constituted by the arithmetic mean of 5 different measurement taken very close to the point at which the thickness is to be measured. When during a series of measurement an individual dry film thickness value does not meet the specified criterion, a repeat measurement not more than 10mm from the point of first measurement shall be carried out. The first value shall then rejected and replaced by the result of the repeat measurement. The maximum number of repeat measurements permitted is 2. If any measurement are less than 80% of the nominal dry film thickness (NDFT). Then the specimen fails this test.

B.4.

Results




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Calculate the arithmetic mean of the measurement values. Unless otherwise specified or agreed, the minimum dry film thickness of the coating shall be 60μm above the peaks. In cases of dispute the result at one point, recalibrate the instrument and carry out five measurements, again very close to the point. Recalculate the arithmetic mean of the 5 measurements.




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C.1.

ANNEX C : (NORMATIVE) RESISTANCE TO GAS PRESSURE VARIATION (REFER TO SUB CLAUSE 5.3.9) General The test consists of verifying, by evaluation of visual appearance and determination of the adhesion, the behavior of the applied coating after it has been subjected to pressure variation in a gaseous environment (N2).

C.2.

Apparatus and materials

C.2.1 Sealed chamber, capable of resisting the test pressures during the whole of the test C.2.2 Nitrogen, as pressurizing gas. C.2.3 Pressurizing system, capable of increasing the pressure by 1 bar per minute C.3

Test specimens Substrates can be of two types: - approx. 100mm x 50mm x 1mm steel panels; - lengths of steel pipe approx. 100mm long with a minimum diameter of 80 mm or, if the diameter is too large for the pipe to fit into the chamber, specimens obtained from the pipe or fitting. The surface of the test panels or lengths of the pipe shall be prepared and coated at the same time and in the same way as the corresponding production surfaces.

C.4

Procedure

C.4.1 General Unless otherwise specified by the coating material manufacturer, wait a month after the coating has been applied to the test panels or lengths of pipe before carrying out any test. C4.2

Cyclic Pressure Test This test is carried out as a qualification test on the inside coating. Put the specimen in the chamber and subject it to the set of 10 test cycles shown schematically in figure C.1, as follows:




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- Progressively increase the pressure in the chamber to 100 bar. - Keep the specimen under pressure for a fixed period of time to allow the pressurizing gas to penetrate into the coating: • 20 h for the 1st to 4th cycles and the 6th to 9th cycles, • 68 h for the 5th and 10th cycles; - Release the pressure rapidly over a few minutes (not more than 5 minutes); - Leave the coating at atmosphere pressure for 4 h to permit the development of any blisters on the coating, so that a cycle lasts either 24h or 72h (this latter period corresponds to the weekend, i.e. from Friday to Monday). Immediately at the end of the 10th test cycle, open the chamber and examine the appearance of the coating, noting all modifications (corrosion, spots or blisters).In addition, carry out an adhesion test in accordance with ISO 2409. Repeat the appearance examination after 24 h and after 48 h, again noting all modifications. Figure C.1 – Complete set of pressure cycles.

C.4.3 Decompression blistering test The test is carried out only when the coated pipes are utilized at operating pressures higher than 100 bar. The test pressure shall be at least the pressure specified for that pipeline. Put the specimen in the chamber and then subject it to the specified pressure for 24 h so that the pressurizing gas can penetrate into the coating. Release the pressure rapidly over a few minutes (not more than 5 minutes) Immediately at the end of the test cycle, open the chamber and examine the GAIL (INDIA) LTD NEW DELHI



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appearance of the coating, noting all modifications (corrosion, spots or blisters).In addition, carry out an adhesion test in accordance with ISO 2409. Repeat the appearance examination after 24 h and after 48 h, again noting all modifications. C.5

Results Record any degradation observed immediately on removing the specimen from the chamber and indicates any further changes after 24 h and 48 h. Record the adhesion of the coating measured in the adhesion test.




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ANNEX D : (NORMATIVE) HYDRAULIC- PRESSURE BLISTERING (REFER TO SUB CLAUSE 5.3.12) D.1

General The test consists of verifying, by evaluation of the visual appearance and determination of the adhesion, the behavior of the applied coating when subjected to pressure variation in a liquid environment (water/CaCO3).

D.2


D.2.1 Sealed chamber, capable of resisting the test pressure during the whole of the test. D.2.2 Water saturated with CaCO3, as pressurizing liquid. D.2.3 Pressurizing system, capable of increasing the pressure by 1 bar per minute. D.3

Test specimens Substrates can be of two types: - approx. 100 mm x 1 mm steel panels; - lengths of steel pipe approx. 100 mm long with a minimum diameter of 80 mm or, if the diameter is too large for the pipe to fit into the chamber, specimens obtained from the pipe or fitting. The surfaces of the test panels or length of the pipe shall be prepared and coated at the same time and in the same way as the corresponding production surfaces.

D.4

Procedure Unless otherwise specified by the coating material manufacturer, wait a month after the coating has been applied to the test panels or lengths of pipe before carrying out any test. This test is carried out at least 100 bar if the maximum operating pressure is 100 bar or less. If the operating pressure is higher than 100 bar, the test pressure shall be at least the pressure specified for that pipeline. Put the specimen in the chamber and then subject it to the specified pressure specified for 24 h so that the pressurizing liquid can be penetrate into the coating. Release the pressure rapidly over a few minutes (not more than 5 minutes).




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Immediately at the end of the test cycle, open the chamber and examine the appearance of the coating, noting all modifications (corrosion, spots or blisters).In addition, carry out an adhesion test in accordance with ISO 2409. Repeat the appearance examination after 24 h and after 48 h, again noting all modifications.

D.5

Results Record any degradation observed immediately on removing the specimen from the chamber and indicates any further changes after 24 h and 48 h. Record the adhesion of the coating measured in the adhesion test.




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ANNEX E : (NORMATIVE) POROSITY OF A FILM OF THE COATING MATERIAL ON A GLASS PANEL (REFER TO SUB CLAUSE 7.2.6) Use a glass panel measuring approx. 75 mm x 25 mm x 2 mm and frosted on one side. Clean the panel by immersion in a suitable solvent and then in acetone. Allow the panel to dry in air for a few seconds. Place a panel inside the pipe to be coated with non-frosted side facing the wall of the pipe; keep it in position at each end by means of adhesive tape (max. overlap on glass 10 mm). Just before coating, check that the panel is free from dust or pollution. Apply the coating material to glass panel during the pipe-coating process. Then examine the panel as follows: (a) Wet film- Five minutes after application of the coating material, place the glass panel over an opaque (dark) shield measuring approx. 300 mm x 300 mm with a 50 mm x 20 mm slot in the middle. Hold the panel, together with the shield, 130 mm from an illuminated 100 W bulb, with the shield facing the bulb. Check for pinholes. More than 5 pinholes shall constitute a failure. (b) Cured film-If the coating is acceptable in the wet state, allow it to cure for an additional 30 min in air at 18 oC to 25 oC and a relative humidity of ≤ 80 %, and then place in a circulating-air oven at (75 + 2 ) oC for a minimum of 30 min. repeat the examination described above. More than 5 pinholes shall constitute a failure. Another curing schedule may be agreed between the coater and the coating material manufacturer. NOTE : if justified by the prevailing application and drying conditions or the type of paint used, the test conditions may be modified by agreement between the interested parties.




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ANNEX F: (NORMATIVE) CURING TEST (REFER TO SUB CLAUSE 7.2.5) Apply the coating material to steel pannels and condition the coated pannels as specified in 7.2.1. Test for resistance to the thinner which is recommended for thinning the coating material, in accordance with ISO 2812-1 , for 4h. Examine the panels after a recovery period of 30 min at 18 o C to 25 o C and ≤ 80 % relative humidity following removal of the panels from the test liquid. The coating shall not show any softening, wrinkling or blistering.




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ANNEX G: (NORMATIVE) WET SPONGE TEST (REFER TO SUB CLAUSE 7.2.6) G1

General

G.2


G.2.1 Adjustable low-voltage wet-sponge tester, equipped with an alarm, an electrode in the form of a sponge and conductors for connecting the coated pipe or fitting under test to earth. G.2.2 Tap water G.3

Procedure Set the test voltage to 9 V. Connect up the instrument, connecting the earth lead, by means of a crocodile clip, to an uncoated section of the metal of the surface under test. Moisten the sponge with tap water. Note that too much water will affect the performance. Switch on the electrode and move it continuously in connect with the surface of the coating to be inspected; the rate of travel of the electrode is not limited, but it shall not be higher than the speed at which it can be demonstrated that a porosity defect can be detected. The presence of a porosity defect is indicated by the emission of a high-pitched note from the alarm.

G.4

Results Record the number of porosity defects per 100 cm2.




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STANDARD SPECIFICATION FOR PIPELINE BALL VALVES


STANDARD SPECIFICATION FOR PIPELINE BALL VALVES (ONSHORE)

SPECIFICATION S – 04 – 02 – 007

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CONTENTS 1.0

SCOPE

2.0

REFERENCE DOCUMENTS

3.0

MATERIALS

4.0

DESIGN AND CONSTRUCTION

5.0

INSPECTION AND TESTS

6.0

TEST CERTIFICATES

7.0

PAINTING MARKING AND SHIPMENT

8.0

SPARES AND ACCESSORIES

9.0

DOCUMENTATION

FIG. 4.9

VENT, DRAIN AND SEALANT DETAILS




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1.0

SCOPE This specification covers the minimum requirements for design, manufacture and supply of carbon steel ball valves of size DN 50 mm (2”) and above and ANSI class 150# thru 900# for use in onshore pipeline systems handling non sour hydrocarbons in liquid or gaseous phase including Liquefied Petroleum Gas (LPG). This specification does not cover ball valves for sour hydrocarbons (liquid/gas) service as defined in NACE Standard MR-0l-75.

2.0

REFERENCE DOCUMENTS

2.1

All valves shall be manufactured and supplied in accordance with the latest edition of American Petroleum Institute (API) Specification 6D, Twenty Second edition, January 2002/ ISO 14313:1999, Petroleum and Natural Gas Industries – Pipeline Transportation Systems- Pipeline Valves, with additions and modifications as indicated in the following sections of this specification.

2.2

Reference has also been made in this specification to the latest edition of the following Codes, Standards and Specifications. ASME B31.3

-

Process Piping

ASME B31.4

- Pipeline Transportation System for Liquid Hydrocarbons and Other Liquids

ASME B31.8

-

Gas Transmission and Distribution Piping Systems

ASME B16.5

-

Pipe Flanges and Flanged Fittings

ASME B16.10

-

Face to Face and End to End Dimensions of Valves

ASME B16.47

-

Large Diameter Steel Flanges

ASME B16.25

-

Butt-welding Ends

ASME B16.34

-

Valves - Flanged, Threaded and Welding Ends.

API 1104 ASME Sec VIII ASME Sec IX


-

Welding Pipelines and Related Facilities Boiler and Pressure Vessel Code- Rules for Construction of Pressure Vessels.

-

Boiler and Pressure Vessel Code-Welding and Brazing Qualifications



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ASTM A-370

- Standard Test Methods and Definitions for Mechanical Testing of Steel Products

ASTM B-733

- Auto catalytic Nickel Phosphorous Coating on Metals

MSS-SP-6

- Standard Finishes for Contact Faces of Pipe Flanges and Connecting- end Flanges of Valves and Fittings.

MSS-SP-44

- Steel Pipeline Flanges.

SSPC-VIS-1

- Steel Structures Painting Council Visual Standard.

2.3

In case of conflict between the requirements of this specification, API 6D and the Codes, Standards and Specifications referred in clause 2.2 above, the requirements of this specification shall govern.

3.0

MATERIALS

3.1

Material for major components of the valves shall be as indicated in Valve Data Sheet. Other components shall be as per Manufacturer’s standard (suitable for the service conditions indicated in the data Sheet) and shall be subject to approval by Purchaser. In addition, the material shall also meet the requirements specified hereinafter. All process wetted parts, metallic and non metallic, and lubricants shall be suitable for the service specified by the Purchaser. Manufacturer shall confirm that all wetted parts are suitable for treated water/ sea water environment, which may be used during field testing. Non metallic parts of the valves (including O-rings, soft seals etc.) intended for hydrocarbon gas service shall be resistant to explosive decompression.

3.2

Carbon steel used for the manufacture of valves shall be fully killed.

3.3

The carbon equivalent (CE) of valve end connections which are subject to further field welding by Purchaser shall not exceed 0.45 on check analysis for each heat of steel used, as calculated by the following formula:

3.4

For valves specified to be used for Gas service or High Vapour Pressure (HVP) liquid service/ LPG service, Charpy V-notch test on each heat of base material shall be conducted as per API 6D, Clause -7.5, for all pressure containing parts such as body, end flanges and welding ends as well as bolting material for pressure containing parts. Unless specified otherwise, the Charpy V-notch test shall be




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conducted at 0°C. Test procedure shall confirm to ASTM A370. The Charpy V-notch test specimen shall be taken in the direction of principal grain flow and notched perpendicular to the original surface of plate or forging. The minimum average absorbed energy per set of three specimens shall be 27 J with an individual minimum per specimen of 22 J. For valves specified to be used for other hydrocarbon services, Charpy V-notch requirements as stated above are not applicable, unless required by the specified material standard as a mandatory requirement. When Low Temperature Carbon Steel (LTCS) materials are specified in Valve Data Sheet or offered by Manufacturer, the Charpy V-notch test requirements of applicable material standard shall be complied with. 3.5

For all such valves where Carbon Steel is used as ball material, the ball shall have 75 micrometers (0.003 inches) thick Electroless Nickel Plating (ENP) as per ASTM B 733 with following classification: -

SC2, Type II, Class 2.

The hardness of plating shall be minimum 50 RC. 3.6

When the valves are specified to be used for Gas service or High Vapour Pressure (HVP) liquid service, hardness test shall be carried out on each heat of base material for all pressure containing parts of the valve. A full thickness cross section shall be taken for this purpose and the maximum hardness shall not exceed 248 HV10 based on minimum four (4) measurements representing the entire thickness. For valves specified to be used for Low Vapour Pressure (LVP) liquid service, requirements as stated herein above are not applicable.

4.0


4.1

Valve design shall meet the requirements of API Specification 6D and shall be suitable for the service conditions indicated in the Valve Data Sheet. The ASME Boiler & Pressure Vessel Code, Section VIII, Division 1 shall be used to design the valve body. Allowable stress requirements shall comply the provisions of ASME B31.3. In addition, corrosion allowance indicated in Valve Data Sheet shall be considered in valve design. However, the minimum wall thickness shall not be less than the minimum requirement of ASME B 16.34. The manufacturer shall have valid license to use API monogram on valves manufactured as per API 6D.




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4.2

Valve body design shall be either fully welded or bolted. Valve body joints with threads are not permitted.

4.3

Ball shall be of single piece, solid type construction.

4.4

Valves shall be Full bore (FB) or Reduced bore (RB) as indicated in the Valve Data Sheet. Full bore valves shall be suitable for the passage of all types of pipeline scraper and inspection pigs on regular basis without causing damage to either the valve component or the pig. The full bore valve shall provide an unobstructed profile for pigging operations in either direction. Full bore valves shall be designed to minimize accumulation of debris in the seat ring region to ensure that valve movement is not impeded. In case of reduced bore valves, the nominal valve size indicated in the Valve Data Sheet shall correspond to that of a full bore valve of smaller nominal diameter as indicated in Table-4.4 of this specification. For sizes of a particular rating not covered in API 6D, the bore size of reduced bore valve shall be as per Manufacturer‘s standard. TABLE - 4.4 Nominal Valve Size,

Nominal Valve size for Reduced Bore

Nominal Valve Size,

DN mm (NPS inches) DN mm (NPS inches) DN mm (NPS inches)

Nominal Valve Size for Reduced Bore

DN mm (NPS inches)

50 (2)

50 (2)

600 (24)

500 (20)

80 (3)

50 (2)

650 (26)

550 (22)

100 (4)

80 (3)

700 (28)

600 (24)

150 (6)

100 (4)

750 (30)

600 (24)

200 (8)

150 (6)

800 (32)

650 (26)

250 (10)

200 (8)

850 (34)

700 (28)

300 (12)

250 (10)

900 (36)

750 (30)

350 (14)

250 (10)

950 (38)

800 (32)

400 (16)

300 (12)

1000 (40)

850 (34)

450 (18)

350 (14)

1050 (42)

900 (36)

500 (20)

400 (16)

1200 (48)

1050 (42)

550 (22)

450 (18)

-

-




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4.5

Ball mounting shall be trunnion or pivot type only. Valve design shall minimize the possibility of debris ingress into the trunnion as far as practicable.

4.6

Valve seats shall be with primary metal to metal contact. O-rings or other seals if used for drip tight sealing shall be encased in a suitable groove in such a manner that it can not be removed from seat ring and there is no extrusion during opening or closing operation at maximum differential pressure corresponding to valve class rating. The seat rings shall be so designed as to ensure sealing at low as well as high differential pressures. Seat design with PTFE inserts is not applicable.

4.7

Valves shall have double block and bleed feature to facilitate complete flush, drain and venting of the valve body cavity. For valves to be used in liquid service, the body cavity over-pressure shall be prevented by self-relieving seat rings/assemblies. A pressure relief hole in the ball is not permitted. Self-relieving seat rings shall relieve at a body cavity differential pressure not exceeding 50% of the valve class rating pressure.

4.8

When specified in the Valve Data Sheet, valves shall be designed to withstand a sustained internal vacuum of at least 1 (one) milli-bar in both open and closed positions.

4.9

Full Bore valves of nominal valve size 200 mm (8”) & above and Reduced Bore valves of nominal valve size 250 mm (10”) & above, shall have provision for secondary sealant injection under full line pressure for seat and stem seals. All sealant injection connections shall be provided with an internal non-return valve. Valve design shall have a provision to replace the sealant injection fitting under full line pressure. Location and arrangement of sealant point shall be as per Fig. 4.9.

4.10 Valves shall be provided with vent and drain connections. Location and arrangement of vents and drains shall be as per Fig. 4.9. Body vent and drain shall be provided with valves (Ball or Plug type). Number and size shall be as per Fig. 4.9. 4.11 Valve design shall ensure repair of stem seals/packing under full line pressure. 4.12 Valve design shall be as to avoid bimetallic corrosion between carbon steel and high alloy steel components, suitable insulation shall be provided as required. 4.13

a)

Valve ends shall be either flanged/or butt welded or one end flanged and one end butt welded as indicated in the Valve Data Sheet. Flanges of the flanged end cast/ forged body valves shall be integrally cast/ forged with the body of the valve. Face to face/end to end dimensions shall conform to API 6D. Face to Face and end to end dimensions for valve sizes not specified in API 6D shall be in accordance with ASME B 16.10. Face to face and end to end dimension not shown in API 6D or ASME B16.10 shall be as per Manufacturer’s Standard and shall be subject to approval by Company.




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4.14

b)

Flanged end, if specified, shall have dimensions as per ASME B16.5 for valve sizes upto DN 600 mm (24”) excluding DN 550 mm (22”) and as per MSS-SP44/ ASME B16.47 Series A for valve sizes DN 550 mm (22”) and for DN 650 mm (26 inches) and above. Flange face shall be either raised face or ring joint type (RTJ) as indicated in Valve Data Sheet. Flange face finish shall be serrated or smooth as indicated in Valve Data Sheet. In case of RTJ flanges, the groove hardness shall be minimum 140 BHN.

c)

Butt weld end preparation shall be as per ASME B16.25. The thickness of the pipe to which the valve has to be welded shall be as indicated in the Valve Data Sheet. Valves shall be without transition pups. In case difference exists between thickness of welding ends of valve and connecting pipe, the welding ends of valve shall have bevel preparation as per ASME B31.4 or ASME B31.8 as applicable.

Design of weld end valves shall be such that during field welding operation, soft seals or plastic components of the valve (where ever used) are not liable to be damaged. The manufacturer shall furnish necessary field welding instructions and post weld test procedure to demonstrate integrity and leak tightness of valves after field welding operations.

4.15 Valve shall be provided with ball position indicator and stops of rugged construction at the fully open and fully closed positions. 4.16 Full Bore valves of nominal valve size, DN ≥ 200 mm (8”) and Reduced Bore valves of nominal valve size, DN ≥ 250 mm (10”), shall be equipped with support foot and lifting lugs. Tapped holes and eyebolts shall not be used for lifting lugs. Height of support foot shall be kept minimum. The location and size of support foot/ lifting lugs shall ensure unrestrictive operation of vent/ drain valves. 4.17 When indicated in Material Requisition, valves shall have locking devices to lock the valve either in full open (LO) or full close (LC) positions. Locking devices shall be permanently attached to the valve operator and shall not interfere with operation of the valve. 4.18 Valves shall be suitable for either buried or above ground installation as indicated in Valve Data Sheet. 4.19 When stem extension requirement is indicated in Valve Data Sheet, the valves shall have the following provisions. a)

Valves provided with stem extension shall have water proof outer casing. Length of stem extension shall be as indicated in Valve Data Sheet. The length indicated corresponds to the distance between centerline of the valve




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opening and the top of mounting flange for valve operating device (gear operator/ power actuator as applicable). b)

Vent and drain connections and sealant injection lines shall be terminated adjacent to the valve operator by means of suitable piping anchored to the valve body. The pipe used shall be API 5L Gr. B / ASTM A 106 Gr. B, with Sch. 160. Fittings shall be ASTM A105/ASTM A234 Gr. WPB, Socket welded ANSI class 6000.

c)

Stem extension and stem housing design shall be such that the complete assembly will form a rigid unit giving positive drive under all conditions with no possibility of free movement between valve body, stem extension or its operator.

d)

Outer casing of stem extension shall have 3/8” or ½” NPT plugs at the top and bottom, for draining and filling with oil to prevent internal corrosion.

4.20 OPERATING DEVICES a)

Valves shall have a power actuator or manual operator as indicated in the Valve Data Sheet. In case of manual operator, valve sizes, DN ≤ 100 mm (4”) shall be wrench operated and valve sizes, DN ≥ 150 mm (6”) shall be gear operated. Valve design shall be such that damage due to malfunctioning of the operator or its controls will only occur in the operator gear train or power cylinder and that damaged parts can be replaced without the valve cover being removed.

b)

The power actuator shall be in accordance with the Purchaser Specification issued for the purpose and as indicated in the Valve and Actuator Data Sheet. Operating time shall be as indicated in Valve Data Sheet. Valve operating time shall correspond to full close to full open /full open to full close under maximum differential pressure corresponding to the valve rating. For actuated valves, the actuator’s rated torque output shall be 1.25 times the break torque required to operate the ball valve under the maximum differential pressure corresponding to the Valve Class Rating.

c)

For the manual operator of all valves, the diameter of the hand wheel or the length of operating wrench shall be such that under the maximum differential pressure, the total force required to operate the valve does not exceed 350N. Manufacturer shall also indicate the number of turns of hand wheel (in case of gear operators) required for operating the valve from full open to full close position.




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d)

Direction of operation of hand wheel or wrench shall be in clock-wise direction while closing the valve. Hand wheels shall not have protruding spokes.

e)

Gear operators, when provided, shall have a self-locking provision and shall be fully encased in water proof/ splash proof enclosure and shall be filled with suitable grease.

4.21 All welds shall be made by welders and welding procedures qualified in accordance with the provisions of ASME Section IX. The procedure qualification shall also include impact test and hardness test when required as per Clause 3.4 and 3.6 of this specification and shall meet the requirements as specified therein. 4.22 Repair by welding is not permitted for fabricated and forged body valves. However repair by welding as per ASME B16.34 is permitted for cast body valves. Repair shall be carried out before any heat treatment of casting is done. Repair welding procedure qualification shall also include impact test and hardness test when required as per Clause 3.4 and 3.6 of this specification and shall meet the requirements as specified therein. 4.23

The tolerance on internal diameter and out of roundness at the ends for welded ends valves shall be as per connected pipe specification as indicated in the Valve Data Sheet.

4.24 Valve stem shall be capable of withstanding the maximum operating torque required to operate the valve against the maximum differential pressure corresponding to applicable class rating. The combined stress shall not exceed the maximum allowable stresses specified in ASME section VIII, Division 1. For power actuated valves, the valve stem shall be designed for maximum output torque of the selected power actuator (including gear box, if any) at valve stem. 5.0 5.1

INSPECTION AND TESTS The Manufacturer shall perform all inspection and tests as per the requirements of this specification and the relevant codes, prior to shipment, at his Works. Such inspection and tests shall be, but not limited to, the following:

5.1.1 All valves shall be visually inspected. The internal and external surfaces of the valves shall be free from any strikes, gouges, and other detrimental defects. The surface shall thoroughly cleaned and free from dirt, rust and scales. 5.1.2 Dimensional check on all valves shall be carried out as per the Purchaser approved drawings.



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5.1.3 Chemical composition and mechanical properties shall be checked as per relevant material standards and this specification, for each heat of steel used. 5.1.4 a)

Non-destructive examination of individual valve material and component consisting of but not limited to castings, forgings, plates and assembly welds shall be carried out by the Manufacturer.

b)

Body castings of all valves shall be radiographically examined as per ASME B16.34. Procedure and acceptance criteria shall be as per ASME B16.34. The extent of the radiography shall be as under:

Pressure Class Rating

Valve Size

Extent of Radiography

ANSI 150 # Class

All sizes

Nil

ANSI 300 # Class

≤DN 400 mm (16”) ≥DN450 mm (18”)

Nil 100%

All sizes

100%

ANSI 600 # Class and above

All castings shall be wet magnetic particle inspected 100% of the internal surfaces. Method and acceptance shall comply with ASME B16.34. c)

All valves, with body fabricated from plates or made by forgings, shall be ultrasonically examined in accordance with the procedure and acceptance standard of Annexure-E of ASME B16.34. All forgings shall be wet magnetic particle inspected 100% of the internal surfaces. Method and acceptance shall comply with ASME B 16.34.

d)

Bodies and bonnets made by welded assembly of segments of castings, forgings, plates or combinations thereof shall be examined, as applicable, by methods of 5.1.4 (b) for cast components or 5.1.4 (c) for forged components and plates.

5.1.5 Full inspection by radiography shall be carried out on all welds of pressure containing parts. Acceptance criteria shall be as per ASME B 31.4 or ASME B3 1.8 as applicable and API 1104. 5.1.6 Welds, which in Purchaser’s opinion cannot be inspected by radiographic methods, shall be checked by ultrasonic or magnetic particle methods and acceptance criteria shall be as per ASME Sec. VIII, Division 1, Appendix 12 and Appendix 6 respectively.



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5.1.7

a) All finished wrought weld ends subject to welding in field shall be 100% ultrasonically tested for lamination type defects for a distance of 50 mm from the end. Laminations shall not be acceptable. b)

Weld ends of all cast valves subject to welding in field shall be 100% radiographically examined and acceptance criteria shall be as per ASME B16.34.

c)

After final machining, all bevel surfaces shall be inspected by dye penetrant or wet magnetic particle methods. All defects longer than 6.35 mm are rejected, as are the defects between 6.35 mm and 1.59 mm that are separated by a distance lessthan50timestheir greatest length. Rejectable defects must be removed. Weld repair of bevel surface is not permitted.

5.1.8 All valves shall be tested in compliance with the requirements of API 6D. During pressure, testing, valves shall not have sealant lines and other cavities filled with sealant, grease or other foreign material. The drain, vent and sealant lines shall be either included in the hydrostatic shell test or tested independently. No leakage is permissible during hydrostatic testing. The body cavity self-relieving feature meeting the requirements of clause 4.7 of this specification shall also be checked. 5.1.9 A supplementary air seat test as per API 6D (Appendix C, Para C.3.3) shall be carried out for all valves. A bubble tight seal is required without the use of any sealant. No leakage is allowed. Test pressure shall be held for at least 15 minutes. 5.1.10 Valves shall be subjected to Operational Torque Test as per Appendix C, Para C.6 of API 6D under hydraulic pressure equal to maximum differential pressure corresponding to the valve rating. For manually operated valves, it shall be established that the force required to operate the valve does not exceed the requirements stated in section 4.20 (c) of this specification. 5.1.11 Power actuated valves shall be tested after assembly of the valve and actuator, at the valve Manufacturer’s works. At least five Open-Close-Open cycles without internal pressure and five Open-Close-Open cycles with maximum differential pressure corresponding to the valve rating shall be performed on the valve actuator assembly. The time for Full Open to Full Close shall be recorded during testing. If required, the actuator shall be adjusted to ensure that the opening and closing time is with in the limits stated in Valve Data Sheet. Hand operator provided on the actuator shall also be checked after the cyclic testing, for satisfactory manual over-ride performance. These tests shall be conducted on minimum one valve out of a lot of five (5) valves of the same size, rating and the actuator model/type. In case, the tests do not meet the requirements, retesting/ rejection of the lot shall be decided by the Purchaser’s Inspector. GAIL (INDIA) LTD NEW DELHI


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5.1.12 Subsequent to successful testing as specified in clause 5.1.8, 5.1.9, 5.1.10 and 5.1.11 above, one (1) valve out of the total ordered quantity shall be randomly selected by the Company Representative for cyclic testing as mentioned below: a)

The valve shall be subjected to at least 100 Open-Close-Open cycles with maximum differential pressure corresponding to the valve rating.

b)

Subsequent to the above, the valve shall be subjected to hydrostatic test and supplementary air seat test in accordance with clause 5.1.8 and 5.1.9.

In case this valve fails to pass these tests, the valve shall be rejected and two more valves shall be selected randomly and subjected to testing as indicated above. If both valves pass these tests, all valves manufactured for the order (except the valve that failed) shall be deemed acceptable. If either of the two valves fails to pass these tests, all valves shall be rejected or each valve shall be tested at the option of manufacturer. Previously carried out test of similar nature shall be considered acceptable if same has been carried out by manufacturer in last two years. Valves of two sizes below and two sizes above the size of valve previously tested, and rating similar or one rating lower of valve tested previously, shall be qualified. 5.2

Purchaser reserves the right to perform stage wise inspection and witness tests as indicated in clause 5.1 above at Manufacturer’s works prior to shipment. Manufacturer shall give reasonable access and facilities required for inspection to the Purchaser’s Inspector. Purchaser reserves the right to require additional testing at any time to confirm or further investigate a suspected fault. The cost incurred shall be to Manufacturer’s account. In no case shall any action of Purchaser or his inspector shall relieve the Manufacturer of his responsibility for material, design, quality or operation of valves. Inspection and tests performed/witnessed by the Purchaser’s Inspector shall in no way relieve the Manufacturer’s obligation to perform the required inspection and tests.

6.0

TEST CERTIFICATES Manufacturer shall submit the following certificates: a)

Mill test certificates relevant to the chemical analysis and mechanical properties of the materials used for the valve construction as per the relevant standards.



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b)

Test certificates of hydrostatic and pneumatic tests complete with records of timing and pressure of each test.

c)

Test reports of radiograph and ultrasonic inspection.

d)

Test report on operation of valves conforming to clause 5.1.10, 5.1.11 and 5.1.12 of this specification.

e) All other test reports and certificates as required by API 6D and this specification. The certificates shall be valid only when signed by Purchaser’s Inspector. Only those valves which have been certified by Purchaser’s Inspector shall be dispatched from Manufacturer’s works. 7.0

PAINTING, MARKING AND SHIPMENT

7.1

Valve surface shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot blasting to SP-6 in accordance with “Steel Structures Painting Council Visual Standard SSPC-VIS-1”. For the valves to be installed underground, when indicated in Valve Data Sheet, the external surfaces of buried portion of the valve shall be painted with three coats of suitable coal tar epoxy resin with a minimum dry film thickness of 300 microns.

7.2

All valves shall be marked as per API 6D. The units of marking shall be metric except nominal diameter, which shall be in inches.

7.3

Valve ends shall be suitably protected to avoid any damage during transit. All threaded and machined surfaces subject to corrosion shall be well protected by a coat of grease or other suitable material. All valves shall be provided with suitable protectors for flange faces, securely attached to the valves. Bevel ends shall be protected with metallic or high impact plastic bevel protectors.

7.4

All sealant lines and other cavities of the valve shall be filled with sealant before shipment.

7.5

Packaging and shipping instructions shall be as per API 6D.

7.6

On packages, following shall be marked legibly with suitable marking ink: a) b) c)


Order Number Manufacturer’s Name Valve size and rating STANDARD SPECIFICATION FOR PIPELINE BALL VALVES (ONSHORE)

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d) e)

Tag Number Serial Number

8.0


8.1

Manufacturer shall furnish list of recommended spares and accessories for valves required during start-up and commissioning.

8.2

Manufacturer shall furnish list of recommended spares and accessories required for two years of normal operation and maintenance of valves.

8.3

Manufacturer shall quote for spares and accessories as per Material Requisition.

9.0

DOCUMENTATION

9.1

At the time of bidding, Manufacturer shall submit the following documents: a)

General arrangement/ assembly drawings showing all features and relative positions and sizes of vents, drains, gear operator/ actuator, painting, coating and other external parts together with overall dimension.

b)

Sectional drawing showing major parts with reference numbers and material specification. In particular a blow up drawing of ball-seat assembly shall be furnished complying the requirement of clause 4.6 of this specification.

c)

Reference list of similar ball valves manufactured and supplied in last five years indicating all relevant details including project, year, client, location, size, rating, service etc.

d)

Torque curves for the power actuated valves along with the break torque and maximum allowable stem torque. In addition, sizing criteria and torque calculations shall also be submitted for power actuated valves.

e)

Clause wise list of deviations from this specification, if any.

f)

Descriptive technical catalogues of the manufacturer.

g)

Installation, Operational and Maintenance Manual.

h)

Copy of valid API 6D Certificate.

i)

Details of support foot including dimensions and distance from valve centerline to bottom of support foot.

j)

List of recommended spares required during start-up and commissioning.



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k) 9.2

List of recommended spares required for 2 years of normal operation and maintenance.

With in three weeks of placement of order, the Manufacturer shall submit four copies of, but not limited to, the following drawings, documents and specifications for Purchaser’s approval: a)

Detailed sectional drawings showing all parts with reference numbers and material specifications.

b)

Assembly drawings with overall dimensions and features. Drawing shall also indicate the number of turns of hand wheel (in case of gear operators) required for operating the valve from full open to full close position and the painting scheme. Complete dimensional details of support foot (where applicable) shall be indicated in these drawings.

c)

Welding, heat treatment and testing procedures.

d)

Details of corrosion resistant paint to be applied on the valves.

e)

Design calculation for pressure containing Parts.

f)

Procedure for cycle testing.

Manufacture of valves shall commence only after approval of the above documents. Once the approval has been given by Purchaser, any changes in design, material and method of manufacture shall be notified to Purchaser whose approval in writing of all changes shall be obtained before the valve is manufactured. 9.3

Within 30 days from the approval date, Manufacturer shall submit to Purchaser one reproducible and six copies of the approved drawings, documents and specifications as listed in clause 9.2 above.

9.4

Prior to shipment, Manufacturer shall submit to Purchaser one reproducible and six copies of the following:

9.5

a)

Test certificates as per clause 6.0 of this specification

b)

Manual for installation, erection, maintenance and operation instructions including a list of recommended spares for the valves.

All documents shall be in English language only.



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SPECIFICATION

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STANDARD SPECIFICATION FOR PIPELINE PLUG VALVES




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CONTENTS Sl. No.

DESCRIPTION

1.0

SCOPE

2.0

REFERENCE DOCUMENTS

3.0

MATERIALS

4.0


5.0


6.0

TEST CERTIFICATES

7.0


8.0


9.0

DOCUMENTATION




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1.0

SCOPE This Specification covers the minimum requirements for design, manufacture and supply of carbon steel plug valves of size DN 50 mm (2 inch) and above and ANSI class 150# thru 900# for use in onshore pipeline systems handling non sour hydrocarbons in liquid phase or gaseous phase including Liquefied Petroleum Gas (LPG). This specification does not cover plug valves for sour hydrocarbons (liquid/gas) service as defined in NACE Standard MR-0l-75.

2.0

REFERENCE DOCUMENTS

2.1

All valves shall be manufactured and supplied in accordance with the American Petroleum Institute (API) Specification 6D, Twenty second edition, January 2002 / ISO 14313:1999, Petroleum and Natural Gas Industries – Pipeline Transportation Systems – Pipeline Valves, with addition and modification as indicated in the following sections of this specification.

2.2

Reference has also been made in this specification to the latest edition of the following Codes, Standards and Specifications: ASME B 31.3

:

Process Piping.

ASME B 31.4

:

Pipeline Transportation System for Liquid Hydrocarbons and Other Liquids.

ASME B 31.8

:

Gas Transmission and Distribution Piping Systems.

ASME B 16.5

:

Pipe Flanges and Flanged Fittings.

ASME B 16.25

:

Butt-welding Ends

ASME B 16.34

:

Valves -- Flanged, Threaded and Welding Ends.

ASME B 16.47

:

API 1104

:

Welding Pipelines and Related Facilities.

ASME Sec VIII/IX

:

Boiler and Pressure Vessel Code.

ASTM A 370

:

Test Methods and Definitions for Mechanical Testing of Steel Products.

ASTM B 733

:

Auto catalytic Nickel Phosphorous Coating on Metals.


Large Diameter Steel Flanges.



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MSS-SP-6

:

Standard Finishes for Contact Faces of Pipe Flanges and Connecting-end Flanges of Valves and Fittings.

MSS-SP-44

:

Steel Pipe Line Flanges.

SSPC-VIS-1

:

Steel Structures Painting Council Visual Standard.

2.3

In case of conflict between the requirements of this specification, API 6D and the Codes, Standards and Specifications referred in clause 2.2 above, the requirements of this specification shall govern.

3.0

MATERIALS

3.1

Material for major components of the valves shall be as indicated in Valve Data Sheet. In addition, the material shall also meet the requirements specified herein. Other components shall be as per Manufacturer’s standard, which shall be subject to approval by Purchaser.

3.2

Carbon steel used for the manufacture of valves shall be fully killed.

3.3

The Carbon Equivalent (CE) of valve end connections which are subject to further field welding by Purchaser shall not exceed 0.45 in check analysis for each heat of steel used, as calculated by the following formula:

CE = C+ Mn + Cr+Mo+V+ Ni+Cu 6 5 15 3.4

For valves specified to be used for Gas service or High Vapour Pressure (HVP) liquid service, Charpy V-Notch test on each heat of base material shall be conducted as per API 6D, clause 3.7 for all pressure containing parts such as body, end flanges and welding ends as well as bolting material for pressure containing parts. Unless specified otherwise, the Charpy V-notch test shall be conducted at 0 °C. The Charpy V-notch test specimen shall be taken in the direction of - principal grain flow and notched perpendicular to the original surface of plate or forging. The minimum average absorbed energy per set of three specimens shall be 27 J with an individual minimum per specimen of 22 J. For valves specified to be used for other hydrocarbon services, the Charpy V-notch requirements stated above are not applicable, unless required by the specified material standard as a mandatory requirement. When Low Temperature Carbon Steel (LTCS) materials are specified in Valve Data Sheet or offered by Manufacturer, the Charpy V-notch test requirements of applicable material standard shall be complied with.




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3.5

For all such valves where Carbon Steel /S.G. Iron is used as plug material, the plug shall have 75 microns (0.003 inches) thick Electroless Nickel Plating (ENP) as per ASTM B733 with following classification: SC2, Type II, Class 2. The hardness of plating shall be minimum 50 RC.

3.6

When the valves are specified to be used for Gas service or High Vapour Pressure (HVP) liquid ervice, hardness test shall be carried out on each heat of base material for all pressure containing parts of the valve. A full thickness cross section shall be taken for this purpose and the maximum hardness shall not exceed 248 HV10 based on minimum four (4) measurements representing the entire thickness. For valves specified to be used for Low Vapour Pressure (LVP) liquid service, requirements as stated herein above are not applicable.

4.0


4.1

Valve design shall meet the requirements of API Specification 6D and shall be suitable for the service conditions indicated in the Valve Data Sheet. The ASME Boiler & Pressure Vessel Code, Section VIII, Division 1 shall be used to design the valve body. Allowable stress requirements shall comply the provisions of ASME B31.3. In addition, corrosion allowance indicated in Valve Data Sheet shall be considered in valve design. However, the minimum wall thickness shall not be less than the minimum requirement of ASME B 16.34. The manufacturer shall have valid license to use API monogram on valves manufactured as per API 6D.

4.2

Valve pattern area shall be as specified in the following table:

ANSI Rating 150

300 600 900

4.3

Size Range, DN mm (inch) 50-100 (2-4) 150-300 (6-12) 350 (14) & above 50-100 (2-4) 150-300 (6-12) 350 (14) & above 50-250 (2-10) 300 (12) & above 50-250 (2-10) 300 (12) & above

Pattern Short Regular Venturi Short Regular Venturi Regular Venturi Regular Venturi

Valves shall have an inherent feature using line pressure to ensure that the line pressure cannot cause taper locking of the plug / plug movement into the taper, i.e. valves shall be of “pressure - balanced” design.




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4.4

Cover shall be bolted to the body and screwed connections are not acceptable.

4.5

Soft seats to achieve a seal between plug and body are not permitted.

4.6

All valves shall have the provision for secondary sealant injection under full line pressure for seat and stem seals. All sealant injection connections shall be provided with an internal non-return valve. Valve design shall have a provision (e.g. Ball Type Check Valve/Needle Valve) to replace the sealant injector fitting under full line pressure. Location and arrangement of sealant injection points shall be as per Figure-4.6.

4.7

When specified in the Vale Data Sheet, valves shall be designed to withstand a sustained internal vacuum of at least 1 (one) milli-bar in both open and closed position.

4.8

Valve design shall ensure repair of gland packing under full line pressure.

4.9

a) Valve ends shall be either flanged or butt-welded or one end flanged and one end butt welded as indicated in the Valve Data Sheet. Flanges of the flanged end cast body valves shall be integrally cast with the body of the valve. Face to face/end to end dimensions shall conform to API 6D. b)

Flanged end shall have dimensions as per ANSI B16.5 for valve sizes upto DN 600 mm (24”) (excluding DN 550 mm (22”)) and as per MSS-SP-44 /ASME B16.47 Series A for valve sizes DN 550 mm (22”) and for DN 650 mm (26”) and above. Flange face shall be either raised face or ring joint type as indicated in Purchase Requisition. In case of RTJ flanges, the groove hardness shall be minimum 140 BHN.

c)

Butt weld end preparation shall be as per ASME B 16.25. The thickness of the pipe to which the valve has to be welded shall be as indicated in the Valve Data Sheet. Valves shall be without transition pups. In case difference exists between thickness of welding ends of valves and connecting pipe, the Data Sheet shall be considered in valve design. However the minimum wall thickness shall not be less than the minimum requirement of ASME B 16.34. The welding ends of valve shall have bevel preparation as per ASME B31.4/ B31.8 as applicable.

4.10 Valves shall be provided with plug position indicator and stops of rugged construction at the fully open and fully closed positions. 4.11 When indicated in Material Requisition, valves shall have locking devices to lock the valve either in full open (LO) or full close (LC) position. Locking devices shall be permanently attached to the valve operator and shall not interfere with operation of the valve.




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4.12 Valves shall be suitable for either buried or aboveground installation as indicated in Valve Data Sheet. 4.13 When stem extension requirement is indicated in Valve Data Sheet, the valves shall have the following provisions: a)

Valves provided with stem extension shall have waterproof outer casing. Length of stem extension shall be as indicated in Valve Data Sheet. The length indicated corresponds to the distance between centerline of the valve opening and the top of mounting flange for valve operating device (gear operator/power actuator as applicable)

b)

Seat sealant injection lines shall be extended and terminated adjacent to the valve operator by means of suitable piping anchored to the valve body/ stem housing. The pipe used shall be API 5L Gr. B/ ASTM A106 Gr. B, with Sch. 160. Fittings shall be ASTM A105/ ASTM A234 Gr. WPB, Socket welded ANSI Class 6000.

c)

Stem extension and stem housing design shall be such that the complete assembly will form a rigid unit giving positive drive under all conditions with no possibility of free movement between valve body, stem extension or its operator.

d)

Outer casing of stem extension shall have ¾” or ½” NPT plugs at the top and bottom, for draining and filling with oil to prevent internal corrosion.

4.14 Operating Devices a)

Valves shall have a power actuator or manual operator as indicated in the Valve Data Sheet. In case of manual operator, valve sizes ≤ DN 100 mm (4”) shall be wrench operated and valve sizes ≥ DN 150 mm (6”) shall be gear operated. Each wrench operated valve shall be supplied with wrench. Valve design shall be such that damage due to malfunctioning of the operator or its controls will only occur in the operator gear train or power cylinder and that damaged parts can be replaced without the valve cover being removed.

b)

The power actuator shall be in accordance with the Purchaser specification issued for the purpose and as indicated in the Valve and Actuator Data Sheet. Operating time shall be as indicated in Valve Data Sheet. Valve operating time shall correspond to full close to full open/ full open to full close under maximum differential pressure corresponding to the valve rating. For actuator valves, the actuator rated torque output shall be at least 1.25 times the break torque required to operate the valve under maximum differential pressure corresponding to the valve class rating.

c)

For the manual operator of all valves, the diameter of the hand wheel or the length of operating Wrench shall be such that under the maximum




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differential pressure, total force required to operate the valve does not exceed 350N. Manufacturer shall also indicate the number of turns of hand wheel (in case of gear operator) required to operate the valve from full open to full close position. d)

Direction of operation of hand wheel or wrench shall be in clock-wise direction while closing the valve.

e)

Gear operators, when provided, shall have a self-locking provision and shall be fully encased in water proof/splash proof enclosure and shall be filled with suitable grease.

4.15 Repair by welding is not permitted for fabricated and forged body valves. However repair by welding as per ASME B 16.34 is permitted for cast body valves. Repair shall be carried out before any heat treatment of casting is done. Repair welding procedure qualification shall also include impact test and hardness test when required as per Clause 3.4 and 3.6 of this specification and shall meet the requirements as specified therein. 4.16 The tolerance on internal diameter and out of roundness at the ends for welded ends valves shall be as per connected pipe specification as indicated in the Valve Data Sheet. 4.17 Valve stem shall be capable of withstanding the maximum operating torque required to operate the valve against the maximum differential pressure corresponding to applicable class rating. The combined stress shall not exceed the maximum allowable stresses specified in ASME section VIII, Division 1. For Power Actuated Valves, the valve stem shall be designed for maximum output torque of the selected power actuator (including gear box, if any) at the valve stem. 5.0


5.1

The Manufacturer shall perform all inspection and tests as per the requirements of this specification and the relevant codes, prior to shipment, at his Works. Such inspection and tests shall be, but not limited to, the following:

5.1.1 Visual and dimensional check on all valves shall be carried out as per the Purchaser approved drawings. 5.1.2 Chemical composition and mechanical properties shall be checked as per relevant material standards and this specification, for each heat of steel used. 5.1.3

a) Non destructive examination of individual valve material and components consisting of but not limited to castings/ forgings shall be carried out by the Manufacturer.




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b)

Body castings of valves shall be radio-graphically examined as per ASME B16.34. Procedure and acceptance criteria shall be as per ASME B16.34. The extent of radiography shall be as follows: ANSI Class 150#

-

All sizes

-

Nil

ANSI Class 300#

-

DN 400mm (16”)

-

Nil

ANSI Class 600# and above

-

DN 450mm (18”)

-

100%

-

All sizes

-

100%

All castings shall be wet magnetic particle inspected 100% of the internal surfaces. Method and acceptance shall comply with ASME B 16.34. c)

All valves made by forgings shall be ultrasonically examined in accordance with the procedure and acceptance standard of Annexure E of ASME B16.34.

5.1.4 Areas, which in Purchaser’s opinion cannot be inspected by radiographic methods, shall be checked by ultrasonic or magnetic particle methods and acceptance criteria shall be as per ASME Sec. VIII, Division 1, Appendix 12 and Appendix 6 respectively. 5.1.5

a) Weld ends of all cast valves subject to welding in field shall be 100 % radiographically examined and acceptance criteria shall be as per ASME B16.34. b) After final machining, all bevel surfaces shall be inspected by dye penetrant or wet magnetic particle methods. All defects longer than 6.35 mm are rejected, as are the defects between 6.35 mm and 1.59mm that are separated by a distance less than 50 times their greatest length. Rejectable defects must be removed. Weld repair of bevel surface is not permitted. c)

All finished wrought weld ends subjects to welding in field shall be 100 percent ultrasonically tested for lamination type defects for a distance of 50 mm from the end. Laminations shall not be acceptable.

5.1.6 All valves shall be tested in compliance with the requirements of API 6D. The sealant lines shall be either included in the hydrostatic shell test or tested independently. No leakage is permissible during hydrostatic testing. 5.1.7 A supplementary air seat test as per API 6D Appendix C3 shall be carried out for all valves.. No leakage is allowed. Test pressure shall be held for at least 15 minutes. 5.1.8 Valves shall be subjected to Operational Torque Test as per API 6D Appendix C4 under hydraulic pressure equal to maximum differential pressure corresponding to the valve rating. For manually operated valves, it shall be established that the force GAIL (INDIA) LTD NEW DELHI



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required to operate the valve does not exceed the requirements stated in section 4.14(c) of this specification. 5.1.9 Power actuated valves shall be tested after assembly of the valve and actuator, at the valve Manufacturer’s works. At least five Open-Close-Open cycles without internal pressure and five Open-Close-Open cycles with maximum differential pressure corresponding to valve rating shall be performed on the valve actuator assembly. The time for full open to full close shall be recorded during testing. If required, the actuator shall be adjusted to ensure that the opening and closing time is within the limits stated in Valve data sheet. Hand operator provided on the actuator shall also be checked after the cyclic testing, for satisfactory manual over-ride performance. These tests shall be conducted on minimum one valve out of a lot of five (5) valves of the same size, rating and actuator model/type. In case the tests do not meet the requirements, retesting/rejection of the lot shall be decided by purchaser’s Inspector. 5.2

Purchaser reserves the right to perform stage wise inspection and witness tests as indicated in clause 5.1 above at Manufacturer’s works prior to shipment. Manufacturer shall give reasonable access and facilities required for inspection to the Purchaser’s inspector. Purchaser reserves the right to require additional testing at any time to confirm or further investigate a suspected fault. The cost incurred shall be to Manufacturer’s account. In no case shall any action of Purchaser or his inspector shall relieve the Manufacturer of his responsibility for material, design, quality or operation of valves. Inspection and tests performed/witnessed by the Purchaser’s inspector shall in no way relieve the manufacturer’s obligation to perform the required inspection and tests.

6.0

TEST CERTIFICATES Manufacturer shall submit the following certificates: a)

Mill test certificates relevant to the chemical analysis and mechanical properties of the materials used for the valve construction as per the relevant standards.

b)

Test certificates of hydrostatic and pneumatic tests complete with records of timing and pressure of each test.

c)

Test reports of radiography and ultrasonic inspection.




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d)

Test report on operation of valves conforming to clause 5.1.8 and 5.1.9 of this specification.

e)

All other test reports and certificates as required by API 6D and this specification.

The certificates shall be valid only when signed by Purchaser’s Inspector. Only those valves which have been certified by Purchaser’s Inspector shall be dispatched from Manufacturer’s works. 7.0


7.1

Valve surface shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot blasting to SP-6 in accordance with “Steel Structures Painting Council Visual Standard SSPC-VIS-l”. For the valves to be installed underground, when indicated in Valve Data Sheet, the external surfaces of buried portion of the valve shall be painted with three coats of suitable coal tar epoxy resin with a minimum dry film thickness of 300 microns.

7.2

All valves shall be marked as per API 6D. The units of marking shall be metric except nominal diameter, which shall be in inches.

7.3

Valve ends shall be suitably protected to avoid any damage during transit. All threaded and machined surfaces subject to corrosion shall be well protected by a coat of grease or other suitable material. All valves shall be provided with suitable protectors for flange faces, securely attached to the valves. Bevel ends shall be protected with metallic or high impact plastic bevel protectors.

7.4

All sealant lines and other cavities of the valve shall be filled with sealant before shipment.

7.5

Packaging and shipping instructions shall be as per API 6D.

7.6

On packages, the following shall be marked legibly with suitable marking ink:

8.0

a)

Order Number

b)

Manufacturer’s Name

c)

Valve size and rating

d)

Tag Number.

e)

Serial Number

SPARES AND ACCESSORIES GAIL (INDIA) LTD NEW DELHI



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8.1

Manufacturer shall furnish list of recommended spares and accessories for valves required during start-up and commissioning.

8.2

Manufacturer shall furnish list of recommended spares and accessories required for two years of normal operation and maintenance of valves.

8.3

Manufacturer shall quote for spares and accessories as per Material Requisition.

9.0

DOCUMENTATION

9.1

9.2

At the time of bidding, Manufacturer shall submit the following documents: a)

General arrangement drawings showing all features and relative positions and sizes of vents, drains, gear operator/actuator, painting, coating and other external parts together with overall dimensions.

b)

Sectional drawing showing major parts with reference numbers and material specification.

c)

Torque curves for the power actuated valves along with break torque and maximum allowable stem torque. In addition, sizing criteria and torque calculations shall also be submitted for power actuated valves.

d)

Reference list of similar plug valves manufactured and supplied in last five years indicating all relevant details including project, year, client, location, size, rating, service etc.

e)

Descriptive technical catalogues of the manufacture.

f)

Clause wise list of deviation from the specification, if any.

g)

Installation, Operational and Maintenance Manual.

h)

Copy of valid API 6D Certificate.

Within three weeks of placement of order, the Manufacturer shall submit four copies of, but not limited to, the following drawings, documents and specifications for Purchaser’s approval: a)

Detailed sectional drawings showing all parts with reference numbers and materials specification.

b)

Assembly drawings with overall dimensions and features. Drawing shall also indicate the number of turns of hand wheel (in case of gear operators) required for operating the valve from full open to full close position and the painting scheme.




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c)

Fabrication details of all valves.

d)

Welding, Heat treatment and Testing procedures.

e)

Details of corrosion resistant paint to be applied on the valves.

Manufacture of valves shall commence only after approval of the above documents. Once, the approval has been given by Purchaser, any changes in design, material and method of manufacture shall be notified to Purchaser whose approval in writing of all changes shall be obtained before the valve is manufactured. 9.3

Within 30 days from the approval date, Manufacturer shall submit to Purchaser one reproducible and six copies of all approved drawings, documents and specifications as listed in clause 9.2 above.

9.4

Prior to shipment, Manufacturer shall submit to Purchaser one reproducible and six copies of the following: a)

Test certificates as listed in clause 6.0 of this specification.

b)

Manual for installation, erection, maintenance and operation instructions including a list of recommended spares for the valves.





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ABOVE GROUND INSTALLATION

UNDER GROUND INSTALLATION

FIGURE- 4.6




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SPECIFICATION FOR GAS POWERED VALVE ACTUATORS

SPECIFICATION NO. GAIL (INDIA) LTD NEW DELHI


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TABLE OF CONTENTS

1.0

SCOPE

2.0

REFERENCE DOCUMENTS

3.0

ACTUATOR SIZING

4.0

DESIGN FEATURES

5.0

COATING

6.0


7.0

NAME PLATE

8.0

SHIPPING

9.0

DOCUMENTATION

10.0


ATTACHMENTS - SKETCH-I - SKETCH-2 - GAS COMPOSITION



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1.0 SCOPE 1.1

This specification, together with the applicable data sheet, covers the minimum requirements for the design, manufacture, inspection, testing and shipping of valves actuators complete with accessories for quarter tarn ball valves.

1.2

This specification indicates the minimum supply requirements and does not relieve the vendor from his responsibilities concerning the design and the safe operation of the supplied equipment.

13

The valve manufacturer shall also be responsible or proper operation of the actuator that shall develop a torque or a thrust sufficient to conveniently open aid close the valve always with in the limits established by the resistance of the mechanical elements of the valve itself.

1.4

Valve and actuator shall be supplied as a single assembly co in all respect and ready for installation at site. 2.0 REFERENCE DOCUMENTS Reference is made in this specification to the latest edition of the following ea: standards and specifications: Codes and Standards a. ASME B31.8

:

Gas Transmission and Distribution Piping System:

b. ASME B 16.5

:

Pipe flanges and Hanged Fittir

c.

ASME B16.47

:

Large dia Steel Flanges NPS 26 through N PS 60

d.

ASME SEC. VIII

:

Boiler and Pressure Vessels Code.

e. ANSI B2. I

:

Pipe Threads, General Purpose

f. NEC

:

National Electric Code

g. IEC

:

International, Electrotechnical commission

h. NEMA

:

National Electrical Manufacturers Association

Purchaser Specification S-04-02-007

Standard Specification for Ball Valves (Onshore) SPECIFICATION NO.



S – 04 – 02 – 012



In case of conflict between the requirements of this specification and above referred documents, the requirements of this specification shall govern. 3.0 ACTUATOR SIZING 3.1 For sizing the actuator, Valve manufacturer shall fl to the actuator manufacturer the following information: a) The maximum break-away torque or thrust required at the valve stem with manual/ remote operation to open and close a valve at the shut off pressure in the line. The actuator shall be sized at 10 kg/cm2(g) gas pressure and meeting the safety factor of 1.25 as required by the valve operation at the maximum differential pressure corresponding to valve class rating. b) The temperature correction factor. c) The pressure correction factor. d) As a result of points (a) to (c) the minimum required torque or thrust output of the actuator. e) Maximum allowable torque or thrust output of the actuator depending on the type and size of valve. 3.2

Actuator manufacturer shall provide the complete model no. decoding for actuators, limit switches and solenoid valves.

3.3

Complete details of Gas/Hydraulic circuit with complete sequencing of port fro open to close and close to open position shall be furnished in the offer for review.

3.4

Manufacturer shall furnish the detailed calculation for actuator sizing after placement of order. The calculation so furnished by manufacturer shall satisfy the sizing criteria as per above clauses. Manufacturer shall agree to upgrade the actuators offered to meet the sizing criteria without any price and schedule impact.

3.5

Manufacturer shall furnish the detailed calculation for actuator sizing after placement of order. The calculation so furnished by manufacturer shall satisfy the sizing criteria as per above clauses. Manufacturer shall agree to upgrade the actuators offered to meet the sizing criteria without any price and schedule impact.

4.0 DESIGN FEATURES 4.1

The actuator shall be powered by Natural Gas from the main pipeline. The gas powered actuator shall operate at 10 kg/cm (g). A typical scheme for tapping the gas SPECIFICATION NO. GAIL (INDIA) LTD NEW DELHI


S – 04 – 02 – 012



from mainline with pressure reduction is shown in SKETCH-1. Actuator electrical/ hydraulic circuit shall he developed as per the SKETCH-2 enclosed. 4.2

Actuator shall be direct gas operated scotch yoke or rotary vane type with manual hydraulic override. The actuator shall he provided with a hydraulic pump or manual operation If there is no gas pressure available to actuator it shall be possible to actuate Direct Pneumatic Actuator by means of Nitrogen bottles or similar pressure source. Actuator: manufacturer shall furnish the capacity and set pressure of nitrogen bottles for at least two opening and two closing stroke of the actuator.

4.3

The actuator shall be suitable for gas operating conditions and ambient temperature as specified in data sheets. The presence of methanol in the gas shall not affect the service of the Actuator.

4.4

All materials in contact with natural gas shall he suitable for the gas composition attached with this specification.

4.5

The actuator and its accessories shall be suitable for outdoor installation and have weather proof enclosure as per IP 55 as a minimum. In addition alt compartments and housing containing electrical devices such as switches, contactors, relay, fuses, terminal box, glands etc. shall be flame proof suitable for IEC Zone-I, Gas Gr. II A & II B, Temp. Class 13 or equivalent. The cable gland shall be 1” NPT thread. The unused cable entries must he plugged off with solid metal plug. Solenoid valves shall be of flame proof design certified for IEC Zone-1, Gas Gr. II A & II B, Temp. Class 13 or equivalent with moulded continuous duty coils and stainless steel valve body. Vendor shall furnish hazardous area certificates for the above items certified by a Statutory body such as FM, UL, BASEEFA, PTB etc. In addition for above electrical items/ instruments supplied for projects in India, approval from CCE (Chief Controller of Explosive) shall be furnished, irrespective of the place of manufacture and the same is mandatory. In case CCE certificate is not available now for any item, vendor to confirm that the same shall he furnished before shipment.

4.6 4.7

All pressure containing parts shall be designed to ASME Section VIII. a)

The actuator shall be suitable for direct mounting to the valve without changing the standard top works of the valve and shall have the capability to but mounted or removed from the valve when the valve is in service, The actuators shall he flanged and bolted directly on the valve body or extension. The connection between actuator and the valve or between the operator, the outer casing of the extension and the valve shall be such that there is no SPECIFICATION NO.



S – 04 – 02 – 012



movement between these connections when the valve is actuated by the actuator under any load. b)

Actuator shall be suitable for installation on a vertical stem unless otherwise specified in the data sheet.

4.8

Provision shall be made to prevent accidental pressure build up in the actuator.

4.9

The construction of the actuator and its controls shall be such that proper manual operation and maintenance can be carried out by skilled personnel without the risk of being injured e.g. by moving parts.

4.10

A position indicator on the actuator shall show the valve in the open, closed or partially open positions.

4.11

Bearings shall be factory packed with grease and shall not require additional lubrication for the life of the actuator.

4.12

Unless specified otherwise in the data sheet, the actuator be equipped with limit valves which immediately shut off the gas supply to actuator when the valve reaches one of its end positions.

4.13

Actuator shall be provided with pressure gauges for pneumatic and hydraulic systems. The pressure gauges for the hydraulic system shall be in circuit with the pressure relief system.

4.14

In selection of pressure regulator due consideration shall be given to the effect of cooling of gas at the regulator and its down stream section,

4.15

A high pressure dehydrating fiter cartridge shall be provided to remove condensate, moisture, foreign particles and any corrosive contaminants from pipeline gas.

4.16

The sound level of the gas escaping into the atmosphere when the actuator is in operation shall not exceed 90 dBA, measured at a distance of 1 meter.

4.17

The actuator shall be operated by either of the following two methods: a)

For the remote control, the actuator shall have a solenoid valve, limit switches, relays, etc. and shall be suitable for remote and local operation as per description in the attached Actuator Data Sheet(s). Electrical signal supplied is a momentary type with 1sec duration signal. Actuator shall have a self retaining system of the above signal in its control circuit. SPECIFICATION NO.



S – 04 – 02 – 012



4.18

b)

For the local-control the actuator shall be suitable for local operation with line gas feed lines or through nitrogen bottles. The devices and accessories, which do not require the electricity for their operation, shall be provided in the actuators as per P this specification. The actuator shall have a hand pump in conjunction with the oil circuit to achieve local control with hydraulic shock functionality.

a)

The actuators shall be provided with limit switches for open and close positions. The position of switches shall be adjustable near the valve open and close positions. The limit switches shall be wired upto terminal block and shall be numbered for proper identification. The limit switches shall have 2 sets of contacts for each open and close position. The contact rating shall be as specified in the data sheet. The power solenoid valves shall he cut-off when the actuator has travelled to extreme positions (close and open).

b)

The limit switches shall he wired in the actuator control circuit by the vendor so as to cut off power to die actuator once the end positions of the valve are reached. This is required to dc-energize the solenoid valves in the steady state condition and failure of electrical power will not affect the valve position.

4.19

The stroke of the Actuator shall he easily adjustable in steps of maximum 0.5° for Ball Valves.

4.20

Speed control nozzles for adjusting the valve speed over a wide range shall be provided.

4.21

If remote control is required, a lock/ remote switch shall be installed to prevent remote control during maintenance work. This switch shall be provided with a hole 12 mm in diameter for locking with pad lock in either position. This local/ remote switch shall be wired upto the junction box as per circuit diagram.

4.22

All control accessories, pneumatic and hydraulic, shall be mounted in an enclosure and shall be fully wired and tubed. The enclosure shall he weatherproof as per IP 55 9or equivalent.

4.23

All bleed and vent connections wherever required shad be piped outside the actuator cabinet so as to prevent gas pocketing inside the actuator cabinet. The actuator will be of an automatic self purging design such that any gas pocket in the actuator will be eliminated.

4.24

Vendor shall be responsible for integrating the potential free NO or NC contacts of Remote Telemetry Unit (RTU’s) for open and close command in interlock circuit. These commands will be of momentary type with 1 sec duration.



S – 04 – 02 – 012



4.25

All mounting accessories needed for installing the actuator, tanks etc. are in manufacturer’s scope of supply.

4.26

The interconnecting cabling, interconnecting pipe work between the actuator and the valve, adapters, tubing, cable glands, junction box are in manufacturer’s scope of supply.

4.27

The actuator shall be supplied totally self-contained, wired, tubed and mounted on ball valve. In case of a separate control box, wiring and tubing between control box and actuator is in the vendor’s scope. Three metres of 3/4” tubing set including all connectors between the actuator and the control box and three metres of interconnecting piping work upstream & downstream of the valve and the control box shall be provided. Owner shall provide 20 mm (3/4’) SW tapping on process main line for line gas tapping.

4.28

Threading connections shall be NPT as per ANSI B 2.1 and flange connection as ANSI B 16.5/ANSI B16.47. The tubing, fitting and valves shall be stainless steel with Swage Lock fitting or equivalent.

5.0

COATING

The actuator. including gear boxes and piping, shall be coated as described below: 5.1

Removal of all rust by means of emery cloth or wire brush.

5.2

Shot blast as per Swedish Standard No. SIS 055900 latest edition SA 2.5 one layer PrimerEpoxyPolyamide DET 75 microns intermediate layer Epoxv-Polyamide DFT 25 microns, final layer Epoxy- Polyamide DFT 75 microns. Total DFT 175 microns and color RAL 5012 (light blue).

6.0


6.1

Test at the Actuator Manufacturer’s Shop a) Electrical and mechanical operating tests. b) Seal test or hydraulic circuits. c) Check of required functions. d) Check of operating time control. e) Check of limiting device operation. f) Check of the actuator torque or thrust. SPECIFICATION NO. GAIL (INDIA) LTD NEW DELHI


S – 04 – 02 – 012



6.2

Test at the Valve Manufacturer’s Shop a) Test and check covered by point 6.1 after assembly with ball/plug valve. b) No load test (DP=0) or load (DP max) Operations with the minimum required feeding pressure (10 kg/cm) c) Check of the limiting device operation. d) Various tests on the valve according to provisions of specific documentation. e) Testing shall conform to actual field operating conditions.

6.3

All actuators shall be visually inspected.

6.4

Dimensional check on actuators shall be carried out as per the Purchaser approved drawings.

6.5

Purchaser reserves the right to perform inspection as indicated above at Manufacturer’s works prior to shipment. Manufacturer shall give reasonable access and facilities required for inspection to the Purchaser’s Inspector. In no case shall any action of Purchaser or his inspector relieve the Manufacturer of his responsibility for material design, quality or operation of actuators.

7.0

NAMEPLATE

Actuator shall have a SS name plate attached firmly to it at a visible place and reporting the following information: a) Instrument tag

number as per Purchaser’s data sheets.

b) Manufacturer’s model, trade mark, serial no. etc. c) Max. allowable operating pressure or voltage. d) Area Classification in which the equipment can be used. e) Actuator characteristics data f) Inspection agency name or logo 8.0

SHIPPING



S – 04 – 02 – 012



8.1

All threaded and flanged opening shall be suitably protected to prevent entry of foreign material.

8.2

The actuator shall be supplied pre-assembled except piping/ tubing, actuator, actuator control unit, tanks and other accessories shall be packed separately.

8.3

Protective grease oil coating shall be applied on the surface to protect them from rusting.

8.4

Package shall be marked legibly with suitable marking ink the following: a) Order number b) Package number c) Manufacturer’s name d) Model No. & Thrust e) Tag number f) Inspection agency name or logo

9.0

DOCUMENTATION

9.1

At the time of bidding the manufacturer shall submit the following documents in accordance with EN10204 3. IC: a) A detailed specification sheet for valve actuator providing all the details regarding type, materials of construction for various parts etc. b) Schematic diagrams showing the complete actuator control circuit. c) A detailed dimensional drawing. d) Installation drawing complete with valve assembly. e) Actuator sizing calculations including relation between required toque of valve and actuator output torque. f) Information asked for vide section 3.0 of this specification and actuator sizing as per Actuator Data Sheet. g) Drawing showing connections by Purchaser (piping, electrical etc.) SPECIFICATION NO. GAIL (INDIA) LTD NEW DELHI


S – 04 – 02 – 012



h)

Wiring diagram (actuator electrical circuitry) incorporating latching of momentary signals, remote/ local switch, and limit switches.

i) Junction box terminal block nos. for I/O signals. j) Parts list. k) Recommended spare parts with prices. l) Assembly details (Valve & Actuator). m) Clause wise List of deviations from this specification, if any n) Information regarding the past experience on similar actuators including (a) Size (b)Numbers (c) Name of Installation (d) Owner (e) Name of Contact Person (f) Date of Installation. o) Technical Catalogue giving detailed technical specification and other information for each type of actuator and its accessories covered in the bid. 9.2

Within 30 days from the date of Purchase Order manufacturer shall submit copies of the following for Purchaser’s review and approval. a) Documents and specifications as listed in Cause 9.1 of this specification. b) Test certificates and certificates from statutory bodies. c) Manual for installation, erection instructions, maintenance and operation instructions. d) Complete assembly drawing of the ball valve matching with the actuator offered. The approval of these drawings/ documents will not absolve vendor of the responsibility with respect to correct operation of the actuator. Manufacturer’s quotation, catalogues, drawings, operating and maintenance manuals etc. shall be in English language.

10.0 SPARES AND ACCESSORIES 10.1

Manufacturer shall furnish list of recommended spares and accessories for actuators required during start-up and commissioning.

10.2

Manufacturer shall furnish list of recommended spares and accessories required for two years of normal operation and maintenance of actuators.

10.3

Manufacturer shall quote for spares and accessories as per Material Requisition. SPECIFICATION NO. GAIL (INDIA) LTD NEW DELHI


S – 04 – 02 – 012



1. Stop Valve (3/4” NPT), 2. Check Valve, 3. High Pressure Shuttle Valve, 4. Filter Separator & Gas Dehydrator, 5. Self Actuated Pressure Regulator, 6. Safety Relief Valve Notes : The Scheme shows outline of Power Gas Feeding System., Vendor shall develop and supply the suitable system in accordance with the specification.



S – 04 – 02 – 012





S – 04 – 02 – 012



GAS COMPOSTION

SL.

PARAMETER

RELIANCE

R-LNG

SPOT

NO

Lean gas at Vijaipur

Typical Mole (%) 1

Methane (C1)

94.0

88.51

92.79

90.84

2

Ethane(C2)

5.0

7.72

5.41

5.02

3

Propane(C3)

1.0

2.33

1.37

0.68

4

T-Butane(C4)

0.00

1.18

0.32

0.05

5

T-Pentane(C5)

0.00

0.07

-

-

6

Hexane(C6)

-

-

-

-

7

Carbon Di-oxid C O

-

-

3.30

0

0.19

0.11

0.11

Total Sulphur content

NA

24 ppmw

24 ppmw

H2S

NA

6ppmw

6ppmw

2 8

Nitrogen (N2)



S – 04 – 02 – 012



STANDARD SPECIFICATION FOR SEAMLESS FITTINGS & FLANGES SIZE UP TO DN 400 mm (16”)


STANDARD SPECIFICATION FOR SEAMLESS FITTINGS & FLANGES (UPTO 400 mm/ 16”)


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CONTENTS

Sl. No.

Description

1.0

SCOPE

2.0

REFERENCE DOCUMENTS

3.0

MANUFACTURER’S QUALIFICATION

4.0

MATERIALS

5.0

DESIGN AND MANUFACTURE

6.0


7.0

TEST CERTIFICATES

8.0


9.0

DOCUMENTATION




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1.0

SCOPE This specification covers the minimum requirements for the design, manufacture and supply of following carbon steel flanges and fittings of size upto DN 400 mm (16”) to be installed in pipeline systems handling hydrocarbons in liquid or gaseous phase including Liquefied Petroleum Gas (LPG): -

Flanges such as welding neck flanges, blind flanges, spectacle blinds, spacers and blinds etc.

-

Seamless fittings such as tees, elbows, reducers, caps, outlets etc.

This specification does not cover the above-mentioned items, which are to be installed in pipeline systems handling sour hydrocarbons (liquid/gas) service as defined in NACE Standard MR-01-75 2.0

REFERENCE DOCUMENTS

2.1

Reference has been made in this specification to the latest edition of the following Codes: ASME B31.4 - Pipeline Transportation System for Liquid Hydrocarbons and Other Liquids ASME B31.8 - Gas Transmission and Distribution Piping Systems ASME B16.5 - Pipe Flanges and Flanged Fittings ASME B16.9 - Factory Made Wrought Steel Butt Welding Fittings ASME B16.11 - Forged Steel Fittings, Socket Welding and Threaded ASME B16.48 - Steel Line Blanks ASME Sec VIII/IX - Boiler and Pressure Vessel Code ASTM A370 - Standard Test Methods and Definitions for Mechanical Testing of Steel Products MSS-SP-25 - Standard Marking System for Valves, Fittings, Flanges and Unions MSS-SP-44 - Steel Pipeline Flanges. MSS-SP-75 - Specification for High Test Wrought Welded Fittings. MSS-SP-97 - Forged Carbon Steel Branch Outlet Fittings-Socket Welding, Threaded and Butt welding Ends. GAIL (INDIA) LTD NEW DELHI



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2.2

In case of conflict between the requirements of this specification and the requirements of above referred Codes and Standards, the requirements of this specification shall govern.

3.0

MANUFACTURER’S QUALIFICATION Manufacturer who intends bidding for fittings must possess the records of a successful proof test, in accordance with the provisions of ASME B 16.9.

4.0

MATERIAL

4.1

The Carbon Steel used in the manufacture of flanges and fittings shall be fully killed. Material for flanges and fittings shall comply the material standard indicated in the Purchase Requisition. In addition, the material shall also meet the requirements specified hereinafter.

4.2

Each heat of steel used for the manufacture of flanges and fittings shall have Carbon Equivalent (CE) not greater than 0.45 calculated from check analysis in accordance with the following formula:

4.3

For flanges and fittings specified to be used for Gas service or High Vapour Pressure (HVP) liquid service, Charpy V-notch test shall be conducted on each heat of steel. Unless specified otherwise, the Charpy V-notch test shall be conducted at 00 C in accordance with the impact test provisions of ASTM A- 370 for flanges and fittings. The minimum average absorbed impact energy values of three full-sized specimens shall be 27 joules. The minimum impact energy value of any one specimen of the three specimens analyzed as above shall not be less than 80% of the above mentioned average value. For flanges and fittings specified to be used for other hydrocarbon service, the Charpy V-notch test requirements as stated above are not applicable, unless required by the specified material standard as a mandatory requirement. When Low Temperature Carbon Steel (LTCS) materials are specified in Purchase Requisition for flanges and fittings, the Charpy V-notch test requirements of applicable material standard shall be complied with.

4.4

For flanges and fittings, specified to be used for Gas service or High Vapour Pressure (HVP) liquid service, hardness test shall be carried out in accordance with ASTM A 370. Hardness testing shall cover at least 10% per item, per size, per heat, per manufacturing method. A full thickness cross section shall be taken for this purpose and the maximum hardness shall not exceed 248 HV10. For flanges and fittings, specified to GAIL (INDIA) LTD NEW DELHI



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be used for other hydrocarbon services, the hardness requirements stated above are not applicable. 4.5

In case of RTJ flanges, the groove hardness shall be minimum 140 BHN.

5.0


5.1

Flanges such as weld neck flanges and blind flanges shall conform to the requirements of ASME B16.5.

5.2

Spectacle blind and spacer & blind shall conform to the requirements of ASME B16.48.

5.3

Fittings such as tees, elbows, reducers, etc. shall be seamless type and shall conform to ASME B 16.9 for sizes DN 50 mm (2”) and above and ASME B16.11 for sizes below DN 50 mm (2”).

5.4

Fittings such as weldolets, sockolets, nippolets, etc. shall be manufactured in accordance with MSS-SP-97.

5.5

Type, face and face finish of flanges shall be as specified in Purchase Requisition.

5.6

Flanges and fittings manufactured from bar stock are not acceptable.

5.7

All butt weld ends shall be bevelled as per ASME B16.5/ ASME B16.9/MSS-SP-97 as applicable.

5.8

Repair by welding on flanges and fittings is not permitted.

6.0


6.1

The Manufacturer shall perform all inspections and tests as per the requirement of this specification and the relevant codes, prior to shipment at his works. Such inspections and tests shall be, not but limited to the following:

6.1.1 All flanges and fittings shall be visually inspected. The internal and external surfaces of the fittings shall be free from any strikes, gauges and other detrimental defects. 6.1.2 Dimensional checks shall be carried out on finished products as per ASME B16.5 for flanges, ASME B16.48 for spacers and blinds and ASME B16.9/ MSS-SP-97 as applicable for fittings and as per this specification. 6.1.3 Chemical composition and mechanical properties shall be checked as per relevant material standards and this specification, for each heat of steel used.




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6.1.4 All finished wrought weld ends subject to welding in field, shall be 100% tested for lamination type defects by ultrasonic test. Any lamination larger then 6.35 mm shall not be acceptable. 6.2

Purchaser’s Inspector reserves the right to perform stage wise inspection and witness tests, as indicated in clause 6.1 of this specification at Manufacturer’s Works prior to shipment. Manufacturer shall give reasonable notice of time and shall provide, without charge, reasonable access and facilities required for inspection, to the Purchaser’s Inspector. Inspection and tests performed/ witnessed by Purchaser s Inspector shall in no way relieve the Manufacturer’s obligation to perform the required inspection and tests.

7.0

TEST CERTIFICATES Manufacturer shall furnish the following certificates: a)

Test certificates relevant to the chemical analysis and mechanical properties of the materials used for manufacture of flanges and fittings as per relevant standards and this specification.

b)

Test Reports on non destructive testing.

c)

Certificates for each fitting stating that it is capable of withstanding without leakage a test pressure, which results in a hoop stress equivalent to 100 % of the specified minimum yield strength for the pipe with which the fitting is to be attached without impairment of serviceability.

8.0


8.1

After all inspection and tests required have been carried out; all external surfaces shall be thoroughly cleaned to remove grease, dust and rust and shall be applied with standard mill coating for protection against corrosion during transit and storage. The coating shall be easily removable in the field.

8.2

Ends of all fittings and weld neck flanges shall be suitably protected to avoid any damage during transit. Metallic or high impact plastic bevel protectors shall be provided for fittings and flanges. Flange face shall be suitably protected to avoid any damage during transit.

8.3

All flanges and fittings shall be marked as per applicable dimension/manufacturing standard.




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9.0

DOCUMENTATION

9.1

Prior to shipment, the Manufacturer shall submit six copies of the test certificates as listed in clause 7.0 of this specification.

9.2

All documents shall be in English Language only.




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STANDARD SPECIFICATION FOR FLANGES & WELDED FITTINGS (SIZE DN 450 mm (18") AND ABOVE)


STANDARD SPECIFICATION FOR FLANGES &WELDED FITTINGS (SIZE 450 MM (18”) AND ABOVE


REV-0 Page 1 of 7


CONTENTS 1.0

SCOPE

2.0

REFERENCE DOCUMENTS

3.0

MANUFACTURER'S QUALIFICATION

4.0

MATERIALS

5.0


6.0


7.0

TEST CERTIFICATES

8.0


9.0

DOCUMENTATION




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1.0

SCOPE:

This specification covers the minimum requirements for the design, manufacture and supply of following carbon steel flanges and fittings of size DN 450 mm (18") and above to be installed in pipeline systems handling hydrocarbons in liquid or gaseous phase including Liquefied Petroleum Gas (LPG): 

Flanges such as weld neck flanges, blind flanges, spectacle blinds, spacers and blinds, etc.



Welded fittings such as tees, elbows, reducers, caps, outlets etc.

This specification does not cover the above-mentioned items, which are to be installed in pipeline systems handling sour hydrocarbons (liquid / gas) service as defined in NACE Standard MR-01-75. 2.0

REFERENCE DOCUMENTS:

2.1

Reference has been made in this specification to the latest edition of the following Codes, Standards and Specifications. ASME B31.3

-

Process Piping

ASME B31.4

-

Pipeline Transportation System for Liquid Hydrocarbons and Other Liquids

ASME B31.8

-

Gas transmission and distribution piping system

ASME B16.5

-

Pipe Flanges and Flanged fittings

ASME B16.9

-

Factory made wrought steel Butt welding fittings

ASME B 16.25

-

Butt welding Ends

ASME B16.47

-

Large diameter steel Flanges

ASME B16.48

-

Steel line Blanks

ASME Sec VIII/IX

-

Boiler and Pressure Vessel code

ASTM A370

-

Standard test methods and Definitions for mechanical testing of Steel products

MSS-SP-25

-

Standard Marking system for Valves, Flanges, Fittings and Unions

MSS-SP-44

-

Steel Pipeline Flanges

MSS-SP-75

-

Specification for high Test Wrought Welded fittings




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MSS-SP-97

-

Forged Carbon Steel Branch Outlet Fittings- Socket Welding, Threaded and Butt Welding Ends

2.2

In case of conflict between the requirements of this specification and the requirements of above referred Codes and Standards, the requirements of this specification shall govern.

3.0

MANUFACTURER'S QUALIFICATION:

Manufacturer who intends bidding for fittings must possess the records of a successful proof test in accordance with the provisions of ASME B16.9 / MSS-SP-75, as applicable. 4.0

MATERIAL:

4.1

The Carbon Steel used in the manufacture of flanges and fittings shall be fully killed. Material for flanges and fittings shall comply the material standards indicated in the Purchase Requisition. In addition, the material shall also meet the requirements specified hereinafter.

4.2

Each heat of steel used for the manufacture of flanges and fittings shall have Carbon Equivalent (CE) not greater than 0.45 calculated from check analysis in accordance with the following formula: CE

4.3

=

C + Mn + Cr+ Mo + V + Ni+Cu 6 5 15

For flanges and fittings specified to be used for Gas service or High Vapour Pressure (WP) liquid service, Charpy V-notch test shall be conducted on each heat of steel. Unless specified otherwise, the Charpy V-notch test shall be conducted at 0' C in accordance with the impact test provisions of ASTM A 370 for flanges and MSS-SP-75 for all fittings. The minimum average absorbed impact energy values of three full-sized specimens shall be 27 joules. The minimum impact energy value of any one specimen of the three specimens analysed as above, shall not be less than 80% of the above mentioned average value. For flanges and fittings specified to be used for other hydrocarbon service, the Charpy V-notch test requirements as stated above are not applicable, unless required by the specified material standard as a mandatory requirement. When Low Temperature Carbon Steel (LTCS) materials are specified in Purchase Requisition for flanges and fittings, the Charpy V-notch test requirements of applicable material standard shall be complied with.




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4.4

For flanges and fittings, specified to be used for Gas service or High Vapour Pressure (HVP) liquid service, hardness test shall be carried out as per ASTM A 370 for each heat of steel used. A full thickness cross section shall be taken for this purpose and the maximum hardness of base metal, weld metal and heat affected zone shall not exceed 248 HV10. For flanges and fittings, specified to be used for other hydrocarbon services, the hardness requirements stated above are not applicable.

4.5

In case of RTJ flanges, the groove hardness shall be minimum 140 BHN.

5.0

DESIGN AND MANUFACTURE:

5.1

Flanges such as weld neck flanges and blind flanges shall conform to the requirements of ASME B16.5 up to sizes DN 600 mm (24") excluding DN 550 mm (22'9, and MSS-SP-44 for sizes DN 550 mm (22") and ASME B16.47 (Series A) for sizes DN 650 mm (26") and above.

5.2

Spectacle blind and spacer & blind shall conform to the requirements of ASME B 16.48 up to sizes DN 600 mm (24"). For sizes DN 650 mm (26") and above, spectacle blind and spacer & blind shall conform to Manufacturer's standard.

5.3

Type, face and face finish of flanges shall be as specified in Purchase Requisition.

5.4

Fittings such as tees, elbows, reducers, etc. shall be either welded or seamless type. All fittings shall comply with the requirements of MSS-SP-75.

5.5

Fittings such as weldolets etc. shall be manufactured in accordance with MSS-SP97.

5.6

Tees shall be manufactured by forging or extrusion method. Stub-in or pipe to pipe connection shall not be used in the manufacture of tees. The longitudinal weld seam shall be kept at 90 degree from the extrusion. Fittings shall not have any circumferential weld joint.

5.7

All butt weld ends shall be beveled as per ASME B16.5 / MSS-SP-44 / ASME B16.47 as applicable for flanges and MSS-SP-75/MSS-SP-97 as applicable for fittings.

5.8

The reinforcement of inside weld seam shall be removed for a distance of 100mm from each end of welded fittings.

5.9

All welds shall be made by welders and welding procedures qualified in accordance with provisions of ASME Sec. IX. The procedure qualification shall include Charpy V-notch test for weld heat affected zone and hardness test in accordance with clause 4.3 and 4.4 of this specification respectively.

5.10

Repair by welding on flanges and parent metal of fittings is not permitted. Repair of weld seam by welding shall be carried out by welders and welding procedures duly qualified as per ASME Section IX and records for each repair shall be GAIL (INDIA) LTD NEW DELHI



REV-0 Page 5 of 7


maintained. Repair welding procedure qualification shall include all tests, which are applicable for regular production welding procedure qualification. 6.0

INSPECTION AND TESTS:

6.1

The Manufacturer shall perform all inspections and tests as per the requirement of this specification and the relevant codes, prior to shipment at his works. Such inspections and tests shall be, not but limited to the following:

6.1.1 All flanges and fittings shall be visually inspected. The internal and external surfaces of the fittings shall be free from any strikes, gauges and other detrimental defects. 6.1.2 Dimensional checks shall be carried out on finished products as per ASME B16.5 / MSS-SP-44 / ASME B16.47 as applicable for flanges, ASME B 16.48 for spacers and blinds and ASME B 16.9 / MSS-SP-75/MSS-SP-97 as applicable for fittings and as per this specification. 6.1.3 Chemical composition and mechanical properties shall be checked as per relevant material standards and this specification, for each heat of steel used. 6.1.4 The non-destructive inspection shall be carried out as given below: a) b)

6.2

All butt and repair welds for welded fittings shall be examined 100 % by radiography. Acceptance criteria shall be as be ASME B 31.4 or ASME B 31.8 as applicable and API 1104. When elbows of size ≥ 18" NB are manufactured, the first elbow of each radius, diameter and wall thickness shall be ultrasonically checked for sufficient wall thickness in areas where a minimum wall thickness is to be expected. This shall be followed by random inspection of one out of every three elbows of the same radius, diameter and wall thickness.

c)

All finished wrought weld ends subject to welding in field, shall be 100% tested for lamination type defects by ultrasonic test. Any lamination larger then 6.35 mm shall not be acceptable.

d)

Magnetic particle or liquid penetrant examination shall be performed on cold formed butt welding tees with extruded outlets (that are subjected to an extreme fibre elongation of greater than 5 %) as per the Supplementary Requirement SR 3 of MSS-SP-75.

e)

Welds, which cannot be inspected by radiographic methods, shall be checked by ultrasonic or magnetic particle methods. Acceptance criteria shall be as per ASME Section VIII Appendix 12 and Appendix 6 respectively.

Purchaser's Inspector reserves the right to perform stage wise inspection and witness tests, as indicated in clause 6.1 of this specification at Manufacturer's Works prior to shipment. Manufacturer shall give reasonable notice of time and




REV-0 Page 6 of 7


shall provide, without charge, reasonable access and facilities required for inspection, to the Purchaser's Inspector. Inspection and tests performed/witnessed by Purchaser's Inspector shall in no way relieve the Manufacturer's obligation to perform the required inspection and tests. 7.0

TEST CERTIFICATES:

Manufacturer shall furnish the following certificates: a)

Test certificates relevant to the chemical analysis and mechanical properties of the materials used for manufacture of flanges and fittings as per relevant standards and this specification.

b)

Test Reports on radiography, ultrasonic inspection and magnetic particle examination.

c)

Test reports of heat treatment carried out as per the specification.

d) e)

Welding procedures and welders qualification reports. Certificate for each fitting stating that it is capable of withstanding without leakage a test pressure, which results in a hoop stress equivalent to 100% of the specified minimum yield strength for the pipe with which the fitting is to be attached without impairment of serviceability.

8.0

PAINTING, MARKING AND SHIPMENT:

8.1

After all inspection and tests required have been carried out; all external surfaces shall be thoroughly cleaned to remove grease, dust and rust and shall be applied with standard mill coating for protection against corrosion during transit and storage. The coating shall be easily removable in the field.

8.2

Ends of all fittings and weld neck flanges shall be suitably protected to avoid any damage during transit. Metallic or high impact plastic bevel protectors shall be provided for flanges and fittings.

8.3

Flange face shall be suitably protected to avoid any damage during transit.

8.4

All flanges and fittings shall be marked as per applicable dimension / manufacturing standard.

9.0

DOCUMENTATION:

9.1

Prior to shipment, the Manufacturer shall submit six copies of the test certificates as listed in clause 7.0 of this specification.

9.2





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STANDARD SPECIFICATION FOR LR BENDS

FOR ONSHORE PIPELINES


STANDARD SPECIFICATION FOR LR BENDS FOR ONSHORE PIPELINE


REV- 0 Page 1 of 10


CONTENTS 1.0

SCOPE

2.0

REFERENCE DOCUMENTS

3.0

MATERIAL

4.0


6.0

TEST CERTIFICATES

7.0

MARKING, PACKING AND SHIPMENT

8.0

DOCUMENTATION

9.0

BEND MANUFACTURING PROCEDURE QUALIFICATION




REV- 0 Page 2 of 10


1.0

SCOPE This specification covers the minimum requirements for manufacture and supply of long radius bends made from Carbon Steel line pipes for use in onshore pipeline systems handling hydrocarbons in gaseous or liquid phase including Liquified Petroleum Gas (LPG).

2.0

REFERENCE DOCUMENTS Reference has been made in this specification to the latest edition (edition enforce at the time of issue of enquiry) of the following codes, standards and specififcations: a)

ASME 31.4

: Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids.

b) ASME B 31.8

: Gas Transmission and Distribution Piping System

c)

MSS-SP-75

: Specification for High Test Wrought Welding Fittings

d)

Purchaser specification of Line pipes

In case of conflict between the requirement of above reference documents and this specification; the requirements of this specification shall govern. 3.0

MATERIAL

3.1

Bends shall be fabricated from steel line pipe. The type of pipe to be used for fabrication of bends shall be indicated in the Work Order. Pipe with positive wall thickness tolerances shall be used for fabrication of bends.

3.2

Unless specified otherwise in the Work Order, the line pipes for fabrication of bends shall be procured by Owner.

3.3

Heat treatment shall be carried out for all finished bends inn case it is established during bending procedure qualification that heat treatment is required to meet the specification requirements. Heat treatment procedure shall be such that the mechanical properties and steel microstructure of the finished bends comply with the minimum requirements specified in the applicable line pipe specification referred under clause 2.0. When TMCP and OLAC steels and micro alloyed steels are used, specific approval of the proposed heat treatment shall be obtained before bending process is employed. The finished product shall be evaluated for mechanical properties and micro structural stability.

3.4

Mechanical testing of test bends performed during the bend manufacturing procedure qualification as per section 9.0 of this specification, shall ensure that all bends made according to the Company approved bend manufacturing procedure have the required mechanical properties and destructive testing of production bend GAIL (INDIA) LTD NEW DELHI



REV- 0 Page 3 of 10


is not required. However, company reserves the right to require destructive testing whenever production bending parameters or heat treatment parameters deviate from those established in the Company approved bend manufacturing procedure. 4.0

MANUFACTURE

4.1

Material grade, bend size, bend radius an bend angle shall be as indicated in the PO. Unless specified otherwise , the bending radius for bends shall be minimum six times the specified outside diameter.

4.2

Bends shall be manufactured by high frequency induction heating and forming method. Once the bending operation has commenced no stoppage shall be permitted until the entire bend has been completed. If bending temperature, bending rate, cooling medium volume or heat treatment temperature- depart from the company approved bend manufacturing procedure, then the pipe shall be discarded and another bend shall be made in its place.

4.3

When bending SAW or Electric Welded Pipes, the longitudinal seam shall be located in the plane of minimum deformation or neutral axis. Acceptable tolerance on location of the longitudinal weld seam shall be ± 50.

4.4

All bends shall be provided with a tangent length at both ends. Tangent length shall be 500 mm or pipe outside diameter whichever is more.

4.5

Unless otherwise specified differently in the PO, the bevels at the ends shall be as per the relevant pipe specification.

4.6

Bends shall not have any circumferential joint.

4.7

No repair by welding is allowed on any part of the bends.

4.8

Bulges, dents and flat areas shall not appear within 100 mm front end of the bend. For the remaining part of the bend these deviations from the original contour of the pipe are permitted provided these deviations do not exceed 6.0 mm. The same shall not extend (in any direction) over a distance of more than 25 % of normal diameter of the bend.

4.9

The excess weld material at the inside of the bend in case of bends made from SAW pipes, shall be removed over a distance of 100 mm at both ends.

4.10

Tolerances The dimensions of bends shall be controlled to make sure that they are manufactured according to the tolerances indicated below, in addition to the requirements of MSS-SP-75. However, the ends of finished pipe bend shall meet the dimensional tolerances of the relevant pipe specification referred in clause 2.0.

4.10.1 Following tolerances shall be applicable for Bend Angle and Bend Radius: GAIL (INDIA) LTD NEW DELHI



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:± 0.50 from the specified angle :± 1 % of bending nominal radius (radius as indicated in clause 4.1 above).

Bend Angle Bend Radius

4.10.2 The manufacturer shall measure the wall thickness of the pipe before bending along both the inside and outside radii of the bend between and including the start and stop points of the bend arc angle, at intervals approximately equal to pipe diameter or 300 mm whichever is less. The wall thickness shall be measured ultrasonically after bending at the same locations as measured before bending. In addition, the wall thickness of the tangents shall also be measured. These measurements shall be taken at four equally spaced locations around the pipe circumference. The measured wall thickness shall be at least equal to : tmin

=

0.95 (tactual - ∆t)

where: tactual = Actual wall thickness of pipe used for bending ∆t

= 0.35 mm for a wall thickness < 10 mm 0.5 mm for a wall thickness ≥ 10 mm

4.9.3 Out of roundness tolerance on the body and ends of the bend shall be as follows: Body Measurement of the outside diameter shall be taken in plane of the bend at locations where wrinkles are present (ODmax.) and at locations where wrinkles are not present (ODmin). Out of roundness shall be considered acceptable, if the value of ((ODmax. - ODmin)/ ODnom) does not exceed 2.5%. The measurements shall be made over the circumference of the bend either at distances approximately equal to pipe diameter or 300 mm whichever is less. Minimum three measurements shall be taken for each bend. Ends Out-of-roundness over a length of 100 mm from the end shall comply with the requirements of relevant company specification. 4.9.4 Off-Plane Off-Plane of bends shall not exceed (θ/ 90) X 10 mm, where θ is the bend angle in degree or the tolerance limit specified in MSS-SP-75, whichever is less. The measurement shall be in accordance with MSS-SP-75. 5.0

INSPECTION & TESTS GAIL (INDIA) LTD NEW DELHI



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5.1

The manufacture shall perform all inspection and tests as per the requirements of this specification and MSS-SP-75 prior to shipment, at his works. Such inspection and tests shall be as a minimum, but not limited to the following: a)

Verify that the unfinished product arriving at Manufacture’s shop is in full compliance with the pipe specification as referred in clause 2.0 of this specification.

b)

Visual inspection

c)

Dimensional and tolerances check as per MSS-SP-75 and requirements of Section 4.0 of this specification.

d)

Check heat treatment, if carried out, as required and maintain its records.

e)

Temperature against time recorder charts for each induction heating.

f)

The non-destructive inspection on the finished bend shall be carried out as given below: -

All seam welds of bends manufactured from SAW pipes shall be 100% radiographed and seam welds of bends manufactured from EW pipe shall be 100% ultrasonically tested. The acceptance criteria shall be relevant pipe specification.

-

The full circumference of both ends of each bend after beveling shall be ultrasonically tested for laminations over a length of 25 mm and acceptance limits shall be as per pipe specification as per relevant pipe specification.

-

The finished bends shall be magnetic particle inspected on the outside and inside radii to include the area encompassed 30 degree either side of the line passing through the plane of bend. Acceptance criteria shall be as per ASME Sec. VII Appendix 6.

g)

A check shall be performed on each bend by passing a gauging pig consisting of two discs having a diameter equal to 95% of the nominal internal diameter of the pipe, connected rigidly together at a distance equal to 500 mm. Details of the gauging pig , including its dimensions shall be approved by company.

5.2

Company’s Inspector reserves the right to perform stage wise inspection and witness tests on all bends as indicated in Clause 5.1 at Manufacturer’s works, prior to shipment. Manufacturer shall give reasonable notice of time and shall provide without charge reasonable access and facilities required for inspection, to the Company’s Inspector. Inspection and tests




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performed or witnessed by Company’s Inspector shall in no way relieve the Manufacturer’s obligation to perform the required inspection and tests. Under no circumstances any action of the Company’s Inspector shall relieve the Manufacturer of this responsibility for the material and quality of bends. 6.0

TEST CERTIFICATES The Manufacturer shall submit the following certificates: a)

Test certificate of chemical analysis, Mechanical tests, heat treatment, NDT, dimensional inspection and hydrotest carried out on pipe used for fabrication of bend. These test certificates are not required when pipe is supplied as free issue by company.

b)

Certificates of non-destructive test/ examination carried out on bends.

c)

Records of heat treatment, ifcarried out for bends.

d)

Certified reports of dimensional tolerance of bends.

e)

Certificates of all other tests as required in this specification.

The Certificate shall be valid only when signed by Company’s Inspector. Only those bends which have been certified by Company’s Inspector shall be dispatched from Manufacturer’s works. 7.0

MARKING, PACKING AND SHIPMENT

7.1

All bends shall be marked as per MSS-SP-75.

7.2

All loose and foreign material like rust, grease, etc. shall be removed from inside and outside of the bends.

7.3

One coat of antirust paint shall be applied on the bends for protection during transit and storage. Type of paint shall be as agreed upon with the company.

7.4

Both ends of all bends shall be suitably protected to avoid any damage during transit by means of metallic or high impact plastic bevel protectors.

7.5

Package shall be marked legibly with suitable marking ink to indicate the following: a)

Order Number

b)

Package Number




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8.0

c)

Manufacturer’s Name

d)

Size (Inches) and Wall thickness (mm)

e)

Radius of bend (mm)

DOCUMENTATION Documentation to be submitted by Manufacturer to Company is summarized below. Number of copies (Hard copies / soft copies etc.) shall be as indicated in CONTRACT document.

8.1

All documents shall be in English language

8.2

At the time of bidding, bidder shall submit the following documents:

8.3

a)

Reference list of previous supplies of bends of similar specifications.

b)

Brief description of manufacturing including heat treatment and quality control facilities of the Manufacturer’s Works.

Within three weeks of placement of order, the manufacturer/ contractor shall submit bend manufacturing procedure including manufacturing, inspection, testing procedures, quality control manual and quality plans. The bend Manufacturing Procedure shall detail the following, as a minimum: a)

Sequence of Operation

b)

Induction forming process including bending temperature, temperature control, bending Rate , cooling rate and cooling procedure.

c)

Temperature measurement and calibration.

d)

Post bend heat treatment procedure including temperature and time.

e)

Dimensional control procedure.

f)

Pipe material used for bend manufacture

g)

NDT procedures

h)

Quality Control and Quality Plans

Upon successful completion of the bend manufacturing procedure qualification as per section 9.0 of this specification, Manufacturer shall submit the qualified procedure to company for approval. Regular production of bends shall commence




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only after the bend manufacturing procedure has been qualified and approved by company. Once the approval has been given by Company any change in material and method of manufacture and quality control shall be notified to company whose approval in writing of all such changes shall be obtained before the bends are manufactured. 8.4

Within 30 days from the approval date, Manufacturer shall submit to Company the approved drawings, documents and specifications as listed in clause 8.3 above.

8.5

Prior to shipment, the Manufacturer shall submit test certificates as listed in section 6.0 of this specification.

9.0

BEND MANUFACTURING PROCEDURE QUALIFICATION

9.1

Prior to start of production bending, Manufacturer shall demonstrate the suitability of the proposed manufacturing procedures for producing pipe bends including the post-bending heat cycle, that meet the requirements of this specification, by mechanically testing additional bend(s) (test bends). The bending procedure shall be qualified in the presence of company representative.

9.2

Test bends shall be made by using the pipe specified in clause 2.0 of this specification. One test bend is required per ‘heat-lot’ where a heat lot is deemed to include all bends of the same diameter, wall thickness, mill heat number and bend forming parameters such as, bending temperature, bending rate, cooling medium volume & heat treatment temperature (excluding bend angle). The test bend shall be bent to an angle of 900.

9.3

Inspection and Testing of Bends

9.3.1 All finished test bends shall meet the requirement of dimensional tolerances, inspection and non-destructive testing requirements specified in section 4.0 & 5.0 of this specification. 9.3.2 In addition all test bends shall be subjected to following mechanical testing to confirm that the bends manufactured meet all mechanical property requirements of relevant linepipe specification. Test procedure and acceptance criteria shall be in accordance with the relevant linepipe specification. The test specimen shall be taken from the bent portion of the bend only. a)

Tensile test One tensile test shall be conducted on the base material of finished test bend, to establish yield strength, ultimate tensile strength and elongation. The specimen shall be taken longitudinal or transverse to the axis as specified in the relevant pipe specification. In case of bends of 450 mm (18”) NB and larger, the specimen shall be taken at inside radius and one at outside radius of bend.




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b)

All Weld Tensile Test In case of bends fabricated from SAW Ppipes, an all weld tensile test shall be conducted to establish yield strength, ultimate tensile strength and elongation of weld material on bend.

c)

Guided Bend Test/ Reverse Bend Test For bends manufactured from SAW pipes one face and one root guided bend test shall be performed. For bends manufactured from EW pipes, reverse bend test shall be carried out. Test method and acceptance criteria shall be same as mentioned in applicable pipe specification.

d)

Hardness Test Hardness testing shall be performed “thru thickness” on a test ring removed from the middle of the bend. Four specimen shall be prepared one from each quadrant. In case of bends fabricated from SAW/EW pipes, one specimen shall have longitudinal weld seam in the middle. Hardness shall be checked for base metal, weld metal and HAZ. In addition, hardness test shall be performed at spots where dents, bulges or wrinkles have been formed on the bends.

e)

Fracture Toughness Test Charpy –V- notch test temperature shall be the same as specified in the relevant pipe specifications. Three base material specimens shall be taken longitudinal or transverse to the axis as specified in the relevant pipe specification. In case of bends fabricated from SAW and EW pipes, three transverse weld material specimens shall be taken with weld in the middle. In case of bends of 450 mm ( 18”) NB and larger, the base material specimens shall be taken at the outside radius of the bend.

Should test bends fail to comply with the above requirements, the bend manufacturing procedure shall be disqualified. The manufacturer shall revise the manufacturing procedure and re-qualify the same at his own cost and time. Upon completion of the successful procedure qualification, manufacturer shall provide a written bending procedure for each test bend. The submitted procedure shall indicate in addition to the details as per clause 8.3, tolerances on various controlling parameters.






STANDARD SPECIFICATION FOR FLOW TEE (BARRED TEE)




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CONTENTS Sl. No.

Description

1.0

SCOPE

2.0

REFERENCE DOCUMENTS

3.0

MATERIALS & REQUIREMENTS

4.0

MANUFACTURE QUALIFICATION AND PRODUCTION TESTING

5.0


6.0

COATING / PAINTING

7.0

MATERIAL TESTING AND TRACEABILITY

8.0

PREPARATION FOR SHIPMENT

9.0

MARKING

10.0

VENDOR DATA REQUIREMENT

11.0

DESIGN OF BARRED TEE




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1.0

SCOPE:

This specification covers the basic technical requirements for design, manufacture, inspection, testing, coating and painting & supply of Pipeline Flow Tees (Barred Tees) (above ground / under ground) to be installed in pipeline system transporting Natural Gas. All Tees shall be suitable for Bi-directional movement of Inspection tools / pigs. 2.0


Reference has also been made in this specification to the latest edition of the following codes, standards and specifications: ASME B 31.8

:

Gas Transmission and Distribution Piping System

ASME B16.9

:

Factory made Wrought Steel Butt Welding Fittings

ASTM A370

:

Mechanical testing of steel products

ASTM E 92

:

Standard test method for Vickers Hardness of metallic materials

ASTM E 709

:

Standard guide for Magnetic particle examination

ASNT-SNT-TC-1A

:

American society of Non-destructive testing

API 5L

:


MSS-SP-75

:

Specification for High Test Wrought Welding Fittings

ISO 9000

:

Quality Management and Quality Assurance Standards

ISO 9001

:

Quality Systems – Model for quality assurance in design, development, production, installation and servicing

EN 10204

:

Metallic products – types of inspection documents

ISO 12094

:

Welded Steel tubes for pressure purposes – ultrasonic testing for the




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detection of laminar imperfections in strips / plates used in manufacturing of tubes OISD 141

:

Design and Construction requirements for cross country hydrocarbon pipelines

In the event of any conflict of data or requirements in any of the above documents, it is the Supplier’s responsibility to resolve these conflicts before proceeding with design, manufacture or purchase. In any case, the most stringent requirement shall prevail. However, client / client’s representative interpretation shall be final. In case of conflict, the order of precedence of the documents shall be as follows:      3.0

National and / or local regulations Technical Data Sheets This Specification Project Specifications & Company Standards International Codes as per Paragraph 2.1

MATERIALS & REQUIREMENTS: 3.1

The design code, design factor, rating, corrosion allowance, grade of material, nominal diameter and nominal wall thickness of mating main pipe and branch pipe shall be as stated in the Material requisition.

3.2

Tees with branches 25% or more than the main pipeline diameter shall have a configuration of bars as indicated in Annexure-A. The bars shall be made of mild steel, ASTM Grade hardness tested applications, and shall be full penetration welded using a qualified procedure.

3.3

The Tees shall be designed to the design code as stated in the material requisition, and shall be manufactured to MSS SP-75 as appropriate and the requirements of this specification. Full encirclement Tee shall not be allowed.

3.4

The Tees shall meet or exceed the strength requirements of the matching pipe as calculated by ASME B 31.8.

3.5

Data supporting the design in form of calculations and drawings shall be submitted for approval prior to commencement of manufacture. Design shall be in strict accordance with the appropriate design code. Documented data of successful proof tests according to the relevant standard shall be submitted in support of the design.

3.6

The wall thickness of weld ends at the bevel of main run and branches of Tees shall have a bevel thickness no greater than 1.5 times the nominal wall thickness of the mating pipe. A 1:4 taper on the outside diameter at the




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ends of the pipe will be acceptable, if the wall thickness of the body of the Tee exceeds this dimension. 3.7

Vendor shall check & confirm the number of bars (as stated in Appendix-A) required for Tees.

3.8

All pipeline Tees shall be suitable for passage of instrumented inspection tools in either direction.

3.9

Fully killed carbon steel shall be used.

3.10

Material of the ends to be field welded by purchaser shall have carbon equivalent less than or equal to 0.45 based on check analysis, for each heat of steel, calculated according to the following formula.

CE =

C+

Mn Cr + Mo + V -------- + --------------------6 5

+

Ni + Cu --------------15

3.11

When specified in data sheet, hardness test shall be carried out as per ASTM A370 for each heat of steel used. The maximum hardness of base metal, weld metal and heat affected zone of all pressure parts shall be 248 HV10, unless specified otherwise.

3.12

When specified in the Data Sheet, charpy V-notch test shall be conducted on each heat of base material, weld metal and heat affected zone of all pressure containing parts such as body, welding ends in accordance with the impact test provisions of ASTM A 370 at a temperature of 0° C. The charpy impact test specimens shall be taken in the direction of principal grain flow and notched perpendicular to the original surface of the plate of forging. Average impact energy value of three full sized specimens shall be 27 joules. Minimum impact energy value of any one specimen shall not be less than 80% of the average impact energy specified. No specimen shall exhibit less than 80% shear area.

3.13

The Tees shall be manufactured from material, which meets the specified minimum yield strength of the mating pipe and shall be as indicated in the data sheet.

3.14

The material for flow Tee shall consist of blooms, billets, slabs, forging quality bar, plate, seamless or fusion welded tubular products with filler metal added.

3.15

The material shall be as per MSS SP-75 or suitable API Standard 5L pipe to achieve tensile properties as indicated in the data sheet.

3.16

The fittings shall be heat treated by normalizing, quenching and tempering to achieve the same strength of line pipe.




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4.0

3.17

Fittings shall not be machined from bar stock or solid forged billets.

3.18

Tees shall be supplied in normalized, normalized and tempered or quenched and tempered condition.

3.19

A ring of material may be required from the main run of pipe for weld procedure qualifications for the main pipeline. Rings shall be 400mm minimum in length and subject to the same forging and heat treatment as the supplied Tee.

MANUFACTURE QUALIFICATION AND PRODUCTION TESTING: 4.1

MANUFACTURE:

4.1.1 Tees shall be made by forging the branch from a suitable pipe and / or a pre-bent fabrication and shall have a maximum of one seam weld only. Circumferential welds are not permitted. Seamless fittings are preferred. 4.1.2 The chemical and physical properties of the material shall meet the line pipe specifications. 4.1.3 The manufacturer shall submit a manufacturing procedure for approval by purchaser prior to manufacture of Tees. 4.1.4 Double sided submerged Arc welding is required for the longitudinal weld in the main run. Single sided weld requires specific approval from Purchaser. 4.2

QUALIFICATION:

4.2.1 A Tee shall be qualified when it passes all production testing as required by clause 5.3 of this specification. The qualification is valid for the main and branch nominal pipe size combination, per grade, heat treatment and manufacturing route only. However, a Tee with an equal branch will qualify for Tees with the same main OD with smaller branch OD’s of the same grade or lower grades. 4.2.2 A test ring from the main run and prolongations of the forged branch of the Tee shall be tested to qualify the manufacturing route per size, grade, and heat treatment and material source. 4.2.3 Welds and body shall be tested in accordance with clause 5.3 of this specification. Testing shall be carried out per steel source per heat. 4.2.4 The full penetration welds for the bars shall be qualified to ASME Sec. IX or other welding code approved by Purchaser. 4.2.5 All welding, including weld repairs, shall be performed in accordance with the procedure approved by Purchaser and welders qualified in accordance GAIL (INDIA) LTD NEW DELHI



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with ASME Sec. IX and API 1104. Welding procedures required for non-sour service applications shall also include the hardness tests. 4.3

PRODUCTION TESTING: Destructive testing of fittings shall include the tests as given below. Specimens and testing shall be carried out in accordance with clause 6.2 of API 5L and shall meet the acceptance of relevant line pipe specification. Test frequency shall be once per heat, per heat treatment batch, per grade of material for each size of Tee. The minimum test temperature shall be 00C.

5.0

4.3.1

One tensile test to include the weld (if present) and one tensile test to include the body of the main run, one tensile test to include the extruded branch. Specimens shall be transverse.

4.3.2

The Charpy V-Notch test shall consist of three specimens. Longitudinally welded Tees shall include one set in the body and four sets to be taken from the weld (if present), one set to be taken from each of the weld centerline, fusion line, fusion line + 2mm, fusion line + 5mm. One set shall be taken from the extruded branch. All charpy specimens shall be transverse.

4.3.3

Proof tests (Bursting tests) as per MSS SP-75. However, this requirement can be waived by Purchaser, where documentary evidence is provided for the design of Tee proven by previous proof testing, in support of the design by the vendor.

INSPECTION AND TESTS: 5.1

GENERAL:

5.1.1 All personnel, performing the non-destructive tests (NDT) shall be qualified in the technique applied, in accordance with ASNT-TC-1A Level II by a third party, or equivalent approved by the Purchaser. 5.1.2 Original certificates shall be made available for inspection by purchaser / purchaser’s representative at the Vendor’s premises, if required. Personal interpreting results of any NDT shall be qualified by a third party to SNT-TC1A, Level II or III. 5.1.3 All NDT shall be performed in accordance with written procedures. These procedures shall have the prior approval of the Purchaser. 5.1.4 NDT shall be carried out on Tees after all mechanical testing, manufacturing stages and heat treatment have been completed.




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5.2

VISUAL INSPECTION:

5.2.1 100% Visual inspection shall be carried out. The body of every fitting shall be inspected internally and externally for surface defects. 5.2.2 The surfaces of the fitting shall be free from all dents, gouges, laps, score marks, arc strikes, under cuts or other detrimental defects. 5.2.3 Welds shall be inspected visually for 100% of the length, both outside and inside. The requirement of workmanship shall be as per the connected line pipe. 5.2.4 Defects shall be removed by grinding or by weld repair except that welding is not allowed on the body of the Tee. Weld repairs shall be qualified and carried out in accordance with the applicable line pipe specification. 5.3

NON-DESTRUCTIVE TESTING OF FITTING:

5.3.1 100% Radiographic testing of all seam welding shall be carried out in accordance with ASME Sec VIII, Div 1, Clause UW – 51. For Butt welds in Tees, with a thickness greater than 20mm (0.8 inches) , radiographic inspection may be replaced with Ultrasonic inspection at the discretion of Vendor. 5.3.2 For the acceptance of radiographic films, the technique used shall result in sensitivity better than 2% of thickness of the weld metal and a relative film density of 2 to 3.5 in the weld metal. 5.3.3 The manufacturer shall record on review form accompanying the radiograph, the interpretations of each radiograph and disposition of the fitting inspected. 5.3.4 The penatrameter used shall be of the wire type in accordance with ISO 1027. The selection of penatrameter wire diameters shall be based on a sensitivity of 2% of weld metal thickness. Penatrameter must be placed source side. 5.3.5 Magnetic particle inspection (MPI) of 100% surface of the Tees, all bevel ends and all welds shall be in accordance with the requirements of ASTM E709. The wet method shall be used, use of probes is unacceptable. Relevant linear indications greater than 3mm in bevel ends shall require rebeveling. Any ground surface shall be re-inspected by MPI to verify that the indication has been removed. The beveled surface shall be free from defects such as cracks, laps or laminations visible to the naked eye as revealed by MPI. 5.3.6 Ultrasonic tests (UT) shall be carried out on all bevel ends of all fittings, in accordance with ASTM E709. Relevant linear defects greater than 3mm are GAIL (INDIA) LTD NEW DELHI



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non-acceptable. Longitudinal edges and body of plate for seam welded fittings shall be tested in accordance with applicable specification of line pipe. UT shall be as per applicable line pipe specifications. 5.3.7 All repairs shall include a minimum preheat of 1000C, unless the qualification test shows that a higher temperature is necessary. 5.3.8 Each repair welding procedure shall be qualified on a pipe section under realistic conditions in accordance with API 5L Appendix-C and this specification. 5.4

DIMENSIONAL INSPECTION:

5.4.1 Each Tee shall confirm to the dimensional requirements of ASME B 16.9 or MSS SP-75 as appropriate and the additional requirements of this section. 5.4.2 The ends of each fitting shall be tested for out of roundness using an internal ring gauge with a diameter of 5mm (0.2 inch) less than the nominal internal diameter. The gauge shall pass freely into each end of the fitting for a distance of 100mm when held perpendicular to the fitting axis. 5.4.3 The tolerance for the internal diameter of the run pipe part of the Tee shall be within 0 to +1.5mm (0 to 0.059 inches) of the nominal dimension of the connecting pipe at the ends. 5.4.4 End bevel preparation for the Tees shall be in accordance with API 5L. If necessary, the ends shall be machined such that the maximum wall thickness at the ends of the Tee is no greater than 1.5 times the nominal wall thickness of the mating pipe. A taper of 1:4 is permitted on out side only to reduce the thickness of the Tee body to meet the thickness of the weld bevel. 5.4.5 A gauging Pig shall be passed through the main run of each Tee. The pig shall consist of two aluminum plates of at least 3mm thick, joined by a rigid rod through their centers. The diameter of the plates shall be 95% (tolerance 0 to +1mm) of the nominal inside diameter of the main pipe. The Pig shall pass without sticking or damage to the Tee. 5.4.6 The gap produced when a flat plate perpendicular to the Pipe Axis is held against the machined bevel of main and branch pipe ends shall be within +3.0mm. 6.0

COATING / PAINTING: After sand blasting and cleaning the surface (SA 2 ½) of the Barred Tee, the following coating shall be applied. For under ground Barred Tees:




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

Coal Tar Polyurethane or equivalent, which shall be approved by Purchaser. The DFT shall be 875 microns.

For above ground Barred Tees:  7.0

8.0

Zinc rich epoxy primer. The DFT shall be 50 microns.

MATERIAL CERTIFICATION AND TRACEABILITY: 7.1

Material test certificates and manufacturer test reports shall be traceable to each Tee within the Vendor Fabrication Book, which shall be part of the QC Data bank.

7.2

The pressure containing and load bearing / stressed materials shall be fully covered by the material test certificates which shall bear Equipment tag numbers, Purchase order numbers and any other Purchase order requirements.

PREPARATION FOR SHIPMENT: The vendor shall submit shipping and handling procedures to Purchaser for approval. The procedures should adequately address storage, shipping and handling in view of the long voyage from manufacturing locations and climatic extremes at the job site. An appropriate design of end cap shall be fitted to each opening to protect the butt weld ends and prevent ingress of foreign material.

9.0

MARKING: The vendor shall mark each fitting with the information specified below as a minimum. The markings shall be painted on the outside surface and shall be executed white block capitals of minimum height ¾ inch.        

Project Name Manufacturer’s name and unique identification number of the fitting Nominal header pipe diameter (inches) and wall thickness (mm) Nominal branch pipe diameter (inches) and wall thickness (mm) Material Grade Design Pressure and test Pressure (when applicable) Purchase Order and Item Number Cast number

10.0 VENDOR DATA REQUIREMENTS: During the fabrication, the Vendor shall submit certification and inspection documents to the Purchaser as specified in the Purchase order. Documents shall include the following as minimum. 

Quality Plan




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        

Manufacturing Procedures covering steel making, chemical composition, welding and forming procedure. Certified material test reports, 3.1B to EN 10204, for all sizes. NDT test reports and operator qualifications All mechanical test reports Certificate of conformance and dimensional check reports Heat treatment procedure reports All concession requests Design Burst test information




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STANDARD SPECIFICATION FOR SCRAPER TRAPS




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CONTENTS Sl. No.

Description

1.0

SCOPE

2.0

REFERENCE DOCUMENTS

3.0

MATERIALS

4.0


5.0


6.0

TEST CERTIFICATES

7.0


8.0

GUARANTEE

9.0

SPARES

10.0

DOCUMENTATION




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1.0

SCOPE:

This specification covers the basic requirements for design, manufacture, inspection, testing & supply of scraper launching & receiving traps to be installed in pipeline system transporting Natural Gas. 2.0


2.1

Reference has also been made in this specification to the latest edition of the following codes, standards and specifications: ASME B 31.1

:

Power Piping

ASME B 31.3

:

Process Piping

ASME B 31.8

:


ASME B 16.5

:

Steel Pipe Flanges and Flanges Fittings

ASME B16.9

:

Factory made Wrought Steel Butt Welding Fittings

ASME B 16.11

:

Forged Steel Fittings, Socket-Welding and threaded

ASME B 16.25

:

Butt-Welding Ends

ASTM A 105

:

Forging, Carbon Steel for Piping components

ASTM A 181

:

Forging, Carbon Steel for general purpose piping

ASTM A 216

:

Carbon Steel Castings suitable for Fusion Welding for High temperature Service

ASTM A 234

:

Piping Fitting of Wrought Carbon Steel and Alloy Steel for moderated and Elevated Temperatures

ASTM A370

:

Mechanical testing of steel products

ASTM A 20

:

ASTM A 516

:

General requirements for steel plate for pressure vessels Carbon steel pressure vessel plates for moderate and low temperature service




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ASTM A 106

:

Carbon steel seamless pipe for high temperature service

ASTM A 193

:

Alloy steel and stainless steel bolting materials for high temperature

ASTM A 194

:

Carbon and alloy steel nuts for bolts for high pressure or temperature

ASME Sec-V, VIII and IX

:

Boiler and Pressure Vessels Codes

API 1104

:

Specification for Welding Pipeline and Related Facilities

API 5L

:


MSS-SP-6

:

Standard Finishes for Contact Faces of Pipe Flanges and Connecting – End Flanges of Valves and Fittings

MSS-SP-44

:


MSS-SP-75

:


MSS-SP-97

:

Integrally Reinforced Forged Branch Outlet Fittings Socket Welding Threaded and Butt Welding Ends

SSPC-VIS-1

:

Steel Structure Painting Council

ISO 10474

:

Steel and Steel Structures Inspection documents

ISO 9000

:

Quality Management and Quality Assurance Standards

ISO 9001

:

ISO 9002

:

Quality Systems – Model for quality assurance in design, development, production, installation and servicing Quality Systems – Model for quality assurance in production, installation and servicing

In the event of any conflict of data or requirements in any of the above documents, it is the Supplier’s responsibility to resolve these conflicts before proceeding with design, manufacture or purchase. In any case, the most stringent GAIL (INDIA) LTD NEW DELHI



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requirement shall prevail. However, client / client’s representative interpretation shall be final. In case of conflict, the order of precedence of the documents shall be as follows:    3.0

Technical Data Sheets This Specification Project Specifications, Company Standards and International Codes as per Paragraph 2.1

MATERIALS: 3.1

Materials and thicknesses of main components used in manufacture of traps shall be indicated by Manufacturer and shall be suitable for service conditions indicated in the data sheets / Technical specifications. These shall be subject to approval by purchaser. The steel used shall have a minimum SMYS of 35,000 psi.

3.2


3.3


CE = 3.4

Mn Cr + Mo + V -------- + --------------------6 5

C+

+

Ni + Cu --------------15

For Materials of Barrel, Neck, Charpy V-notch test shall be conducted at -20°C and 00C. The minimum transverse impact energy values of three full sized specimens (10mm x 10mm as per ASTM E23) shall be as under: MATERIAL

TEST TEMPERATURE

BASE METAL AND WELD

(-) 200C 00 C

MINIMUM AVERAGE VALUE (FOR SPECIMENS) 35 J 100 J

MINIMUM SINGLE VALUE 27 J 75 J

Impact test shall be carried out on samples with the notch at the following locations for the weld zone:    

Weld Metal Fusion line Fusion line + 2mm Fusion line + 5mm

The four sample locations specified above shall constitute of 3 test specimens each, and shall be taken from the mid-thickness of the weld. GAIL (INDIA) LTD NEW DELHI



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Impact test shall also be carried out on a transverse sample (3 test specimens) removed from the base metal. The samples shall beat 90 shore D to weld scam. Shear area at the fracture surface shall be recorded. The shear area shall be determined for base metal samples only. The required levels are 85% average fibrous shear, and 75% individual minimum. The test specimens shall be in a transverse direction with the notch axis oriented through the pipe wall /plate wall thickness. All carbon steel forgings shall be heat-treated either in the normalized, normalized and tempered or quenched and tempered condition. 3.5

For Scraper Traps, hardness test shall be carried out as per ASTM A370 for each heat of steel used. A full thickness cross section shall be taken for this purpose and the maximum hardness of the base material, weld metal and heat affected zone (HAZ) of all the pressure containing parts shall not exceed 248 HV10. The maximum difference in hardness of Base metal, Weld metal and Heat affected zone (HAZ) of pressure containing parts of the traps shall be less than 80 points Vicker’s HV10.

3.6

Material Test Certificates provided by the MANUFACTURER shall conform to ISO 10474 for the following: COMPONENTS All pressure retaining parts (for minor and major barrel, reducer and quick opening closure) All parts in contact with fluid (for nozzles and flanges) All attachments welded to the vessel Trap assembly inspection and test Vessel structural supports and non pressure parts Others, if any

MATERIAL CERTIFICATION REQUIRED EN10204Type 3.2C EN10204Type 3.2 C EN10204Type 3.2C EN10204Type 3.2C EN10204Type 3.2C EN10204Type 3.2C

Certified mill test report, showing the chemical and physical properties for each item of material furnished by the Manufacturer, shall be witnessed / reviewed by third party Inspection agency (TPIA). A report of results obtained from magnetic particle and radiographic examinations of welds indicating all defects were identified and the disposition of all repairs shall be provided. All original radiographs shall be available to the PURCHASER / PURCHASER’S REPRESENTATIVE/TPIA for review upon request. A list of welders shall be provided on the drawings to indicate who made each weld. GAIL (INDIA) LTD NEW DELHI



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A certified copy of all hydrostatic test charts shall be provided. Owner’s approved Third Party Inspection Agency (TPIA) shall be deputed by the MANUFACTURER for inspection at manufacturer premises to witness / review material Tests certification as per EN-10204 type 3.2C certification at manufacturer’s cost. 4.0

DESIGN, CONSTRUCTION & FABRICATION: 4.1

DESIGN & CONSTRUCTION:

4.1.1 The cylindrical portion of the trap shall be designed as per design code and design factor indicated in the data sheets. Quick end closure shall be designed as per sec. ASME Sec. VIII, Div. 1 for design conditions indicated in data sheets. A corrosion allowance of 3mm shall be considered in design of the traps. Quality of welding shall be such that weld efficiency factor of 1.0 is achieved. 4.1.2 The trap shall be capable of handling instrumented pigs, model like Linalog 360 of AMF Tuboscope or British gas magnetic inspection vehicle or equivalent and scraper pigs as specified in scraper Trap data sheet. 4.1.3 The trap body and neck, diameter has been indicated in the data sheet. Trap length to suit the purpose and thickness to meet the class rating shall be suggested by the manufacturer and approved by the purchaser. Circumferential weld on scraper trap body and neck shall not be permitted. 4.1.4 Concentric or eccentric reducer, as indicated in data sheets, used in the manufacture of traps shall conform to MSS-SP-75 (as per the grades specified in the data sheets). Thickness of the Reducer shall match with that of the adjoining body / neck thickness. 4.1.5 Vents and drains shall be provided on each trap. The trap shall be provided with a suitable slope and the drain location shall be such that complete drainage of the trap is possible. Sizes for vent and drain shall be as indicated in data sheet. In case of Scraper Receiver, the minimum slope shall be 1:100 downwards the end closure where as in case of Launcher it shall be 1:100 downwards the pipe line. 4.1.6 All branch connections shall be made by weldolets/ nippolets or by extrusions as indicated in the data sheet. All weldolets shall confirm to MSSSP-97 and nippolets shall be of manufacturer’s standard. The extruded opening shall be adequately heat treated and stress relieved. 4.1.7 End connections of traps shall be flanged or butt welded as indicated in data sheet. a) Flanged ends, if specified shall have dimension as per ASME B16.5 for sizes up to 24" NB (excluding 22 NB) and as per ASME B16.47 / MSSGAIL (INDIA) LTD NEW DELHI



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SP-44 for sizes 22 NB and 26 NB and above. Flanges shall be as indicated in data sheets. b)

Butt weld ends if specified shall have ends prepared as per ASME B16.25. However, end preparation for butt welding ends having unequal thicknesses with respect to connecting pipe shall be as per ASME B31.4/ ASME B31.8 as applicable.

c)

The location & orientation of all nozzle connections shall be submitted for purchaser's approval before manufacturing.

4.1.8 The quick opening end closure shall be of quick actuating GD band lock type or equivalent design. The design of the quick opening end closure shall be in accordance with design code adopted for the adjoining pig trap as stated in the data sheet. The design of the end closure shall be robust and should consider fail safe design of the opening mechanism and allow opening and closing by one man in a period of approximately one minute without the use of additional devices. The closure shall also consist of a safety relief system allowing the opening only when there is no pressure in the trap. Safety bleeder device shall alert operator of possible hazard unless pressure in the pig trap is relieved completed. Screwed type or plug-in types of end closures are not acceptable. End closures of size 24" and above shall be fitted with worm gear operator for the opening of the closure. Hinge of the closure shall be so designed that the weight of the end closure is fully supported with out sagging. The end closure shall be designed in accordance with safety requirement of ASME Sec. VIII Div. 1, Clause UG-35. End closure hinge axis shall be horizontally aligned, not withstanding any slope on the barrel section. 4.1.9 Traps shall be provided with a pig indicator in the middle of the neck and the indicator shall conform to the specification issued for the purpose. Pig indicator shall be suitable for bi-directional operation and shall have visual flag and manual reset. The same shall also have provision for remote indication. Refer Pig Signaler Data Sheet. 4.1.10 The Scraper trap shall be supplied with Pig Handling system, Jib Crane and Winch for pulling the SS tray and Pig as mentioned below. 

Pig handling trolley shall be designed from structural steel and shall be suitable to move on rail through a gear train.



Trolley shall be designed to contain pig tray which will contain pig. Trolley shall have proper braking system. Pig tray shall have perforated holes and shall be suitable to contain any type of pig, including intelligent pig.




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

Tray shall have proper strengthening system to avoid bending with load. The tray shall be provided with suitable stops. Lock bracket shall be provided such that the tray does not stop within the Launcher / Receiver. Rear end of the tray shall be provided with suitable lug to enable retrieval of the tray by hooks.



The handling system (for inserting and retracting the intelligent pigs from the equipment) shall be complete with handling devices. In case any rails are required for sliding of the handling system, the same shall be provided by the Scraper Launcher / Receiver manufacturer.



Winch to push tray and pig inside the launcher / receiver shall be provided.



Complete system shall be designed to operate by one person.



Jib Crane shall be designed as per IS: 3177, IS: 3832, IS: 3938 of latest edition and shall be mounted on a structural column.



Jib Crane shall swivel 3600 with one person and shall have antifriction bearing for swivel operation.



Lifting of equipment and movement of Trolley shall be anti-spark type HoistTrolley system, suitable to operate by one person.



Crane shall be balanced with load at maximum span and shall have counter weight if required. Suitable locking and braking system shall be provided. End stoppers shall be provided for trolley movement.



Crane shall be tested with 1.5 times of rated load at maximum radius. Deflection test shall be as per IS: 807 of latest edition. Wire ropes used for hoisting and traveling shall be checked as per IS: 6594 and IS: 3973 latest edition.



Crane shall be complete with foundation bolts.



Jib crane shall be designed to be operated by one man for all operations.



Manufacturer shall furnish all technical parameters of Pig handling system, Winch and Jib Crane along with offer.

4.1.11 Fabricated steel supports, minimum two numbers at suitable spacing shall be provided with traps for mounting on concrete blocks. These supports will not be subjected to pipeline anchorage forces. The material of support shall be compatible with trap material for welding purposes. All welds shall be examined by magnetic particle method. 4.1.12 Completed assembly shall be stress relieved as per the provisions of the design codes. GAIL (INDIA) LTD NEW DELHI



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4.1.13 Welds shall be made by welders and welding procedures qualified in accordance with the provisions of ASME Sec. IX. The procedure qualification shall include impact test and hardness test when required as per clause 3.4 & 3.5 of this specification and shall meet the requirements as specified therein. 4.1.14 Repair by welding on parent metal is not allowed. Repair of welds shall be carried out only after specific approval by purchaser's representative for each repair. The repair welding shall be carried out by the welders and welding procedures duly qualified as per ASME Section IX and records for each repair shall be maintained. The repair welding procedure qualification shall include impact test and hardness test when required as per clause 3.4 & 3.5 of this specification and shall meet the requirements as specified therein. 4.1.15 The traps shall be equipped with a half internal removable filtering basket consisting of a punched plate with a least five rows of drain holes. 4.1.16 The filtering basket shall slide on guides on wheels and in all cases the material of the parts being in contact with each other shall be of the anti spark type. 4.1.17 The tolerance on internal diameter and out of roundness at the ends for the welding end of the neck (at the end where connecting pipeline will be welded) shall be as per applicable connected pipe specification as indicated in the data sheet. 4.1.17 Opening for nozzles shall be from material conforming to the same requirements as the pressure containing parts, and adequately reinforced as per ASME B31.8. All nozzles shall be flushed with the inside contour of the barrel. The minimum distance between the edge of any attachment weld of a pressure part (e.g. a nozzle) to the edge of another pressure weld of the trap body shall be 50 mm or twice the thickness of the pressure part, whichever is the greater. The nozzles shall be terminated with weld neck type raised faced flanges conforming to ASME B16.5/16.47. 4.2

FABRICATION:

4.2.1 General: Prior to commencement of fabrication, calculations and fabrication drawings, welding procedures (WPS’s, PQR’s and supporting lab test reports), procedures for NDT, PWHT, hydrostatic test, coating, production weld




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hardness testing, and quality assurance plan (QAP) shall be submitted to purchaser / purchaser’s representative review and approval. The inside of the trap barrel shall be free from obstructions which could prevent the free rolling of spheres, or travel of pigs or carriers. All inside welds shall be ground smooth and nozzle ends shall be made to suit inside curvature of barrel. The inside diameter of the minor barrel of the trap and the main flange shall match the inside diameter of the pipeline on which it is to be installed. Gasket contact surface of flanges shall be protected against oxidation during the PWHT. 4.2.2 Welding: Welding shall be performed with procedures and operators who have been qualified in accordance with the design code and ASME code Section IX. All welding procedures, qualification of welders and welding procedure qualifications, design and preparation of joints, inspection and testing, standards of acceptability of welding, repairs and radiography shall be fully in accordance with design code and shall be documented by MANUFACTURER before fabrication commences. No welding shall be carried out after post weld heat treatment. The final non-destructive testing of welds for acceptance purposes shall be carried out after completion of any post weld heat treatment (PWHT). Tack welds for welding fit-up shall be removed when making the final welds. All welds shall be continuous unless specified otherwise. All main seam welds and nozzle to shell welds shall be of full penetration type. Double side welding shall be carried out wherever possible. Single welded butt joints are permitted for circumferential joints and will be 100% radiographically tested. All weld spatters and arc strikes shall be removed by grinding prior to inspection and testing of welded joints. All repair works on pressure parts welding shall be in accordance with approved weld repair procedure. No attachments weld shall intersect any seam weld or lie in 50 mm or less than 2 times the thickness of shell whichever is greater (if this is not applicable, MANUFACTURER shall provide he practicable limits and perform the necessary NDT / calculation). Corners of reinforcement pad shall be radiuses. GAIL (INDIA) LTD NEW DELHI



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4.2.3 Tolerance: Diameter and out of roundness tolerances for the minor barrel shall be in accordance with the requirements of Project Specification for Line Pipe. The maximum straightness deviation, measured at the outside surface of the cylinder from a straight line parallel to the vessel axis, shall not exceed 1.5mm per 1000 mm cylindrical shell length. Tolerance on overall length shall be to + 10 mm with respect to approved drawings. Nozzles tolerances with respect to approved drawings shall be in accordance with the following requirements: Position Projection Alignment of nozzle flange face Radial Bolt hole

: Measure from neck end +6 mm : Measure from shell outer surface +3mm : Max. ½ deg in any direction from true vessel axis and true radial centre line : Measured from reference centre line to centre line of nozzle + 2mm : Maximum total indicated run-out 0.2mm from true position.

Alignment of end closure flange face shall be max +1 deg in any direction. 5.0


The manufacturer shall perform all inspections and test as per the requirements of this specification and the relevant codes prior to shipment at his works. Such inspections and tests shall be, but not limited to, the following:5.1.1 All traps shall be visually inspected. Undercuts, overlaps, craters and other unacceptable defects on the welds shall be removed and / or welded. 5.1.2 Chemical composition and mechanical properties including hardness shall be checked for each heat of steel used. 5.1.3 Dimensional check shall be carried out as per the approved drawings. 5.1.4 If the traps are provided with welded reinforced attachments, tell-tale holes shall be provided in order to test with dry air at 7 bar g pressures and checked with foam agent for leaks. This shall be carried out prior to the final hydrostatic pressure test. 5.1.5 Hydrostatic test shall be conducted for all scraper traps complete in all respects including mounting of pig indicators at a pressure equal




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to 1.5 times the design pressure. The test pressure shall be held for a minimum period of four hours. The temperature of the trap material and test liquid shall not be less than 10ºC during the hydrostatic test. A continuous recording of the pressure test is to be made including a calibration (witnessed and certified) and is to be included in the documentation to be provided by MANUFACTURER. The pressure test shall be performed after completion of all welding, heat treatment, installation of any specified instrument and building of all flanges, and before painting. Quick opening type end closure shall be hydro-tested for minimum 24 hours in 20 cycles from zero to hydrostatic test value. 5.1.6 A minimum of two closing and opening cycles shall be performed and correct operation of both quick opening closure and safety system shall be ascertained after the pressure cycles. No excessive force should be required to operate the mechanism. 5.1.7 Non-destructive examination shall be carried out as per code but shall not be less than the following: QOC forgings and mainline flange : UT All pressure part butt joints

:

100% RT and UT

Nozzle to shell joint

:

100% UT and MPT

Attachments welds and lifting lug welds :

100% MPT and PT

All mating clamp and machined surfaces, Door hinges attachment of end closure :

100% MPT or PT

Pig Trap barrel / Body material

:

100% Ultrasonic

Seam

:

100% RT scan

Ultrasonic inspection is required on Pig trap shell material where locally reinforced fittings are to be welded. Prior to welding all weld ends are also to be checked using ultrasonic inspection. NDT examination and acceptance criteria shall be as follws: NDT METHOD Ultrasonic Testing for Forgings Ultrasonic Testing for GAIL (INDIA) LTD NEW DELHI

PROCEDURE ASME Sect. V. Article 5 & 23 ASME Sect. V. Article 5 & 23


ACCEPTANCE CRITERIA ASME Sect. VIII, Div. 3, Art. AM 203.2(c) ASTM A 578, Level I Cracks DOCUMENT NO. S-04-02-017

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Shell & Welding Ends Ultrasonic Testing for welds Magnetic Particle

5.2

6.0

ASME Sect. V. Article 5 & 23 ASME Sect. V. Article 5 & 23

Dye Penetrant

ASME Sect. V. Article 5 & 23

Radiography

ASME Sect. V. Article 5 & 23

Not Allowed ASME Sect. VIII, Div. 1, App. 12 ASME Sect. VIII, Div. 1, App. 6 ASME Sect. VIII, Div. 1, App. 6 ASME Sect. VIIII, Div. 1, Art. UW51

Purchaser's Representative reserves the right to perform stage wise inspection and witness tests including hydrostatic test, as indicated in specification at manufacturer’s works prior to shipment. Manufacturer shall give reasonable notice of time & shall provide without charge reasonable access and facilities required for inspection, to the purchaser's representative. Inspection and tests performed / witnessed by Purchaser's Representative shall in no way relieve the Manufacturer's obligation of specific integrity of the scraper traps. Manufacturer's equipment shall be subject to examination and approval by purchaser to ensure proper fabrication and testing of traps.

TEST CERTIFICATES: Manufacturer shall furnish the following certificates: a)

Test certificates relevant to the chemical and Mechanical properties including Hardness of the materials used for manufacture of trap as per relevant standards and this specification.

b)

Hydrostatic test certificates.

c)

Test reports on radiography, ultrasonic inspection and magnetic particle examination.

d)

Test reports on heat treatment carried out, if any.

The certificate shall be considered valid only when signed by purchaser’s representative. 7.0

PAINTING, MARKING AND SHIPMENT: 7.1

After all inspection and tests required have been carried out; all external surfaces shall be thoroughly cleaned to remove grease, dust and rust. Surface preparation shall be carried out by shot blasting to SP-6 in accordance with "Steel Structures Painting Council Visual Standard - SSPCVIS-1". Machined parts shall be coated with anti-rust removable paint and non machined parts shall be applied with two coats of protective paint. Manufactures shall indicate the type of paint used in the drawings submitted for approval.




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The inner surfaces must be free of loose particles, lamination flakes, welding spatter and sharp edges or any protruding element that interferes with the pig / scraper. 7.2

Marking shall be done on a stainless steel plate and affixed to the body by means of corrosion resistant fasteners. Marking shall include the following:a) b) c) d) e) f) g) h) i) j) k)

Manufacturer's Name Trap/ Neck Diameter, Thickness Material ASME Class Rating Tag Number Design Pressure Design Temperature Test Pressure Design Factor Year of Manufacture Empty weight of the trap assembly.

7.3

Equipment shall be drained of test liquid, cleaned and thoroughly dried prior to shipment. Surfaces subject to atmospheric corrosion or rusting shall be coated with rust preventive. External non-painted surfaces including bolting and flange faces also shall be coated with rust preventive designed for at least six months of storage.

7.4

All components shall securely anchor to the skid and package supports.

7.5

All opening, flange facings, etc., shall be sealed with waterproof coverings for shipping. Threaded coupling shall be provided with steel plugs.

7.6

Two extra O-rings and the closure actuation tool shall be attached to the inside of the barrel to prevent loss. The scraper barrels shall be handled in such a manner to prevent damage, including damage to the bevel or closure. Service bolting and gaskets shall be suitably rated and properly marked.

7.7

Flanged openings shall be protected with one-piece plywood cover and rubber gasket. Plywood covers shall be 3/8 inch thick, for flanges 6 inches and smaller, ½ inch thick for 8 inch through 12 inch flanges, and ¾ inch thick for larger sizes.

7.8

A minimum of four 3/8 inch bolts shall be used for flanges 12 inches and smaller end eight 3/8 inch bolts for larger flanges.

7.9

Large washers shall be used on the flange side of the bolt. Suitable washers shall be used on the plywood side of all such covers.

7.10

Only those traps, which have been inspected and certified by the purchaser’s inspector shall be supplied.




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8.0

GUARANTEE: 8.1

9.0

Manufacturer shall guarantee that the trap along with accessories is in compliance with the requirements of this specification for materials and workmanship. Manufacturer shall replace or repair all parts which should result defective due to inadequate design or the workmanship. In case the defect can not be eliminated, Manufacturer shall replace the trap without any delay. Any defect occurring within the time period specified elsewhere Shall be repaired making all necessary modifications and repair of defective parts free of charge to the purchaser.

SPARES: 9.1

Manufacturer shall furnish list of recommended spares and accessories for Scraper Traps required during start up and commissioning. As a minimum, the commissioning spares shall include 200% extra consumable spares viz. gaskets/ o-rings/ seals etc. for each trap. Cost of such spares shall be included by the Manufacturer in the item rates indicated in Purchase Requisition.

9.2

Manufacturer shall furnish separately a list of recommended spares and accessories required for two years of normal operation and maintenance of Scraper Traps.

10.0 DOCUMENTATION: 10.1

Manufacturer shall furnish the following documents at the time of bidding:-

(a)

Outline General Arrangement Drawings of the equipment

(b)

Completed data Sheets

(c)

Confirmation of scope of supply, including detailed material and painting specifications

(d)

Thickness of major and minor barrel

(e)

Vessel weight data, Erection weight, Operational weight, Maximum weight

(f)

Materials of Construction

(g)

Proposed manufacturing/delivery schedule

(h)

Proposed Quality Assurance/Safety Plan

(i)

Proposed Surface Treatment

(j)

Typical Inspection and Test Plan




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(k)

Table of Compliance

(l)

Catalogue of End Closure

(m)

Reference list of similar supplies for the past seven years including project, client year of supply & contact person. Failure to provide this information may exclude the manufacturer’s bid from Evaluation.

10.2

Within three weeks of placement of order, the manufacturer shall submit four copies of, but not limited to, the following drawings, documents and specifications for approval. a)

Design calculations according to the relevant codes for the body including branch connections and quick end closures

b)

Support Assembly Drawing

c)

Trap assembly, Closure assembly and sectional drawings showing all parts with materials and dimensions

d)

Welding procedure and method of manufacture

Once the above said documents have been approved by the Purchaser, any changes in design, material and method of manufacturer shall be notified to the Purchaser, whose approval in writing of all changes shall be obtained before the traps are manufactured. 10.3

Within four weeks from the approval date Manufacturer shall submit one reproducible and six copies of all approved drawings, documents and specification as listed in clause 10.2 of this specification.

10.4

Prior to shipment, the manufacturer shall submit one reproducible and six copies of the following:

10.5

a)

Test certificate as listed in clause 6.0 of this specification.

b)

Manual for installation, erection instructions, maintenance and operations instruction.

All documents shall be in English Language.




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STANDARD SPECIFICATION FOR PIG SIGNALERS




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CONTENTS Sl.No.

Description

1.0

SCOPE

2.0

MATERIALS

3.0

DESIGN AND CONSTRUCTION REQUIREMENTS

4.0


5.0

TEST CERTIFICATES

6.0


7.0

GUARANTEE

8.0


9.0

DOCUMENTATION




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1.0

SCOPE:

This specification covers the basic requirements for design, manufacture, inspection, testing & supply of Pig Signalers used for detection of the passage of scraper and instrumented gauging pigs to be installed in pipeline system transporting Natural Gas. 2.0

MATERIALS: 2.1

All materials used in the manufacture of the main components of the pig signallers shall be as indicated in the data sheets. Other components shall be as per manufacturer's standard suitable for the service conditions indicated in Annexure – I and data sheets which will be subject to approval by Purchaser.

2.2


2.3


CE = 2.4

3.0

C+

Mn Cr + Mo + V -------- + --------------------6 5

+

Ni + Cu --------------15

The maximum hardness of Base metal, Weld metal and Heat affected zone (HAZ) of pressure containing parts of the traps shall be 248 points Vicker’s HV10.

DESIGN AND CONSTRUCTION: 3.1

Pig signallers shall be bi-directional type having pivot-less tumbler mechanism and laminated trigger blades.

3.2

Pig signallers shall be designed to meet the requirements of pipeline material, diameter, wall thickness & service conditions indicated in the data sheet.

3.3

Design of pig signallers shall be such that any possibility of signaler being operated by line pressure is eliminated.

3.4

Design of pig signallers shall also be such that repair and installation of internals/ accessories are possible under pressure, without removing the unit from the line.




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3.5

Pig signallers shall be provided with a visual indicator to indicate the passage of pigs, by means of spring loaded metal shaft. The arm shall lock in down position when manually reset.

3.6

Pig signalers shall be fitted with sealed, weather proof and explosion proof micro switch for remote signal indication. The area classification and rating of micro switch shall be as indicated in data sheet. Suitable for installation in NEC class I Division 1, hazardous area. Micro switch shall have the following rating: 2 Amp, 24 Volts, 50 Hz. Type : SPDT. Contacts : 2 NO and 2 NC

4.0

5.0

3.7

All welds shall be made by welders and welding procedures qualified in accordance with the provision of ASME Section IX. The procedure qualification shall include hardness test and shall meet the requirements of clause 2.4 of this specification

3.8

Whenever specified in the data sheet, pig signallers shall be provided with extension, suitable for installation on underground pipeline.


Manufacturer shall perform all inspection and tests required to supply the signallers as per the requirements of this specification.

4.2

All pig signallers shall be visually inspected.

4.3

Chemical composition & mechanical properties including hardness shall be checked for each heat of steel used.

4.4

All welds shall be non-destructively examined.

4.5

The welding end shall be inspected ultrasonically over the entire circumference for lamination type defects. Any lamination larger than 6.35mm shall not be acceptable.

4.6

Hydrostatic test shall be conducted at a pressure equal to 1.5 times the design pressure. Hydro test duration shall be 15 Minutes.

4.7

Manufacturers shall perform functional tests to establish satisfactory performance of both manual and electrical indications.

TEST CERTIFICATES:




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6.0

5.1

Manufacturer shall supply the test certificates for material compliance as per the relevant Material Standards.

5.2

Certificate for hydrostatic test and functional test.

5.3

Test reports on heat treatment carried out, if any.

PAINTING, MARKING AND SHIPMENT: 6.1

Exterior surface of the pig signallers shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion resistant paint. Manufacturer shall indicate the type and corrosion resistant paint used in the drawings submitted for approval. In case of pig signallers with extension, the buried portion shall be coated with three coats of coal tar epoxy resin. The minimum dry film thickness shall be 300 microns.

6.2

A corrosion resistant metal tag shall be permanently attached with each unit, with the following marking:i) ii) iii) iv)

6.3

7.0

8.0

Manufacturer’s name Suitable for installation in_______mm dia. pipeline ANSI Rating Tag No.

Each unit shall be suitably protected to avoid any damage during transit. Care shall be exercised during packing to prevent any damage to the welding ends. All machined surfaces subject to corrosion shall be well protected by a coat of grease or other suitable materials.

GUARANTEE: 7.1

Manufacturer shall guarantee that the pig signallers comply with the requirements stated in this specification and in the purchase order. Manufacturer shall replace or repair all parts found to be defective due to inadequate engineering or quality of material. Manufacturer shall replace the signaler without delay, if the defect or malfunctioning cannot be eliminated.

7.2

Any defects occurring within the time period specified elsewhere shall be repaired making all necessary modifications and repair of defective parts free of charge to the purchaser.

SPARES: 8.1

Manufacturer shall furnish list of recommended spares and accessories for Pig Signalers required during start up and commissioning. Cost of such spares shall be included by the Manufacturer in the item rates indicated in Purchase Requisition.




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8.2

9.0

Manufacturer shall furnish separately a list of recommended spares and accessories required for two years of normal operation and maintenance of Pig Signallers.

DOCUMENTATION: 9.1

9.2

At the time of bidding, bidder shall submit the following documents:a)

General Arrangement drawing with overall dimensions.

b)

Clause wise list of deviation from this specification, if any.

c)

Reference list of similar supplies of pig signaler shall be furnished including project, year of supply, client, size, rating and service for last five years.

Within three weeks of placement of order, the manufacturer shall submit four copies, but not limited to, of the following drawings, documents and specifications for approval. a)

Fabrication drawings/ sectional arrangement drawings showing all parts with reference numbers and material specification.

b)

Assembly drawing with overall dimension.

c)

Welding and testing procedure.

d)

Cable connection details and cable specification.

Once the approval has been given by Purchaser, any change in design, material, etc. shall be notified to the Purchaser whose approval in writing for all changes shall be obtained before Pig Signallers are manufactured. 9.3

Within four weeks from the approval date, Manufacturer shall submit one reproducible and six copies of the approved drawings and specifications as listed in 9.2 of this specification.

9.4

Prior to shipment, Manufacturer shall submit one reproducible and six copies of following: a) b)

9.5

Test certificates as per clause 5.0 of this specification. Manual for installation, erection instructions, maintenance and operation instructions.





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STANDARD SPECIFICATION FOR INSULATING JOINTS




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CONTENTS Sl. No.

Description

1.0

SCOPE

2.0

REFERENCE DOCUMENTS

3.0

MATERIALS

4.0


5.0


6.0

TEST CERTIFICATES

7.0


8.0

GUARANTEE

9.0

DOCUMENTATION




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1.0

SCOPE This specification covers the basic requirements for design, manufacture, testing and supply of carbon steel insulating joints to be installed in onshore pipeline systems handling Natural Gas.

2.0

REFERENCE DOCUMENTS 2.1 Reference has been made in this specification to the latest edition of following Codes, Standards and Specifications.

3.0

the

a)

ASME B 31.8 (Gas Transmission & Distribution piping System)

b)

ASTM A 370 (Mechanical testing of Steel Product)

c)

ANSI B 16.25 (Butt Welding Ends)

d)

ASME Section Boiler & pressure Vessel Code viii & ix

e)

API 1104 (Standard for welding pipelines and related facilities)

f)

SSPC-VIS-1 (Steel Structures painting Council Visual Standard)

g)

MSS-SP-53 (Quality standard for steel castings and forgings for valves flanges and fittings and other piping components - magnetic particle examination method)

h)

MSS-SP-75 (Specification for high test wrought welding fittings)

i)

NACE RP 0286 (Standard for electrical isolation of cathodically protected pipelines)

2.2

In case of conflict between the requirements of this specification and any code, Standard or Specification referred to in this Specification, the requirements of this specification shall govern.

MATERIALS 3.1

Material for the pressure containing parts of the insulating joints shall be as indicated in the data sheets. Material for pups shall be equivalent or superior to the material of connecting pipeline which is indicated in the data sheets. Other part shall be as per manufacturer's standard suitable for the service condition indicated in Insulating Joint Data Sheets and shall be subject to approval by Purchaser.

3.2

Insulating joints, which are subject to field welding by purchaser, shall have carbon equivalent (CE) not exceeding 0.45 based on check analysis for each heat of steel calculated according to the following formula:




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CE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni +Cu)/15 3.3

When specified in the IJ Data Sheet, charpy V-notch test shall be conducted on each heat of base material, weld metal and heat affected zone of all pressure containing parts such as body, welding ends in accordance with the impact test provisions of ASTM A 370 at a temperature of 0° C. The charpy impact test specimens shall be taken in the direction of principal grain flow and notched perpendicular to the original surface of the plate of forging. Average impact energy value of three full sized specimens shall be 27 joules. Minimum impact energy value of any one specimen shall not be less than 80% of the average impact energy specified. No specimen shall exhibit less than 80% shear area.

3.4

Carbon steel used for the manufacture shall be fully killed

3.5

When specified in data sheet, hardness test shall be carried out as per ASTM A370 for each heat of steel used. The maximum hardness of base metal, weld metal and heat affected zone of all pressure parts shall be 248 HV10, unless specified otherwise.

3.6

Insulation material shall be minimum 20 mm thick and shall comply section 5, NACE RP 0286.

4.0

DESIGN & CONSTRUCTION REQUIREMENTS

4.1

Mechanical 4.1.1 Insulating joints shall be of integral type fabricated by welding and with pups on either side as shown in data sheet. A corrosion allowance as indicated in data sheet shall be considered in design. Bolted and threaded joints are not acceptable. 4.1.2 All materials used for the manufacture of the insulating joint shall be in accordance with clause 3.0 of this Specification. 4.1.3 Insulating joints shall be designed using the design principles of ASME Section- VIII Div. 1. The design shall be checked for the following two cases: Case-I: Design Pressure (as per Data Sheet) + Axial Force (F) The Axial force shall be calculated as under: F = 0.1 x S x A Where S = SMYS of connected pipe (refer Data Sheet) A = Metal cross-sectional area of connected pipe. The allowable stress in this case shall be less than or equal to 0.5 x SMYS of insulating joint material. GAIL (INDIA) LTD NEW DELHI



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Case-II: Hydrostatic Test Pressure The allowable stress in this case shall be less than or equal to 90% of SMYS of insulating joint material. All design parameters shall be as per Insulating Joint Data Sheet. Detailed calculations shall be submitted for Purchaser approval. 4.1.4 Insulating joint design and materials shall be capable of being vacuum tested to 1 millibar. 4.1.5 The joint between pipe pup pieces and main forging shall be full penetration butt weld type. Weld design shall be such as resulting in a weld joint factor of 1.0. 4.1.6 Butt weld ends shall have ends as per ASME B16.25. However, end preparation for butt welding ends having unequal thickness with respect to connecting pipe, shall be as per ASME B31.4/ B31.8 as applicable. 4.1.7 The reinforcement of inside weld seam, in case pups fabricated from LSAW pipes, shall be removed for a distance of at least 50mm from each end. 4.1.8 Insulating joints shall allow free passage of scraper/ instrumented pigs. The internal bore shall be same as that of connecting pipe including its tolerances. 4.1.9 The insulating joint shall be formed by sandwiching and locking in positions the insulating material in a bell and spigot type of joint. The joint shall be assembled in such a way that its various components are firmly locked in position and the completed joint is capable of withstanding stresses due to designed operating conditions and field hydrostatic testing. 4.1.10 Insulating joints shall be suitable for aboveground or underground installations as indicated in the data sheets. 4.1.11 All welds shall be made by welders and welding procedures qualified in accordance with the provisions ASME section IX. The procedure qualification shall include impact test and hardness test and shall meet the requirements of clause 3.3, 3.5 of this specification. 4.1.12 Repair welding on parent metal is not allowed. Repair of welds shall be carried out only after specific approval by purchaser's representative for each repair. The repair welding shall be carried out by welders and welding procedures duly qualified as per ASME section IX and records for each repair shall be maintained. 4.1.13 Internal diameter at the welding end shall not vary more than + 1, -3 mm from the nominal internal diameter. GAIL (INDIA) LTD NEW DELHI



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4.1.14 Out of roundness measured at the root face of the welding ends shall not be more than 0.5% of the specified inside diameter. 4.2

Electrical 4.2.1 The average dielectric strength of the insulating joint shall be minimum 15 kilo Volts. 4.2.2 Two cleats as shown in data sheet shall be provided on the pups on either side of the insulating joint for connecting 10 mm2 and 50 mm2 cables for measurement/ shorting purposes. Cleats shall be attached to the insulating joint by welding.

5.0

INSPECTION AND TESTS 5.1

The manufacturer shall perform all inspection and tests as per the requirements of this specification and the relevant codes, prior to shipment at his works. Such inspection and tests shall be, but not limited to the following: 5.1.1 All insulating joints shall be visually inspected 5.1.2 Dimensional checks shall be carried out as per the purchaser approved drawings 5.1.3 Chemical composition and mechanical properties including hardness shall be checked as per relevant material standards and this specification, for each heat of steel used 5.1.4 Non-destructive inspection of insulating joints shall be carried out as given below: a)

100% radiography shall be carried out on all butt & repair welds of pressure containing parts. Acceptance limits shall be as per API 1104. Welds, which in purchaser's opinion can not be inspected by radiographic methods, shall be checked by ultrasonic or magnetic particle methods. Acceptance criteria shall be as per ASME Section VIII Appendix-12 and Appendix-6 respectively.

b)

All finished weld ends shall be 100% ultrasonically tested for lamination type defects for a distance of 50mm from the ends. Any lamination larger than 6.35 mm shall not be acceptable.

c)

All forgings shall be wet magnetic particle inspected on 100% of forged surfaces. Method and acceptance shall comply with MSS-SP53.




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d)

All fillet weld of thickness < 6mm shall be examined 100% by magnetic particle inspection and ≥ 6mm shall be examined 100% by UT. Acceptance criteria for MPI & UT shall be as per ASME Sec. VIII Appendix-6 & Appendix-12 respectively.

5.1.5 Insulating joint shall be hydrostatically tested to a pressure as indicated in data sheet. The test duration shall be of 15 minutes 5.1.6 After the hydrostatic test insulating joints shall be tested with air at 5 kg/cm2 for 10 minutes. The tightness shall be checked by immersion or with a frothing agent. No leakage will be accepted. 5.1.7 Dielectric Test

5.2

6.0

a)

Insulation resistance of each insulating joint shall be at least 25 mega ohms when checked with 500-1000 V DC.

b)

Insulating joint before and after the hydrostatic test, shall be tested for dielectric integrity for one minute at 5000 V A.C., 50 cycles and the leakage current before and after hydrostatic test shall be equal. Testing time voltage and leakage shall be recorded and certified. No repair shall be permitted to the insulating joints failed in the above mentioned tests.

Purchaser reserves the right to perform stage wise inspection and witness test as indicated in Para 5.1 at Manufacturer's works prior to shipment. Manufacturer shall give reasonable notice of time and shall provide without charge, reasonable access and facilities required for inspection to the purchaser's Representative. Inspection and tests performed/witnessed by the Purchaser's Representative shall in no way relieve the Manufacturer's obligation to perform the required inspection and test.

TEST CERTIFICATES 6.1

Manufacturer shall Representative.

submit

following

certificates

to

Purchaser's

a)

Test certificates relevant to the chemical analysis and mechanical properties including hardness of the materials used for construction of insulating joint as per this specification and relevant standards.

b)

Test reports on non-destructive testing.

c)

Test certificates for hydrostatic and air tests.

d)

Test certificate for electrical test.

e)

Test report on vacuum test.




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7.0

PAINTING, MARKING AND SHIPMENT. 7.1

Insulating joint surface shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot blasting to SP-6 in accordance with "steel structures painting council - Visual standard SSPC-VIS-l". External surfaces of buried insulating joints shall be painted with three coats of suitable coal tar epoxy resin with a minimum dry film thickness of 300 microns. Manufacturer shall indicate the type of corrosion resistant paint used, in the drawings submitted for approval.

7.2

Insulating joints shall be marked with indelible paint with the following data:a. b. c. d. e. f. g. h.

8.0

9.0

Manufacturer's name Suitable for inch nominal diameter pipeline End thickness in mm Material Design Pressure/ Hydrostatic Test Pressure ANSI Class Rating Tag No. Year of Manufacture

7.3

Insulating joints shall be suitably protected to avoid any damage during transit. Metallic bevel protectors shall be provided to weld ends.

7.4

Only those insulating joints which have been inspected and certified by Purchaser shall be shipped.

GUARANTEE 8.1

The manufacturer shall guarantee that the materials used comply with the requirements of this specification.

8.2

Manufacturer shall replace or repair insulating joints found defective due to inadequate engineering or quality of material.

8.3

Manufacturer shall replace the insulating joint without delay if the defect or malfunctioning can not be eliminated.

8.4

Any defects occurring within 12 months from the date of installation or within 30 months from the date of dispatch, whichever is earlier shall be repaired making all necessary modifications and repair of defective parts free of charge to the purchaser.

DOCUMENTATION 9.1





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9.2

9.3

At the time of bidding, Bidder shall submit the following documents:a) General arrangement drawing along with cross sectional view, overall dimensions and details of insulating materials recommended. b)

Reference lists of previous supplies of insulating joint of similar specification.

c)

Clause wise list of deviation from this specification, if any.

Within three weeks of placement of order, the Manufacturer shall submit four copies of the following drawings, documents and specifications for approval. a)

Fabrication drawings and relevant calculations for pressure containing parts.

b)

Welding procedure and method of manufacture for all phases of manufacture.

c)

Quality Assurance Plan (QAP)

d)

Any other Drawing / Document etc. as requested by Purchaser

Once the approval has been given by purchaser, any changes in design, material and method of manufacture shall be notified to the Purchaser whose approval in writing of all changes shall be obtained before the insulting joints are manufactured. 9.4

Within four weeks from the approval date, Manufacturer shall submit one reproducible and six copies of the approved drawings, documents and specifications as listed in 9.3 of this specification.

9.5

Prior to shipment, the manufacturer shall submit one reproducible and six copies of the test certificates as listed in clause 6.0 of this specification.




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STANDARD SPECIFICATION FOR CASING INSULATORS AND END SEALS

SPECIFICATION S – 04 – 02 - 020

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PART – A 1.0

CASING INSULATORS

SCOPE This specification covers the minimum requirements of design, material, manufacture and supply of casing insulators intended to be used for cased pipeline crossings.

2.0

FUNCTION Pipeline insulators shall be used to support the carrier pipe inside the casing pipe and electrically isolate the carrier pipe from the casing pipe at the cased crossings. The casing insulators shall have the following properties:

3.0

-

Resist cold flow and will not soften at design temperature.

-

Resist corrosion.

-

Resist mechanical damage while being pulled into the casing.

-

Have high electrical insulating value and low water absorption, thus preventing leakage and maintain electrical isolation between carrier and casing pipes.

-

Have high compressive strength in order to ensure a permanent support to the carrier pipe.

DESIGN The arrangement of insulator shall be generally in accordance with Fig. 3.0. It shall be made in segments duly held together with cadmiudXYLAN plated bolts and nuts, to be supplied with casing insulators. The number of segments shall be two for pipe diameters upto DN 300 rnm (12"). For larger diameter, the number of segments may be more than two, but their number shall be kept minimum. The skid height shall be such that it is slightly less than the value obtained by following formula: Casing Internal Dia - Carrier Outer Dia 2 Manufacturer shall obtain prior approval from OWNER on casing insulators drawingsldesign.

4.0

MATERIAL GAIL (INDIA) LTD NEW DELHI



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Casing insulators shall be made of injection moulded high density polyethylene or other material, equivalent or superior, as approved by OWNER. The material shall meet the following specifications: Property Dielectric Strength Compressive Strength Tensile Strength Impact Strength Water Absorption 5.0

Value 450 – 500 Volts/Mil 3200 psi 3100 – 5000 psi 4.0 ft.lb/ inch of notch 0.01 %

ASTM Test Method D-149 D-695 D-638, D-651 D-256 D-570

INSPECTION AND TESTING Manufacturer shall furnish material test certificates of the components used in the assembly of casing insulators as per the requirements of clause 4.0 of this specification.




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PART - B

CASING END SEALS

SCOPE This specification covers the minimum requirements of design, material, fabrication and supply of casing end seals intended to be used for pipeline cased crossings. FUNCTION Casing end seals are intended to be used for sealing the annular space between casing pipe and carrier pipe at casing ends so as to prevent ingress of moisture and water. DESIGN The seals shall be suitable for the casing and carrier pipe diameters as applicable for each case. The casing end seal shall be flexible to cater for the expansion and contraction of carrier and casing pipes and shall be able to tolerate both angular and concentric misalignment of casing pipe without loss of sealing efficiency. The design of the casing end seals shall permit easy installation of the seal to the cased pipeline crossing. It shall provide moisture-proof seals when installed for the entire anticipated life of the buried pipeline. Manufacturer shall obtain prior approval from OWNER on casing end seals design/drawings. MATERIAL The casing end-seals shall be made of heat shrink high density radiation cross linked polyethylene with an adhesive having a melt point suitable for the pipeline service temperature and ambient temperatures foreseen during construction. End seals material shall be resistant to heat, cold, vibration, impact, abrasion, corrosive fluids, disbonding, organic and biodeterioration. Manufacturer shall confirm compatibility of end seals with carrier pipe coating. Casing end seals shall meet following minimum property requirements: a)

Backing (Sleeve and closure patch) Property

Minimum Value

Test Method

Tensile strength

2200 psi

ASTM D 638

Ultimate Elongation

400 %

ASTM D 638




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Heat Shock

b)

No Visual Cracks, Flow or Drips at 250°C, 4 hours

ASTM D 2671

Propertv

Minimum Value

Test Method

Ring and Ball Softening Point

90°C

ASTM E 28

Lap Shear

60°C - 25 psi 23°C - 250 psi (2 inchlmin.)

ASTM D 1002

Property

Minimum Value

Test Method

Peel strength (To casing and carrier pipe and closure patch)

5 pli (1 0 inchlmin.)

ASTM D 1000

Adhesive

c)

System (As Applied)

5 .O

INSPECTION AND TESTING Manufacturer shall furnish material test certificates of the components used in the assembly of casing end seals as per the requirements of this specification.




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PART - C

SUPPLEMENTARY REQUIREMENTS

1.0

The manufacturer shall replace, at no extra cost, any material not conforming to the material and performance requirements of this specification.

2.0

Manufacturer shall submit detailed specification of the materials used in the assemblies, along with instructions for handling, use and installation of the material for OWNER approval prior to procurement.

3.0

Manufacturer shall submit all the documents, test reports, records and other information to OWNER for record after approval as per clause 2.0 above. Number of Copies (Hard copies / soft copies etc.) shall be as indicated in CONTRACT document.




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STANDARD SPECIFICATION FOR FIELD JOINT COATING (ONSHORE PIPELINES)


STANDARD SPECIFICATION FOR FIELD JOINT COATING (ONSHORE PIPEINE)

SPECIFICATION S-04-02-021

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1.0

SCOPE

1.1

This specification establishes the minimum requirements of materials, equipment and installation of field joint anti-corrosion coating of buried onshore pipelines factory coated with either three layer polyethylene or fusion bonded epoxy coating, by heat shrink wraparound sleeves or by cold applied tapes conforming to DIN EN 12068 "Cathodic Protection - External Organic Coatings for the Corrosion Protection of Buried or Immersed Steel Pipelines used in Conjunction with Cathodic Protection - Tapes and Shrinkable Materials" and the requirements of this specification. Unless modifiedlreplaced by this specification, all requirements of DIN EN 12068 shall remain fully applicable and complied with. This specification shall be read in conjunction with the conditions of all specifications and documents included in the Contract between Company and Contractor. Unless specified otherwise, all sections of this specification shall apply to all specifications referred in this specification.

2.0

REFERENCE DOCUMENTS Reference has also been made to the latest edition (edition enforce at the time of issue of enquiry) of the following standards, codes and specifications:

a)

ASTM D- 149

:

Standard Test Methods of Dielectric Breakdown voltage & Dielectric strength of solid electrical insulating materials at commercial frequencies.

b)

ASTM D-257

:

Standard Test Methods for D-C Resistance or conductance of insulating materials.

c)

ASTM D-570

:

Standard Method of Test for Water Absorption of Plastics.

d)

e)

IS0 8502 – 3

ISO 8503 – 1


: Preparation of Steel Substrates before Application of Paints and Related Products -Part 3 - Assessment of Dust on Steel Surfaces Prepared for Painting (Pressure Sensitive Tape Method) :

Part 1: Specification and definitions for IS0 surface profile comparator for the assessment of abrasive blast cleaned surfaces.



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f)

ISO 8503 – 4

:

Part 4: Methods for calibration of IS0 surface profile comparator and for the determination of surface profile – Stylus instrument procedure.

g)

SIS 055900

:

Pictorial Surface Preparation Standard for Painting Steel Surfaces.

h)

SSPC-SP 1

:

Steel Structure Painting Council

In case of conflict between the requirements of this specification and that of above referred documents, the requirements of this specification shall govern. The CONTRACTOR shall be familiar with the requirements of these documents and shall make them readily available at the site to all personnel concerned with carrying out the works specified in this specification. 3.0

MATERIALS AND EQUIPMENT

3.1

Field joint anti-corrosion coating material shall be either heat shrinkable wraparound sleeve or cold applied tape suitable for a maximum operating temperature of (+) 60°C (Tmax) and shall conform to designation EN 12068 - C HT 60 UV. In addition, the field joint anti-corrosion coating shall comply the requirements specified in para 3.2 of this specification.

3.1.1 Heat shrinkable wraparound sleeves: Heat shrinkable wraparound sleeve shall consist of radiation cross-linked, thermally stabilized,Ultra violet resistant semi-rigid polyolefin backing with a uniform thickness of high shear strength thermoplastic/co-polymer hot melt adhesive. The joint coating system shall consist of a solvent free epoxy primer applied to the pipe surface prior to sleeve application. The backing shall be provided with suitable means (thermo-chrome paint, dimple, or other means) to indicate the desired heat during shrinking in field is attained. The sleeve shall be supplied in pre-cut sizes to suit the pipe diameter and the requirements of overlap. The total thickness of heat shrinkable wraparound sleeve in the as applied condition shall be as follows: Pipe Size (Specified Outside Diameter) ≤30" (762 mm) ≥32'' (813.0 mm)


Thickness (mm) Average 2.0 2.4

On Pipe Body Min. 1.8 2.2


On Weld Bead (Min.) 1.6 2.0


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The heat shrink wraparound sleeve shall have the required adhesive properties when applied on various commercial pipe-coating materials. The pre-heat and application temperatures required for the application of the shrink sleeve shall not cause loss of functional properties of the pipe coating. Heat shrinkable wraparound field joint coating system manufactured by M/S Tyco Adhesives Raychem and M/S Canusa are acceptable for the supply of field joint coating materials. The Contractor shall propose the specific grade of field joint coating system meeting the requirements of this specification from these manufacturers. In case the Contractor proposes to supply heat shrinkable wraparound sleeve from any other manufacturer, then the Contractor shall propose only those coating systems that have been previously used for pipelines of size same or higher than the size indicated in tender, for a length of 50 Km and above in a single project for similar operating conditions. 3.1.2 Cold Applied Tapes: Cold applied tape system shall comprise of primer, an inner wrap and an outer wrap. The inner and outer wraps shall be asymmetric 3-ply tape with co-extruded polyethylene carrier film and butyl rubber adhesive layers on both sides. The inner layer of butyl rubber adhesive of inner wrap shall have a thickness of min. 1.0 mm. The inner and outer wraps are to be spirally wrapped with 55% overlap, equivalent to two layers each providing a total minimum thickness of 3.0 mm on the pipe body and 2.5 mm on the weld. The Contractor shall propose only those cold applied tape coating systems that have been previously used in pipelines of size 16" and above and a length of 50 km and above in a single project for similar operating conditions. 3.2 Functional Requirements of Field Joint Coating 3.2.1 Properties of the PE backing shall be as follows: Sl. No. a.

PROPERTIES

UNIT

REQUIREMENT

TEST METHOD

Tensile Strength @ + 25 0C

N / mm2

≥ 12

DIN EN 12068

b.

Ultimate Elongation @ + 25 0C

%

≥ 250 0C

DIN EN 12068

c.

Dielectric Withstand with 1000 Volts/Sec

KV

≥ 30

ASTM D 149

d

Water absorption @ +25 0C for 24 Hours

%

≤ 0.05

ASTM D 570

e.

Volume Resistivity @ +25 0C

Ohm-cm

≥ 1015

ASTM D 257




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3.2.2

Functional Properties of Joint Coating System (As applied) As applied field joint coating system shall comply the requirements of DIN EN 12068, Table 1 and 2 corresponding to designation DIN EN 12068 - C HT 60 W, except as modified below:

a)

Cathodic Disbondment Resistance at Tmax i.e 60°C shall be 20 mm when tested as per Annexure K of DIN EN 12068. Test shall be carried out at (+) 60°C

b)

Peel Strength shall be as follows : Peel Strength Inner to Inner (+) Outer to Inner

@ 23 0C

N/mm

Requirement for Mechanical Resistance Class – C (minmum) 1.5

@ Tmax

N/mm

0.3

Outer to Outer

@ 23 0C

N/mm

1.5

@ Tmax

N/mm

0.3

@ 23 0C

N/mm

3.5

@ Tmax

N/mm

0.5

@ 23 0C

N/mm

3.5

@ Tmax

N/mm

0.5

To pipe surface

To Factory Coating

Unit

Test Method as per DIN EN 12068 ANNEXURE - B

ANNEXURE - C

Tmax shall be (+) 60 0C

Contractor shall obtain prior approval from Company regarding the Manufacturer of the joint coating material and the specific grade of the joint coating system. Complete technical details along with test certificates complying with the requirements of clause 3.2.1 and 3.2.2 shall be submitted to Company for this purpose. The Contractor shall finish test certificates from an independent DIN recognized / approved laboratory for all the properties required for the specified EN designation of field joint coating and the requirements of this specification. 3.3

The material shall not be older than their period of validity at the time of application by the Contractor. Deteriorated/ decomposed material shall be disposed off and replaced by the contractor at his own expenses. Contractor shall ensure that the coating materials supplied by him are properly packed and clearly marked with the following: -

Manufacturer's name




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– -

Material qualification Batch number Date of manufacturing and date of expiry

3.4

Contractor shall ensure that the Manufacturer has carried out all quality control tests on each batch and manufacturer shall provide test certificates to certify that the supplied materials meet the manufacturer's specifications as indicated in the purchase order and as approved by COMPANY. Certificates and data sheets certifying the qualities of the coating materials shall be submitted by Contractor to Company prior to application. Company reserves the right to have the materials tested by an independent laboratory.

3.5

Materials shall be stored in sheltered storage in the manufacturer's original packing and away from direct sunlight and in accordance with manufacturer's instructions.

3.6

Contractor shall provide and maintain mobile facilities which contain all necessary equipment and its spares for cleaning, coating, repairs, inspection and tests.

3.7

Contractor shall furnish sufficient number of the following equipment and the required spares as a minimum for inspection and test purposes for each crew: a)

Fully automatic full circle adjustable holiday detector with a visible and audible signal system for inspection of coatings.

b)

Thickness gauge for measuring thickness.

c)

Contact type temperature recording thermometer (Digital Pyrometer with flat probe type contact).

d)

Roughness profile measuring (Stylus) instrument

4.0

APPLICATION PROCEDURE

4.1

General

4.1.1 The application procedure shall be in accordance with manufacturer's instructions and the minimum requirements specified below whichever are the most stringent and shall be demonstrated to and approved by the Company. Manufacturer's expert shall supervise the application and shall be available at site upon request during qualification of application procedure and during construction at Contractor's cost. 4.1.2 Operators for coating application shall be given necessary instructions and training before start of work, by the Contractor. To verify and qualify the application procedures, all coating applied during the qualification test, shall be removed for destructive testing as detailed subsequently in this specification. Contractor shall only




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utilize those operators who have been approved/ prequalified by the field joint coating manufacturer. 4.1.3 Oil, grease and salt shall be removed from steel surface by wiping with rags soaked with suitable solvents such as naphtha or benzene. Kerosene shall not be used for this purpose. Solvent cleaning procedure according to SSPC-SP1 shall be followed. 4.1.4 Each field joint shall be blast cleaned using a closed cycle blasting unit or an open expendable blasting equipment. With the first equipment type, steel or chilled shot and iron grit shall be used and Garnet material with the second one (in case the authority having jurisdiction have no objection, the contractor may adopt sand blasting instead of garnet material). During blast cleaning the pipe surface temperature shall be simultaneously more than 5 0C and more than 3°C above ambient Dew Point, while the ambient Relative Humidity shall not be greater than 85 %. Prior to surface cleaning the surfaces shall be completely dry. The surface shall be cleaned to a grade Sa 2 ½ in accordance with Swedish Standard SIS-055900 with a roughness profile of 50 - 70 microns. Surface roughness profile shall be measured using an approved profile comparator in accordance with IS0 8503-1 and shall be calibrated prior to the start of the work in accordance with IS0 8503-3 or IS0 8503-4. The blast cleanliness shall be checked on every joint and the roughness profile shall be checked 1 every 10 joints. Dust, girt or foreign matter shall be removed from the cleaned surface by an industrial vacuum cleaner. The dust contamination allowed shall be of a rating max 2 as per IS0 8502 -3. The frequency of checking for dust contamination shall be 1 every 10 joints. Blast cleaned field joint shall be coated within 2 - 4 hours according to the conditions below:   

Relative Humidity (RH) > 80 % Relative Humidity (RH) 70 - 80 % Relative Humidity (RH) < 70 %

- 2 hours - 3 hours - 4 hours

Pipe delayed beyond this point or pipes showing any visible rust stain, shall be blast cleaned again. 4.1.5

The field joint surface shall be inspected immediately after blast cleaning and any feature of the steel surface such as weld spatter, scabs, laminations or other imperfections considered injurious to the coating integrity, made visible during blast cleaning, shall be reported to the Company Representative and on permission from Company Representative, such defects shall be removed by filing or grinding. Pipes affected in this manner shall be then re-blast cleaned if the defective area is larger than 50 mm in diameter.

4.1.6 The ends of existing pipe protective coating shall be inspected and chamfered. Unbounded portions of the coating shall be removed and then suitably trimmed. GAIL (INDIA) LTD NEW DELHI



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Portions where parent coating is removed shall be thoroughly cleaned as specified. The adjacent chamfered areas of the line pipe coating shall be cleaned and abraded, to expose a clean uniform fresh surface of uncontaminated factory applied coating. 4.1.7 All steel joint surfaces shall be thoroughly examined before the application of the coating in order to ensure the surfaces are free of oil, grease, rust, mud, earth or any other foreign matter. All these substances shall be removed before coating, to the procedures herein described. 4.1.8 Protection coating shall be applied on the joints immediately after the completion of cleaning operation. 4.2

Application Procedure for Heat Shrink Wraparound / Sleeves In addition to the requirements stated above, following shall be complied with:

4.2.1 The wrap around sleeve shall be of a size such that a minimum overlap of 50 mm is ensured (after shrinking) on both sides of the yard applied corrosion coating of pipes. In the cases where carrier pipe is installed by direct boring/ jacking, the overlap on the mill coating for the leading edges of the joints shall be minimum 200 mm. When this extra overlap is achieved by providing an additional patch of heat shrink tape/ wraparound, it shall be applied in such a manner that the square edge of the patch on the joint coating is in the direction opposite to the direction of boring / jacking. 4.2.2 Before centering the wraparound sleeve, the bare steel surface shall be preheated either with a torch moved back and forth over the surface or by induction heating. The minimum pre-heat temperature shall be as recommended by manufacturer and shall be checked by means of contact type temperature-recording thermometer (Digital Pyrometer with flat probe type contact). Temperature indicating crayons shall not be used. Pre-heat temperature shall be checked on every joint. Care shall be taken to ensure that the entire circumference of the pipe is heated evenly. Temperature measuring instruments shall be calibrated immediately before the start of the works and thereafter at intervals recommended by the manufacturer of the instrument. 4.2.3

Upon pre-heating, the pipe surface shall be applied with two pack epoxy primer of wet film thickness 150 microns or as per manufacturer's recommendation whichever is higher, to cover the exposed bare metal of the welded field joint and 10 mm min. onto the adjacent pipe coating if recommended by the manufacturer. The wet film thickness of the primer shall be checked on every joint with a wet film thickness gauge prior to installation of sleeve. Thickness gauge shall be calibrated once per shift.

4.2.4 Immediately after application of epoxy primer, the wraparound sleeve shall be entirely wrapped around the pipe within the stipulated time recommended by the manufacturer. Sleeve shall be positioned such that the closure patch is located to one side of the pipe GAIL (INDIA) LTD NEW DELHI


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in 10 or 2 O'clock position, with the edge of the undergoing layer facing upward and an overlap of min. 50 mm. Gently heat by appropriate torch the backing and the adhesive of the closure and press it firmly into place. 4.2.5 A heat shrinking procedure shall be applied to shrink the sleeve in such a manner to start shrinkage of the sleeve beginning from the center of the sleeve and heat circumferentially around the pipe. Continue heating from the center towards one end of the sleeve until recovery is completed. In a similar manner, heat and shrink the remaining side. Shrinking has been completed when the adhesive begins to ooze at the sleeve edges all around the circumference. The complete shrinking of the entire sleeves shall be obtained without undue heating of existing pipe coating and providing due bonding between pipe, sleeve and pipe coating. The installed sleeve shall not be disturbed until the adhesive has solidified. 4.3

Application Procedure for Cold Applied Tapes

4.3.1 Cold applied joint protection tape shall be of the type, which can be applied by spiral wrapping on the pipe. 4.3.2 Immediately after the completion of surface preparation, the approved primer of wet film thickness 150 microns or as per manufacturer's recommendation whichever is higher, to cover the exposed bare metal of the welded field joint and 10 mm min. onto the adjacent pipe coating if recommended by the manufacturer. Any dirt on the primed surface shall be removed. If the primer is damaged, the damaged area shall be cleaned and re-primed. 4.3.3 Approximately 100 mm of inner wrap interleaving paper shall be peeled back and inner wrap shall be applied with the thicker adhesive side to the pipe. Whilst continuously removing the interleaving paper, the tape shall be spirally applied through a machine to provide a minimum of 55% overlap. Sufficient tension shall be applied to ensure good conformity, avoiding air pockets and also continuously smooth out as the wrapping proceeds. The wrapping shall start and finish to give a minimum 50 mm overlap on to the adjoining yard applied coating. Outer wrap shall also be applied in similar method. 4.4

Pre-Qualification of Field Joint Coating System The field joint coating system materials and the procedures proposed by the Contractor shall be pre-qualified during the sleeve installation start-up phase. Five joints (5) shall be coated with the requirements of this specification and then inspected and tested in accordance with the requirements of this specification with respect to the following: (i)

Surface preparation, cleanliness, roughness profile and dust contamination

(ii)

Pre-heat temperature (as applicable)



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(iii)

Primer thickness

(iv)

As applied coating thickness

(v)

Holiday detection

(vi)

Peel test at (+) 23°C & (+) 60°C on pipe surface & factory applied coating and at overlaps (as applicable). If required to achieve the temperature of (+) 60°C, suitable thermal blanket may be used.

(vii)

Visual appearance and void after installation on the body, area adjoining the weld and area adjoining the factory applied coating. (To establish voids adjoining the weld and factory coating, a strip of 50 mm wide and 200 mm long shall be stripped and examined.)

Company Representative shall witness the tests and inspection. Regular application of field joint coating shall commence only upon successful completion of the prequalification testing. After successful completion of the pre-qualification testing as above, the entire field joint coating shall be removed, the pipe surface re-blasted and field joint coating reapplied as per the requirements of this specification. 5.0


5.1

Visual Inspection Visual inspection of the as applied coating shall be carried out on every joint, for the following: (i)

Mastic extrusion on either ends of the sleeve shall be examined

(ii)

There shall be no sign of punctures or pinholes or bend failure. The external appearance of the sleeve shall be smooth, free of dimples, air entrapment or void formation. All sleeves shall be tested for the presence of voids by knocking on the sleeves. A hollow sound compared to the remainder of the sleeve may indicate the presence of voids under the sleeve. Such sleeve shall be tested for adhesion at the discretion of the Company Representative.

(iii)

Weld bead profile shall be visible through the sleeve

(iv)

Visual indicator provided on the backing and the closure patch showing desired heat is achieved.



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5.2

Holiday Inspection The entire surface of each joint shall be inspected by means of a full circle holiday detector approved by Company, set to a DC voltage applicable as per the requirements of factory applied mainline coating specification of Company. Inspection of the sleeves shall be conducted only after the joint has cooled below 50°C. The holiday detector used shall be checked and calibrated daily with an accurate DC voltmeter. The detector electrode shall be in direct contact with the surface of coating to be inspected. No field joint shall be covered or lowered in the trench until it has been approved by the Company.

5.3

As-applied Coating Thickness Coating thickness shall be checked by non-destructive methods for each field joint. Average thickness of the as-applied coating on pipe body shall be established based on measurements at min. eight locations i.e four measurements on either sides of the girth weld at 3, 6, 9 & 12 O'clock positions. To establish the minimum thickness on the girth weld, four measurements shall be taken on apex on the weld at 3, 6, 9 & 12 O'clock positions. All such measurements shall be recorded. Company Representative reserves the right to ask for additional measurements at any location on the field joint coating, whenever doubt arises.

5.4

Peel Strength Testing

5.4.1 One out of every 50 joint coatings or one joint coating out of every day's production, whichever is stringent, shall be tested to establish the peel strength on steel and factory applied coating. Contractor shall carry out such testing in the presence of Company Representative. 5.4.2 From each test sleeve selected as above, one or more strips of size 25rnrn x 200 mm shall be cut perpendicular to the pipe axis and slowly peeled off. The required peel strength shall meet the requirements of this specification as applicable for (+)23 0C or (+) 60 0C whichever is feasible. This test shall be conducted between wrapping & metal and mill coating & between layers at overlap with joint coating (wherever applicable). After removal of strip, the bulk of adhesive shall remain adhered to the pipe showing no bare metal, otherwise, test shall be considered failed. The adhesive layer that remains on the pipe surface shall generally be free of voids resulting from air or gas inclusion. In case the peel strength test at a different temperature than that specified is warranted due to the ambient site conditions, then the peel strength shall comply the recommendation of the manufacturer. Manufacturer shall be asked to furnish peel strength values corresponding to various expected temperatures, prior to start of the works.



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5.4.3 If the sleeve does not meet the requirements of clause 5.4.2, the adjacent two sleeves shall also be tested. If the adjacent two sleeves are acceptable the test rate shall be increased to one sleeve every twenty five until Company's Representative is satisfied. The test rate can then be reduced as per clause 5.4.1 at discretion of Company's Representative. If either or both of the adjacent two sleeves do not meet the requirements of clause 5.4.2, the field coating shall be stopped. 5.4.4 Company Representative reserve the right of 100% removal of sleeves if he is not convinced that the requirements of clause 5.4.2 are achieved. 6.0

REPAIRS

6.1

If a field joint is detected to be unacceptable after testing as per section 5.0 of this specification the Contractor shall, at his own cost: (i) (ii) (iii) (iv)

Determine the cause of the faulty results of the field coating. Mobilise the expert of manufacturer, if required. Test to the complete satisfaction of Company, already completed field coatings. Stop the field coating works until remedial measures are taken against the causes of such faults, to the entire satisfaction of the Company.

6.2

Contractor shall replace all joint coating found or expected to be unacceptable as per section 5.0 of this specification.

6.3

Contractor shall, at his own cost repair all areas where the coating has been removed for testing by the Company.

6.4

After the coating work on welded joints and repairs to the coating have been completed the coating as a whole shall be tested with a spark-tester before lowering or jacking the pipeline.

6.5

Company shall be entitled to check the coating on buried pipelines or parts of pipelines with equipment such as the "Pearson Meter" and the resistance meter. If coating defects are established, the Contractor shall be responsible for excavation at such points, repairing the coating, spark testing and backfilling the excavations without extra charge.

7.0

DOCUMENTATION

7.1

Prior to procurement of coating materials, Contractor shall furnish the following information for qualification of the Manufacturer and material: a.

Complete information as per clause 3.2 and DIN EN 12068 along with descriptive technical catalogues.



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b. c.

7.2

Prior to shipment of materials from the Manufacturer's Works, Contractor shall furnish the following documents: a. b. c.

7.3

Test certificates and results of previously conducted tests, for all properties listed in clause 3.2 of this specification. Reference list of previous supplies, in last 5 years, of the similar material indicating the project details such as diameter, quantity, operating temperature, year of supply, project name, contact person and feed back on performance. Once the Company's approval has been given, any change in material or Manufacturer shall be notified to Company, whose approval in writing of all changes shall be obtained before the materials are manufactured.

Test certificates / results as per Manufacturer's Quality Control Procedure for each batch of materials. Specific application instructions with pictorial illustrations. Specific storage and handling instructions.




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STANDARD SPECIFICATION FOR CONCRETE WEIGHT COATING OF ONSHORE PIPELINES


STANDARD SPECIFICATION FOR CONCRETE WEIGHT COATING OF ONSHORE PIPELINE


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1.0

SCOPE

1.1

This specification covers the minimum requirements for the materials, application, inspection, handling and other activities for external concrete weight coating of pipelines.

1.2

This specification shall be read in conjunction with the conditions of all specifications and documents included in the CONTRACT between Company and Contractor.

1.3

Contractor shall, with care and diligency, execute the work in compliance with all laws, bylaws, ordinances, regulation, etc. and provide all services and labour, inclusive of supervision thereof, all materials, excluding the materials indicated as Company supplied materials in the CONTRACT, equipment, appliances or other things of whatsoever nature required in or about the execution of the work, whether of temporary or pemanent nature.

1.4

Unless otherwise specified, all sections of this specification shall apply to all the specification referred in this specification.

2.0

REFERENCE DOCUMENTS

2.1

Reference has been made in this specification to the latest edition (edition enforce at the time of issue of enquiry) of the following codes and specifications: IS-269

:

Indian Standard Specification for Ordinary Portland Cement.

IS-383

:

Indian Standard Specification for Coarse And Fine Aggregates From Natural Sources For Concrete.

IS-2386 (Parts-I

:

Indian Standard Methods of Test for Aggregates for Concrete. thru' VIII)

IS-8 1 12

:

Indian Standard Specification for High Strength Ordinary Portland Cement.

ASTM A-82

:

Specification for Steel Wire, Plain, for concrete Reinforcement.

ASTM A-1 85

:

Specification for Steel Welded Wire Fabric, Plain, for Concrete Reinforcement

ASTM A-64 1

:

Specification for Zinc Coated (Galvanized) Carbon Steel Wire.




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ASTM C-39

:

Test Method for Compressive strength of cylindrical concrete specimens.

ASTM C-138

:

Test Method for Unit weight, Yield and Air Content of Concrete.

ASTM C-309

:

Specification for Liquid Membrane Forming Compounds for Curing Concrete.

ASTM C-642

:

Test Method for Specific Gravity, Absorption and Voids in Hardened Concrete.

In case of conflict between the requirements of this specification and that of the above referred codes and standards, the requirements of this specification shall govern. The Contractor shall be familiar with the requirements of these documents and shall make them readily available at the coating plant. 2.2

For the purpose of this specification, the following definition shall hold: -

3.0

the words 'Shall' and Must' are mandatory; the words 'Should', 'May' and 'Will' are non-mandatory, advisory or Recommended.

MATERIALS The Contractor shall supply all the materials necessary for the performance of the work. Materials for concrete weight coating shall comply with the following requirements. All the materials supplied by the Contractor, which in the opinion of Company's Representative / Inspector, do not comply with the appropriate specifications, shall be rejected and removed from the site.

3.1

Cement Portland Cement (conforming to IS-269), or High Strength Ordinary Portland Cement (conforming to IS-81 12) shall be used. Cement which has hardened or partially set or which has become lumpy shall not be used. Test certificates form the cement Manufacturer shall be supplied to the Company for all cement delivered to site. In case concrete weight coating is to be provided at locations affected by sea water tidal flats etc., Portland cement in accordance with ASTM C-150 Type III shall be used.

3.2

Aggregates




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3.2.1 Aggregates shall comply with the requirements of IS:383 and shall be tested in accordance with IS:2386. 3.2.2 Fine Aggregates 'Fine Aggregates' shall mean any of the following, as defined in IS:383: i) ii) iii) Sand

Natural sand; Crushed stone sand; Crushed gravel sand. shall be well graded from fine to coarse in accordance with Table 4 of IS:383.

3.2.3 Coarse Aggregates Use of coarse aggregates shall be subject to Company approval. 3.2.4 Aggregates (fine and coarse) shall be clean and free from clay and injurious amounts of salt, alkali, deleterious substances or organic impurities. 3.3

Water The water shall be fresh and clean and shall be free from injurious amounts of oils, acids, alkalis, salts, sugar, organic materials or other substances that may be deleterious to concrete or steel. It shall not contain chlorides, sulphates, and magnesium salts. Water from each source shall be tested prior to its use and shall be approved by Company. Seawater or contaminated water shall not be used. Water from doubtful sources shall be tested by the Contractor at his expanse and approved by Company before use.

3.4. Reinforcement Concrete coating shall be reinforced by a layer or layers of steel reinforcement according to the provisions hereinafter described. 3.4.1

Reinforcement shall consist of welded steel wire fabric manufactured in flat sheets or in rolls (ribbon mesh) and shall conform ASTM A-185. Wires shall conform to ASTM A-82.

3.4.2 Steel wire shall be galvanised at finished size as per ASTM A-641. The diameter of the wire and spacing of wires (mesh dimensions) shall be selected according to the following criteria. 3.4.2.1 Wire fabric manufactured in flat sheets shall be 2 x 4 inches max. Steel wire mesh, 13 gauge U.S. Steel wire (2.4 mm) min. each way.




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3.4.2.2 Wire fabric manufactured in rolls (ribbon mesh) shall be 1 x 2.5 inches of 14 gauge U.S. Steel wires (2mm wire). The above dimensions will be applied unless otherwise specified by designs. As a rule wire fabric (sheets) shall be used when concrete coating is applied by casting method, while ribbon mesh (rolls) shall be used when concrete coating is applied by impingement method. 4.0

COATING REQUIREMENTS Pipes shall be concrete coated to a thickness and density as specified in the drawings and CONTRACT documents. The concrete unit weight shall be minimum 2245 kg/m3 (140 pounds per cubic foot) and the compressive strength shall not be less than 200 kg/cm2 in 28 days and 135 kg/cm2 in 7 days. Concrete coating shape shall be circular and concentric to pipe outside diameter. Other concrete coating shapes are not acceptable.

5.0

APPLICATION METHOD Concrete coating shall be applied either using casting or impingement method. Any alteration or modifications to the methods described in this specification shall be submitted to theCompany for approval. The application method shall however ensure the basic characteristics of concrete coating in compliance with the minimum requirements of this specification. Contractor shall submit to the Company, prior to commencement of work, the Procedure / method of application for approval. Wherever practical, the total thickness of coating shall be applied in a single pass.

6.0

EQUIPMENT The equipment used for performing the concrete coating shall be capable of doing so with a required degree of uniformity with respect to thickness, density and strength. The proportioning equipment and procedure shall be of the type to assure consistently proportioned material by weight. Concrete shall be mixed in a mechanical mixer, which shall ensure thorough mixing of all materials. Any equipment that tends to separate the ingredients shall not be used.

7.0

MEASUREMENTS AND LOGGING

7.1

All measurements as mentioned below shall be taken during the work stages and clearly logged in a logbook. A special logbook shall be used for recording tests and trial results. A logbook shall refer to pipe lengths having the same nominal diameter, and steel wall thickness.

7.2

The following shall be subject to measurement and logging for each pipe length : GAIL (INDIA) LTD NEW DELHI



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a)

Line Pipe 1) Field identification number * 2) Mill serial number * 3) Length * 4) Weight * 5) Outside diameter, mm & Wall Thk, mm

b)

(F) (M) (L) (BW) (OD) / (WT)

Corrosion coating ** 6) Type of coating ** 7) Thickness of corrosion coating, mm 8) Weight of coated pipe, kg ** 9) Presence of anode (Yes or No) ** 10) Date of Corrosion Coating Application

c)

(C) (CT) (CW) (A) (DCC)

Concrete Coating 11) Batch identification number 12) Date of placing the concrete coating 13) Average concrete coating thickness, mm 14) "Dry Weight" of concrete coated pipe (Weight and date of weighing or Related Weight 28 days after placing of concrete and so identifiable) 15) "Unit dry weight" of concrete coated pipe 16) "Negative Buoyancy" (unit) of concrete (NB) Coated pipe

(B) (T) (CCT) (DW)

(UDW)

*Data can be obtained from Pipe Mill tally Sheets. ** Data can be obtained from Coating Plant Tally Sheets. 7.3

No concrete placing shall be allowed before items 1 through 10 listed at clause 7.2, have been logged.

8.0

PROCEDURE QUALIFICATION Before commencement of the work, Contractor shall perform all tests, either in laboratory or in field and trials necessary to properly select type of mix, which meets the requirements of this specification.

8.1

The type of mix, i.e. the correct combination of the cement, aggregates and water which results in the desired properties of concrete shall be at first determined for each mix and following shall be accurately checked and recorded: GAIL (INDIA) LTD NEW DELHI



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- proportion and weights of the respective materials used; - the water / cement ratio; - the grading of the aggregates. 8.2

Samples shall be prepared and tested in accordance with ASTM C-642 to determine the dry specific gravity of the concrete. In parallel, test according to ASTM C-138 shall be performed so as to determine the expected correlation between concrete weight after placing and dry specific gravity (28 days after placing). Test for concrete specific gravity at Intermediate time (7 days after coating) shall be performed.

8.3

When the results of the above tests do not meet the requirements, the mix shall be modified and concrete samples tested until a proper mix has been determined.

8.4

The mix so determined, shall then be used for sampling of concrete to be submitted to compressive strength tests as per ASTM C39.

8.5

Frequency of sampling for tests for density and compressive strength of concrete shall be as follows: “Quantitv" of Concrete in the Work (m3)

Number of Samples

Upto 25 26 to 50 5 1 and above

3 4 4

plus one additional sample for each additional 50 m3 or part thereof.

'Quantity' means the volume of concrete to be used for each qualified mix. 9.0

APPLICATION OF REINFORCEMENT AND CONCRETE COATING

9.1

Two test cubes each per day shall be obtained from batches and tested at the end of 7 days after coating, for compressive strength and specific gravity.

9.2

The moisture content of the aggregates used shall be such as to maintain a satisfactory control on the water / cement ratio of the concrete mix. To maintain the waterlcement ratio constant at its correct value, determination of moisture contents in both fine and coarse (if used) aggregates shall be made as frequently as possible, the frequency for a given job being determined by the Engineerin-Charge according to weather conditions.




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9.3

Pipe Length Preparation Prior to placing of reinforcement, the anti-corrosion coating of each pipe length shall be carefully inspected visually and by holiday detectors and, if damages are found, they shall be repaired in accordance with the relevant specification, before start of the work. Foreign matters, if any, shall be removed from the surface of the anti-corrosion coating.

9.4

Reinforcement Application

9.4.1 Reinforcement shall be placed around the pipe in such a way as to cover the whole pipe length or sections to be concrete coated. The reinforcement shall not protrude beyond the concrete coating ends. 9.4.2 Reinforcement shall rest on synthetic resin or concrete/ RCC spacers forming a "Crown" whose number shall be such as to avoid any contact with the pipe's protective coating. Spacing between the two consecutive "crown" centres shall be 500 to 1000 mm. 9.4.3 Splices and attachments shall be done by binding with steel wire having 1.5 mm diameter. Circular and longitudinal joints of wire fabric in sheets shall be lapped at least for one mesh. When wire fabric in rolls (ribbon mesh) is used, the spiral lap shall be one mesh while and spliced lap shall be three meshes. 9.4.4 One layer of reinforcement steel shall be provided for concrete thickness less than 50 mm. The reinforcing steel shall be embedded approximately midway in the concrete coating thickness. For concrete thickness 50 mm and above two layers of reinforcing steel shall be provided. If application method requires more than one pass concrete, one reinforcement layer for each pass is to be applied independently from concrete coating thickness. In case of one layer of reinforcement, it shall be located approximately in the middle of the concrete thickness. In case of two layers of reinforcement, layers shall be located at 1/3rd and 2/3rd of the concrete thickness. In case of three layers of reinforcement, layer shall be located at 1/4th , 1/2 and 3/4th of concrete thickness. Contractor shall demonstrate that the procedure used ensures no physical contract between steel reinforcement and the pipe and the reinforcement is placed in position as mentioned above. 9.5

Concrete Placing

9.5.1 Concrete shall be placed within a maximum of 30 minutes from the time of mixing (i.e. after adding water to mix) and shall be handled in such a way so as to prevent




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aggregate segregation and excessive moisture loss. Concrete containers shall continuously be kept clean and free from hardened or partially hardened concrete. 9.5.2 If casting method is used, once reinforcement and mould have been applied around the pipe, concrete mixture shall be poured through an opening on the upper section of the same mould. Concrete shall not be deposited from a height greater than 1 metre. During pouring of concrete, vibrator sets applied inside of pipe or outside the mould shall vibrate the mix so as to obtain the best possible compactness. 9.5.3 If impingement method is used, placement of concrete shall be up to the specified thickness in one continuous course, allowance being made for splices of reinforcement and providing reinforcement in the right location. Concrete shall be projected at high velocity against the external surface of pipe, to produce a hard, tight-adhering coating of the specified thickness. 9.5.4 No casting shall be interrupted or passes shall be stopped for more than 30 minutes. Before placing fresh concrete against the joint, the contact surfaces shall be carefully cleaned and wetted to obtain a good bond between the fresh material and the previously placed material. 9.5.5 Suitable means shall be provided to ensure that the temperature of the concrete, when placed, does not exceed 32°C. 9.5.6 All pipes shall be kept clean and free from cement concrete and grout either inside or outside of the uncoated sections. 9.5.7 Bevel protectors shall be kept in place throughout the coating application and after. 9.5.8 The coating at each end of the pipe shall be bevelled to a slope of approximately twoto-one (2: 1). It shall terminate about 50 mm short of the end of the corrosion coating applied on the pipe surface. 9.6

Curing

9.6.1

Immediately after concreting, the exposed surfaces of the concrete shall be protected during hardening from the effects of sunshine, drying winds, rain, etc. and then after the initial set has taken place, the concrete coating shall be properly cured. The coated pipe sections shall be handled gently by suitable means to prevent undue distortion.

9.6.2 Curing shall be performed by application of an approved curing membrane using sealing compounds and shall meet the requirements of ASTM C-309. The material shall be stored, prepared and applied in strict conformity with the instructions of the Manufacturer. The ingredients of any such compound shall be non-toxic and noninflammable and shall not react with any ingredient of the concrete, the reinforcement, protective coating or pipe. The application of the curing compound shall take place GAIL (INDIA) LTD NEW DELHI



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immediately after the coating is completed and preferably before the pipe is removed from the concrete coating apparatus. The surface of the concrete shall be lightly sprayed with water before applying the curing compound. The membrane curing period shall not be less than 4 days, during which period the freshly coated pipes shall not be disturbed. The pipe surface shall be kept wet during daylight hours for seven days after application of the concrete coating. The concrete coating shall not be allowed to dehydrate. Curing of concrete coating may also be done by using jute bags, provided continuous wetting is ensured by the Contractor. 9.6.3 Before handling and hauling the concrete coated pipes, a check shall be made to make sure that the concrete coating is properly cured. Stacking and shipment of the coated pipe shall be initiated only after seven days provided that the concrete coating suffers no damage. 10.0 TOLERANCES 10.1

Contractor shall maintain a surface tolerance of 8 mm (5/16") maximum for the radial distance between high and low areas of the surfaces. The diameter of each coated pipe shall be obtained at three (3) or more points, spaced at equal intervals between the end points.

10.2

The acceptable weight tolerance for any single pipe shall be limited to plus five (5) or minus two (2) percent of the calculated theoretical weight. The theoretical weight shall be calculated using total weight of the pipe with concrete and corrosion coating.

11.0 WEIGHING 11.1

The test specimen shall be selected at equal intervals during the course of production.

11.2

Contractor shall weigh each pipe when dry prior to shipment and 28 days after placing of concrete and mark the weight with paint on the inside of the pipe. The weight mark shall be followed with letters "DW" meaning Dry Weight. In case contractor opts not to weigh the pipe, the contractor shall provide 20% extra concrete coating thickness over the specified concrete thickness at no extra cost and time to Company.

11.3

The acceptable weight tolerance of any single pipe shall be limited to +5% or -2% of the calculated weight of concrete. Calculated weight shall consider only the weight of concrete coating based on approved concrete density and thickness.




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In case Contractor opts not to weigh the pipes, the Contractor shall provide 20% extra concrete coating thickness over the specified concrete thickness at no extra cost and time to Company. 12.0 INSPECTION AND TESTS 12.1

After curing, every length of concrete coated pipe shall be non-destructively tested by means such as "ringing" to determine if any suspected defects are present. In case this indicates faulty coating, cores shall be removed form coating and inspected. When defective coating appears from cores, the concrete costing shall be removed from the pipe lengths.

12.2

Every length of concrete coated pipe shall be checked to verify insulation between steel reinforcement and pipe by means of a megger or equivalent device. To this purpose provisions should be made during placing of concrete such as to leave at least a point of exposed steel reinforcement whenever the latter shall terminate inside of concrete coating.

12.3

During the tests as per clause 12.2 above, and before transporting of concrete coated pipes, every pipe length shall be visually inspected to detect whether any damages and / or defects are present. Possible damages and/or defects with their allowable limits are described at following clause 14.0. Repairable concrete coatings shall be clearly marked while the non-repairable once shall be removed from the pipe lengths.

13.0 REPAIRS The following repairs are permitted to coating due to unavoidable damage in handling and in storage (This applies only to concrete that has hardened). 13.1

Spalling due to compression or shearing caused by impact against other objects. Spalling is defined as damage, which causes a loss in concrete of more than 25 % of the total thickness of the coating at the point of damage.

13.2

Damage due to spalling of an area of less than 0.1 m2 (1 square foot) where the remaining concrete is sound and reinforcement steel is not exposed, will be accepted without repairs.

13.3

Damage due to spalling of an area of less than 0.1 m2 with reinforcement exposed; and area more than 0.1 m2 and less than 0.3 m2 shall have the concrete remaining in place over that area removed as necessary to expose the reinforcing steel throughout the damaged area. Edges of the spalled area shall be under-cut so as to provide a key lock for the repair material. A stiff mixture of cement, water and aggregate shall be trowelled into and through the reinforcement and built up until the surface is level with the coating around the repair. The pipe shall then be carefully laid with the repaired




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area at the top and shall be moist cured for a minimum of thirty six (36) hours before further handling. 13.4

Should the damaged area be more than 0.3 m2, coating shall be removed around the entire damaged area. A repair shall be made by satisfactorily restoring the reinforcement, forming the area with a metal form and pouring a complete replacement of materials similar to that from which the coating was made. The mixture shall be one (1) part of cement to three (3) parts of aggregate and the necessary water to produce a slump not to exceed 100 mrn (four inches). The resulting coating shall be equal in weight, density, uniformity, thickness, strength and characteristics to the originally applied coating. The pipe shall then be carefully laid in a position where it shall be allowed to remain for a minimum of 36 hours before furtherhandling.

14.0 MARKING 14.1

Every concrete coated pipe length shall be clearly marked by a suitable type of paint (i.e. red and/or white lead paint). Markings of concrete coating shall be made inside of pipe close to bevel end, in such a way that the area involved by welding operations is not affected by paint.

14.2

For each concrete coated pipe length, at one of the two ends, the field identification number and the date of concrete placing shall be marked, while the dry as well as the wet weight along with number of days after coating shall be marked at the other end. In addition, Contractor shall develop a colour coding (band) system to be marked on the outside surface for easy identification of the coated pipe for each concrete coating thickness, concrete density, pipe diameter, pipe thickness and pipe material variation.

15.0 HANDLING, UNLOADING, STORING AND TRANSPORTATION 15.1

Once the pipe sections have been taken on charge, the Contractor, complying with provisions of the CONTRACT, shall execute their transport together with other material, either supplied by him or by the Company, from the site of receipt to the coating yard and after concrete coating completion and acceptance, to delivery point at laying field or storage areas as previously established providing each time the necessary storages.

15.2

Materials other than pipes and which are susceptible of deteriorating or suffering from damages especially due to humidity or other adverse weather conditions, shall be suitably stored and protected.

15.3

During loading, transport, unloading and hauling of inert aggregates, any contact and mixing with mud, earth, grease and any other foreign material shall be carefully avoided. Precautions shall be taken to prevent contamination, to maintain the cleanliness and against effects of hot or cold weather or other adverse climatological condition.




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15.4

During the operations of loading, unloading and stock-piling, the pipe sections shall be handled in such a way so as to avoid dents, cuts, cracks and other damages especially at bevelled ends or damages to protective and / or concrete coating.

15.5

Stacks shall consist of a limited number of layers such that the pressure exercised by the pipes own weight does not cause damage to coating. Stacking with more number of layers shall be agreed upon with the Company provided that each pipe section is separated by means of spacers suitably spaced so as to avoid stresses and compressed points of contact on the coated surfaces.




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STANDARD SPECIFICATION FOR REPAIR OF POLYETHYLENE COATING




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1.0

SCOPE This specification covers the minimum requirements for materials and equipment, application procedure and inspection of repair of damaged Polyethylene coatings on steel pipes. The repair shall be carried out using repair patch made of radiation cross-linked polyolefin backing, coated on the inside with semi-crystalline thermoplastic adhesive and filler mastic. The repair patch shall have thermal indicators to ensure correct heat is being applied during application.

2.0

MATERIAL AND EQUIPMENT

2.1

The repair material shall be as under: a)

Repair Patch: radiation cross-linked polyolefin with semi-crystalline thermoplastic adhesive (PERP80 of make Covalence Raychem or equivalent).

b)

Filler Mastic: PERPFILLER of make Covalence Raychem or equivalent.

c)

PERP melt stick of make Covalence Raychem or equivalent

2.2

The repair material shall be certified by DIN to meet the requirements of EN12068 Stress Class CHT 80

2.3

The material shall not be older than their period of validity at the time of application by the Contractor. Deteriorated / decomposed materials shall not be used.

2.4

Materials shall be stored in sheltered storages in the manufacturer's original packing away from direct sunlight and in accordance with manufacturer's instructions.

2.5

Contractor shall supply all equipment and manpower required for a skillful application in the field in accordance with the specification.

3.0 APPLICATION PROCEDURE 3.1

The application procedure to be followed for holiday type of damage shall be in accordance with manufacturer's instruction and minimum requirement specified below whichever are the more stringent.

3.1 .1 Preparation




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Remove coating from damaged area with knife, scraper or power brush. Scrap off the damaged area and adjacent coating to remove oil, grease, rust, dirt and moisture. 3.1.2 Preheating Preheat the exposed bare metal surface to approx. 80" C and adjacent pipe coating to approx. 600 C with a torch moved back and forth over the surface. 3.1.3 Application of the Filler Plastic filler shall be cut to size and applied to all exposed metal surface. The mastic shall be heated and smoothed down with a paint scraper to cover all bare metal in a manner such that all entrapped air is removed. 3.1.4 Application of repair tape A patch shall be cut from the tape in a manner such that it extends 50 mm (2 inch) beyond the damaged area on all sides. The patch shall be positioned over the damaged area and heated until the temperature sensitive paint on the outside of the patch changes colour or dimples on the backing vanish. It shall be smoothed down to confirm with the contour of lap, and shall be freed of any air bubbles or wrinkles. 3.2

For cosmetic type of defects such as minor gouging, tearing, andlor scratches, which do not indicate holiday during holiday inspection, following procedure shall be adopted.

3.2.1 The defective area shall be roughened to remove loose polyethylene coating, oil, grease, dirt, etc. 3.2.2 This shall be followed by application of patch as detailed in clause 3.1.4 4.0

INSPECTION AND TEST

4.1

A visual inspection shall be carried out for the following:

4.2

-

Mastic extrusion on ends of the patch shall be examined

-

There shall be no sign of punctures or pinholes or bend failure. The external appearance of the patch shall be smooth, free from dimples, air entrapment or void formation.

-

The entire closure patch shall have changed colour uniformly.

Holiday lnspection




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The holiday detector used shall be checked and calibrated daily with an accurate D.C. Voltmeter. The detector electrode shall be in direct contact with the surface of coating to be inspected. The entire surface of the repaired section shall be inspected by means of a full circle holiday detector approved by Owner set to a D.C. Voltage of at least 25 KV. Inspection of repaired patch shall be conducted only after it has cooled below 500 C. 4.3

Procedure qualification shall be carried out for repair patch. The value for peel strength to pipe surface and to factory coating carried out as per EN 12068 shall be 0.5 N/mm minimum at 60°C.

4.4

All repaired joint shall be approved by the Owner.

5.0

DOCUMENTATION

5.1

Prior to procurement of coating repair materials, Contractor shall furnish four copies of, but not limited to, the following for qualification of the Manufacturer and material:

i)

Complete descriptive technical catalogs describing the materials offered along with samples of repair coating materials, its properties and installation instruction as applicable specifically to the project.

ii)

Test certificate and results of previously conducted tests from independent inspection agency, for properties listed in Para 4.3 of this specification.

iii)

Reference list of previous supplies of the similar material indicating the project details such as diameter, quantity, service conditions, year of supply, project name, contact person and feed back on performance.

Once the Company's approval has been given, any change in material or Manufacturer shall be notified to Company, whose approval in writing of all changes shall be obtained before the materials are manufactured. 5.2

5.3

Prior to shipment of materials from the Manufacturer's works, Contractor shall furnish six copies of the following: i)

Test certificates for each batch of materials,

ii)

Specific installation instruction with pictorial illustrations

iii)

Specific storage and handling instructions.





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SPECIFICATION FOR QUICK OPENING END CLOSURE


STANDARD SPECIFICATION FOR QUICK OPENING END CLOSURE


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CONTENTS SI.No.

Description

1.0

SCOPE

2.0

REFERENCE DOCUMENTS

3.0

MATERIALS

4.0


5.0


6.0

TEST CERTIFICATES

7.0


8.0

GUARANTEE

9.0

SPARES

10.0

DOCUMENTATION




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SCOPE This specification covers the minimum requirements for design, manufacture, testing and supply of quick opening end closures to be installed at various blow-down points/ lines handling non-sour hydro carbons in gaseous phase. 1.0

REFERENCE DOCUMENTS Reference has been made in this specification to the latest edition (edition enforce at the time of issue of enquiry) of the following codes, standards and specifications: a)

ASME B 31.8

:


b)

ASME B 16.25

:

Butt - Welding Ends

c)

ASME Sec. VIII

:

Boiler and Pressure Vessels Code- Rules for the Construction of Pressure vessels

d)

ASME Sec. IX

:

Boiler and Pressure Vessels Code-Welding and brazing qualifications.

e)

API 6H

:

Specification on End closures, Connectors and Swivels

f)

API 1104

:

Specification for Welding Pipeline and Related Facilities

g)

SSPC-VIS-1

:

Steel Structures Painting Council

In case of conflict between the requirement of this specification and the requirements of above referred documents, the requirements of this specification shall govern. 3.0 MATERIALS 3.1 Carbon steel material used in the manufacture of pressure containing parts of quick opening enclosure shall be fully killed. In addition, the material shall also meet the requirements specified herein. The minimum SMYS of the material of pressure containing part of the closure shall be 35,000 psi. Other components shall be as per Manufacturer’s Standard. However, all the materials used shall be suitable for the service Conditions indicated in the Data Sheets, which will be subject to approval by Purchaser. GAIL (INDIA) LTD NEW DELHI



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3.2 Material of the ends to be field welded by Purchaser shall have carbon equivalent not more than 0.45 based on check analysis, for each heat of steel used, calculated as per the following formula: Mn CE = C + ------ + 6

Cr+Mo+V Ni+Cu ---------------- + ----------5 15

3.3 For quick opening end closures specified to be used for Gas service and LPG service, Charpy V-notch test shall be conducted at 00C on each heat of carbon steel material used in manufacture of quick opening end closures. Test procedure shall conform to ASTM A 370. The average absorbed impact energy values of three full-sized specimens shall be 27 Joules. The minimum impact energy value of any one specimen of the three specimens analyzed as above, shall not be less than 22 Joules. When Low Temperature Carbon Steel (LTCS) materials are specified in Data Sheet or offered by Manufacturer, the Charpy V-notch test requirements of applicable material standard shall be complied with. 3.4 For quick opening end closures specified to be used for Gas service and LPG service, hardness test shall be carried out as per ASTM A 370 for each heat of steel used in the manufacture of pressure containing parts of traps. A full thickness cross section shall be taken for this purpose and the maximum hardness of base metal, weld metal and HAZ of all the pressure containing parts shall not exceed 248 HVlo. 4.0 DESIGN AND CONSTRUCTION 4.1 End closure shall be designed in accordance with the provisions of ASME B 31.8 and ASME Sec. VIII Division 1. Design factor and corrosion factor shall be as indicated in the data sheet. 4.2 Diameter, thickness, material, ANSI rating of the pipeline with which the end closure to be welded shall be as indicated in the Data Sheets. End closure supplied shall be suitable for the same. 4.3 The quick opening end closure shall be of clamp ring/ band lock type or equivalent design and shall consists of a safety pressure release system allowing the opening only when there is no pressure in the trap. End closure shall be hand operated by a single lever operation and operable by one operator. Screwed type or plug -in type of end closures are not permitted. 4.4 End closure shall be suitable for installation in vertical position at an elevation of 2.0 meters above ground level. 4.5 The handing device shall be attached to the welding end hub, which shall be suitable for such attachment. GAIL (INDIA) LTD NEW DELHI



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4.6 End closure shall be provided with a butt-welding end for direct welding with the pipeline. The weld end shall be prepared in accordance with ASME B 31.8. 4.7 All welds shall be made by welders and welding procedures qualified in accordance with the provisions of ASME Sec. IX. The procedure qualification shall also include impact test and hardness test as per clause 3.3 and 3.4 of this specification and shall meet the requirements as specified therein. 4.8 Completed assembly shall be stress relieved as per the provisions of the design codes. 4.9 The tolerance on internal diameter end out of roundness shall be as per connected pipe specifications indicated in the Data Sheet. 4.10 When closed, the closure shall provide a positive seal without any leakage. Gaskets or seals when provided for this purpose shall be self sealing and suitable for the service condition indicated in Annexure-I & Data Sheets. 5.0 INSPECTION AND TESTS 5.1 Manufacturer shall perform all inspection and tests as per the requirements of this specification and the relevant codes, standards and specifications, prior to shipment at his Works. Such inspection shall be, but not limited to, the following: 5.1.1 All closures shall be visually inspected. The internal and external surfaces shall be free from any strikes, gouges and other detrimental defects. The surfaces shall be thoroughly cleaned and free from dirt, rust and scales. 5.1.2Chemical composition and mechanical properties shall be checked as per relevant material standards and this specification, for each heat of steel used. 5.1.3Dimensional check shall be carried out as per the approved drawings. 5.1.4 Hydrostatic test shall be conducted for all end closures complete in all respects, at a pressure equal to 1.25 /1.4 times the design pressure for liquid / gas service as indicated in data sheet. Test duration shall be 15 minutes. 5.1.5 All butt welds shall be 100% radiographically inspected. Procedure and acceptance criteria shall be as per API 1104. 5.1.6 Welds, which cannot be radiographically inspected, shall be inspected by ultrasonic or magnetic particle methods. Procedure and acceptance criteria shall be as per ASME Sec. VIII, Appendix-U and Appendix VI respectively. 5.1.7 All finished wrought weld ends shall be ultrasonically inspected for lamination type defects for a distance of 50 mm from the end. Any lamination larger than 6.35 mm shall not be acceptable.




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5.1.8 A minimum of two Closing and opening cycles shall be performed and correct operation of both quick opening and safety system shall be established. 5.2

Company inspector reserves the right to perform inspection and witness tests including hydrostatic test, as indicated in clause 5.1 at Manufacturer’s works prior to shipment. Manufacturer shall give reasonable notice of time and shall provide without charge reasonable access and facilities required for inspection, to the Company’s inspector. Only those closures, which have been inspected and certified by Company’s Representative, shall be shipped. Inspection and tests performed / witnessed by Company's Inspector shall in no way relieve the Manufacturer's obligation to perform the required inspection and tests.

6.0

TEST CERTIFICATES Manufacturer shall furnish the following certificates: a. Test Certificates relevant to chemical and mechanical properties of the material used as per the relevant standards. b. Hydrostatic test certificates. c. Report on Non-Destructive examination. d. Certificate of satisfactory performance of end closure as per Clause 5.1.8.

7.0


7.1

After all inspection and tests required have been carried out, the exterior surface of Quick Opening End Closures shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion resistant paint. Manufacturer shall indicate the type and corrosion resistant paint used in the drawings submitted for approval.

7.2

Marking shall be done on a stainless steel plate and affixed to the body permanently. Marking shall include the following: a. Manufacturer's Name b. Suitable for --------- Dia x ---------- Thick Pipeline. c. ANSI Rating d. Tag Number




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7.3

Before shipment, closures shall be properly packed against damage during transportation. Suitable protection shall be provided for the weld ends.

8.0

GUARANTEE

8.1

Manufacturer shall guarantee that the closure along with the davits is in compliance with the requirements of this specification for material and workmanship. Manufacturer shall replace or repair all parts which should result defective due to inadequate engineering of quality of material or workmanship. In case the defect cannot be eliminated, Manufacturer shall replace the closure without any delay. Any defects occurring within the time period specified elsewhere shall be required making all necessary modifications and repair of defective parts free of charge to the purchaser.

9.0

SPARES

9.1.1

Manufacturer shall furnish list of recommended spares and accessories for Quick Opening End Closures required during start-up and commissioning and supply of such spares shall be included in the price quoted by Manufacturer.

9.1.2

Manufacturer shall furnish list of recommended spares and accessories required for two years of normal operation and maintenance of Quick Opening End Closures and price for such spares shall be quoted separately.

10.0

DOCUMENTATION Documentation to be submitted by Manufacturer to Company is summarized below. Number of Copies (Hard copies / soft copies etc.) shall be as indicated in CONTRACT document.

10.1

At the time of bidding, Manufacturer shall submit the following documents: a) General arrangement drawing of end closure with overall dimensions and crosssectional drawings. b) Clause wise list of deviations from this specification, if any. c) Reference list of similar previous supplies. Reference list of similar supplies of Quick Opening End Closures shall be furnished including project, Year of supply, Client, Size, Rating and Service for the last five years. d) Quality Control Manual and Quality Control Plan.




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e) List of recommended spares and accessories required during start-up and commissioning. f) List of recommended spares and accessories required for 2 years of normal operation and maintenance. 10.2

Within three weeks of placement of order, the Manufacturer shall submit the following drawings, documents and specifications for approval: a. Design calculations according to relevant codes for the end closure. b. Closure assembly and sectional drawings showing all parts with materials and dimensions. c. Welding procedure and method of manufacture. Once the above-mentioned documents have been approved by the Company, any change in design, material and method of manufacture shall be notified to the Company, whose approval in writing of all changes shall be obtained before the closures are manufactured.

10.5

Within four weeks from the approval date, Manufacturer shall submit the approved drawings, documents and specifications listed in Clause 9.2 of above.

10.6

Prior to shipment, the Manufacturer shall submit the following: a. Test certificates as listed in Clause 6.0 of this specification. b. Manual for installation, erection instructions, maintenance and operation instructions.

10.7





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STANDARD SPECIFICATION FOR PIPELINE RIVER CROSSINGS USING DIRECTIONAL DRILLING METHOD


STANDARD SPECIFICATION FOR PIPELINE RIVER CROSSING USING DIRECTIONAL DRILLING METHOD


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CONTENTS 1.0

SCOPE

2.0

DESIGN AND ENGINEERING

3.0

CONSTRUCTION

4.0

DOCUMENTATION




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1.0

SCOPE:

1.1

This specification covers the minimum requirements for various activities to be performed by the CONTRACTOR for the engineering and construction of pipeline river crossings using directional drilling method.

1.2

This specification shall be read in conjunction with the requirements all specifications and documents included in the CONTRACT between COMPANY and CONTRACTOR.

1.3

CONTRACTOR shall, execute the work in compliance with laws, by-laws, ordinances and regulations. CONTRACTOR shall provide all services, labour, inclusive of supervision thereof, supply of all materials, (excluding "COMPANY supplied Materials ") equipment, appliances.

1.4

CONTRACTOR shall take full responsibility for the stability and safety of all operations and methods involved in the work.

1.5

CONTRACTOR shall be deemed to have inspected and examined the work area and its surroundings and to have satisfied himself as far as practicable with sub-surface conditions, hydrological and climatic conditions, the extent and nature of the work and materials necessary for the completion of the work, and the means of access to the work area.

1.6

CONTRACTOR shall be deemed to have obtained all necessary information with regard to risks, contingencies and all other circumstances, which may influence the work.

1.7

CONTRACTOR shall, in connection with the work, provide and maintain at his own costs all lights, guards, fencing, as necessary or directed by COMPANY.

1.8

For the purpose of this specification, the following definitions shall hold:   

The words 'Shall' and 'Must' are mandatory. The words 'Should, May and Will' are non- mandatory advisory, or recommended.

2.0

DESIGN & ENGINEERING:

2.1

The minimum requirement of limits of each river crossing shall be as defined in the drawings furnished by COMPANY. CONTRACTOR may change the limits slightly to suit his equipment and installation technique, with prior written approval from COMPANY. Within the entire limits of crossing, as defined in the CONTRACT drawings, the cover to top of corrosion coated pipe shall be at least 2.5 meters below the "specified" minimum scour level profile for the river with normal soil, and at least 1.5 meters below the "specified" minimum scour level profile for the river with rock sub-strata.

2.2




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2.3

The entry and exit points of the pipeline at ground level shall not come within the limits of crossing as defined for individual river crossings.

2.4

Wherever the drilled length for a river crossing includes the crossings of other obstacles such as roads, railroads, canals, streams, etc., the following minimum requirements of cover to the pipe shall be satisfied: For Road crossing

-

1.4 m from top of road to top of pipe

For Railroad crossing

-

1.7 m from base of rail to top of pipe

For canal / stream crossing

-

1.5 m from lowest bed level to top of pipe

2.5

CONTRACTOR shall carry out calculations for determining the maximum permissible overburden on pipe, to check that the empty pipeline is safe from collapse at any point along the drilled crossing section. CONTRACTOR shall submit these calculations to COMPANY for approval.

2.6

Pipeline Axis As shown in the reference drawing at each crossing, the plane containing the pipe axis shall be perpendicular to the horizontal plane. There shall be no bending of longitudinal pipe axis at depths shallower than two meters below ground level.

2.7

Back-reamed Hole and Pipeline Interface For each crossing, CONTRACTOR shall device a suitable combination of the following: 

Back-reamed hole diameter



Bentonite density



Pipeline submerged weight in Bentonite (and means to achieve that weight)

In order to optimize the crossing design in terms of pipeline stresses and pull force requirements. CONTRACTOR shall indicate what maximum shear stress in the pipeline coating will result from his choice of above parameters and other design characteristics described in this section. CONTRACTOR shall furnish all calculations for COMPANY'S approval. If shear stress on pipe coatings is, in the opinion of COMPANY, beyond the permissible limits, CONTRACTOR shall revise his choice of parameters to reduce shear stress on pipe coating to permissible values.




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2.8

CONTRACTOR shall determine the minimum allowable elastic bend radius for pipe from the following considerations.

2.8.1 Pipeline maximum longitudinal stress during installation Total maximum longitudinal stress in the pipeline due to tension and bending at any location shall not exceed 90 % of the SMYS of the pipe material. CONTRACTOR shall, in order to check this requirement, evaluate the maximum tension forces to which the pipeline is subjected at any phase of its installation during the pulling operation. 2.8.2 Pipeline maximum equivalent stress during final hydro test After installation, the pipeline shall be hydrostatically tested to a minimum test pressure equal to 1.4 times design pressure for gas pipeline and 1.25 times design pressure for liquid pipeline. The combined equivalent stress in the pipeline due to bending and test pressure shall not exceed 90 % of the SMYS of pipe material. 2.8.3 Pipeline maximum equivalent stress during service Permissible values of pipeline maximum equivalent stress during service shall be governed by the requirements of ASME B3 1.8/B3 1.4, as applicable. 2.8.4 The minimum allowable radius of curvature for the pipeline shall be the highest value of the minimum pipeline elastic bend radius as computed from the considerations outlined in clause 2.8.1 thru' 2.8.3 above after correction for drilling inaccuracies or multiplication by the factor 1.85, whichever result in the highest permissible value of minimum elastic bend radius. 2.8.5 CONTRACTOR shall submit all calculations for COMPANY'S approval. 2.9

Pipeline Configuration Along The Supported String Before Entry Point For each crossing, CONTRACTOR shall determine the required pipeline configuration in order to allow smooth pull in the crossing entry point and admissible stress in the supported pipeline string. Pipeline combined stress shall not exceed 90 % of the specified minimum yield strength for line pipe material. CONTRACTOR shall furnish all calculations and specify the number of required supports, description of the supports, their coordinates and capacity in metric tons. CONTRACTOR shall also furnish a drawing of the launching ramp indicating the pipeline configuration. The distance between each roller shall also be specified and justified.

2.10

CONTRACTOR shall, based on results of design and engineering carried out by him, prepare construction drawings for each river crossing and shall submit the same for COMPANY'S approval. Construction drawings shall indicate the pipeline profile GAIL (INDIA) LTD NEW DELHI



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with levels furnished at sufficient intervals for proper control during construction. Other relevant details viz. entry and exit angles, radii of bends, etc. shall also be indicated. CONTRACTOR shall also calculate the total length of pipeline required as well as the maximum tension required on the pull head of the rig. All construction works shall be carried out in accordance with the construction drawings approved by COMPANY. 2.11

Before commencement of any field work, CONTRACTOR shall furnish for COMPANY'S approval all design calculations as stipulated in clause Nos. 2.5, 2.7, 2.8, 2.9 and 2.10 above and all construction drawings. COMPANY shall inform CONTRACTOR within 21 calendar days if any objection against the design requires resubmission by CONTRACTOR.

3 .O CONSTRUCTION: CONTRACTOR shall comply with all the conditions and requirements issued by Authorities having jurisdiction in the area where the work is to be performed. If no public road exists, CONTRACTOR shall arrange on his own for access to his work area at no extra cost to COMPANY. 3.1

Installation Procedure CONTRACTOR shall, before commencing any work at site, submit for COMPANY'S approval a detailed installation procedure for each river crossing. The installation procedure as a minimum shall include the following: a)

Project Organization Chart (This shall indicate CONTRACTOR'S organizational set-up at site and manpower deployment)

b)

Preparation of Fabrication Yard and Launching Areas

c)

Details of Equipment CONTRACTOR shall furnish the complete list of all equipment to the deployed for preparation of pipe string and installation of crossing. Technical characteristics and capacity of each equipment including instrumentation, monitoring and control equipment shall be furnished in details.

d)

Pipeline String Preparation Details (hauling, stringing, welding, etc.)

e)

Pre-Installation Hydrostatic Test Procedure.




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f)

Method of Installation covering all steps of construction, viz. Rig up, Pilot Hole, Back- reaming, Pulling, Rig Down, Backfilling.

g)

Calculations for Maximum Pulling Force on the rig and recommended maximum pulling velocity.

h)

Final Hydrostatic Test Procedure after backfilling.

i)

Time Schedule for construction.

COMPANY shall inform CONTRACTOR within 21 calendar days if any objection against the document and procedures described requires resubmission by CONTRACTOR. The time schedule shall be in accordance with overall time schedule for the project. Approval by COMPANY of the methods used by CONTRACTOR shall in no way relieve CONTRACTOR from the sole responsibility for safe and satisfactory installation of the crossing. 3.2

R.O.U. Preparation CONTRACTOR shall clear and grade the length of ROU required for installation of on land portion and drilled river crossing portion in his scope. CONTRACTOR shall do such grading on Right of Use to provide access to the pipeline construction and to ensure safe construction of pipeline. CONTRACTOR shall ensure that his construction activities shall not cause inconvenience to public nor there any undue interference with the normal use of the land and water courses. Minimum necessary trees on ROU to be felled shall be identified; permissions obtained, recorded and record shall be handed over to COMPANY.

3.3

Taking-over, Handling, Hauling, Storing and Stringing of pipes and other materials

3.3.1 CONTRACTOR shall receive and take-over against requisition corrosion coated line pipe from COMPANY'S designated place(s) of issue. CONTRACTOR shall be fully responsible for the pipe and pipe identification marking from the time of taking delivery from the COMPANY, until such time that the pipes are installed in permanent installation. The CONTRACTOR shall be entitled for extra compensation for repair and rectification of defects recorded at the time of taking delivery as per the rates set forth in the 'Schedule of Rates'. Repair of all damages beyond such record shall be to the CONTRACTOR'S cost. CONTRACTOR shall be fully responsible for arranging and paying for storage areas.




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3.3.2 Materials which are susceptible of deteriorating or suffering from damages especially due to humidity, exposure to high thermal excursions or adverse weather conditions, shall be suitably stored and protected. Deteriorated materials shall not be used and shall be replaced with no extra cost to COMPANY. 3.4

Pipe String Complete pipe string shall be prepared as a single string for pulling.

3.5

Repair of Pipe Corrosion Coating Repair of pipe corrosion coating shall be carried out by CONTRACTOR as per relevant specification included in the Bid Package.

3.6

Lining-Up Each length of pipe shall be thoroughly examined internally and externally to make sure that it is free from visual defects, damage, severe corrosion, dirt, animals, or any other foreign objects. Each length of the pipe shall be adequately swabbed, either by use of canvas belt disc of proper diameter or by other methods approved by the COMPANY. Damaged / corroded pipes shall be kept separate. Each length of pipe shall be pulled through just before being welded.

3.7

Pipe Defects and Repairs It is CONTRACTOR'S responsibility to repair all internal and/or external defects. Immediately prior to aligning pipe for welding, the beveled ends of each joint of pipe and the area immediately adjacent thereto (at least 25mm from the edge on the inside and outside of the pipe) shall be thoroughly cleaned of paint, rust, mill scale, dirt or other foreign matter by use of power driven wire buffing wheels, disc sanders, or by other methods approved by COMPANY. This shall be done at no extra cost. All damaged ends of pipes that are bent, cut or otherwise mutilated such that, in the opinion of the COMPANY, faulty alignment or unacceptable welding would result, shall be repaired or cut-off and re-beveled to the correct angle with a beveling machine of a type approved by COMPANY. Dents in bevels with a depth of less than 1 mm shall be removed by CONTRACTOR during cleaning and grinding, ahead of the welding in the field at no extra cost. CONTRACTOR shall re-bevel dented bevel ends with a depth of dent between 1 mm and 3mm. Dents over 3mm depth shall be repaired by cutting and rebeveling.

3.8

Welding




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Welding of the Pipeline shall be in accordance with Welding Specification and Welding Specification Charts included in the contract. 3.9

Corrosion Coating of Field weld Joints The complete field joint shall be blast cleaned to near white metal finish to Swedish Standard SIS 055900 Grade SA 2.5. The coating edges shall be suitably roughed and chamfered to provide smooth transition. The joint coating material shall be Raychem’s "DIRAX" or other COMPANY approved equivalent. The method of application shall be strictly as per manufacturer’s recommendations and will be subject to COMPANY approval prior to use. Coating of field weld joints shall be carried out after pre-installation hydrostatic testing.

3.10

Installation

3.10.1 Installation shall be carried out in accordance with approved installation procedures. 3.10.2 The lateral offset of the actual exit point of the pilot hole from the calculated and theoretical exit point shall not exceed two percent of the length of the crossing, however the actual exit point shall not come outside the ROU limits of the pipeline. The length tolerance shall not exceed one per cent of the crossing length, subject to the condition that the actual exit point shall not be within the limits of crossing as defined in the CONTRACT drawings. 3.10.3 Back reaming shall be done separately from the pipeline pulling operation. The size of the back-reamed hole shall be adequate (approximately 1.5 times the pipeline diameter) to allow enough clearance for smooth pull-back of the pipeline. 3.10.4 CONTRACTOR shall be responsible for maintaining the drilled hole till such time the pipeline is pulled in. 3.10.5 During pulling operation, the buoyancy of the pipeline shall be controlled by suitable approved methods so as to maintain the buoyancy as close as possible to zero during pullback in order to reduce friction forces of the pipeline in the hole. Bentonite slurry of specified viscosity shall be pumped into the hole, preventing the wall from collapsing and protecting the pipeline coating. 3.10.6 CONTRACTOR shall provide free of charge reasonable facilities to COMPANY'S personnel to witness all stages of construction. 3.10.7 CONTRACTOR shall be responsible for the integrity of the corrosion coating and shall apply any necessary approved protective coatings.




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Coating inspection of the pipeline after completion of pulling operation shall be made by: a) Pulling the pipe to the extent possible with normal rig set up at the exit point. b)

Excavating the adjacent portion up to and including the first field joint. The pipeline and joint coating shall be examined visually and with holiday detectors for defect. The length to be inspected shall, as a minimum, be one pipe length and one joint coating. In case damages / holidays are detected in the first pipe length / joint, the subsequent pipe length / joint shall be exposed and coating integrity checks shall be made. If found acceptable by COMPANY, the first pipe length / joint shall be repaired and / or replaced as directed by COMPANY. If the coating of second pipe length / joint is also found damaged, CONTRACTOR shall propose further course of action and COMPANY'S instructions shall be followed. All works shall be done at no extra cost to COMPANY.

3.10.8 Before final hydrostatic testing, CONTRACTOR shall 'prove' the diameter of the pipeline by passing a gauging pig through the pipeline. The gauging pig shall have a diameter equal to 95 % of the nominal internal diameter of the pipe. CONTRACTOR shall supply and install all temporary scraper launchers / receivers and other equipment, piping and materials and consumable for the purpose. 3.11

Protection of Underground Utilities and Special Methods CONTRACTOR shall obtain plans and full details of all existing and planned underground services from the relevant Local Authorities and be responsible for location and protection of the same. Where the pipeline crosses other underground utilities/ structures, CONTRACTOR shall first manually excavate to a depth and in such a manner that the utilities / structures are located. Should any damage to any structure/utility etc. occur, the owner / Authority concerned shall be contacted by the CONTRACTOR and repair shall forthwith be carried out by the CONTRACTOR at his expense under the direction and to the satisfaction of COMPANY and the concerned Owner / Authority.

3.12

Bending

3.12.1 After pulling the pipeline across the drilled crossing, CONTRACTOR shall cut the extended portion of the pipeline at the entry and exit points. Thereafter, the drilled portion of the pipeline shall be cut at suitable location / depth and extended on either bank by installing a cold field bend with minimum bend radius of 40 times the pipe O.D. and a straight pipe length of 12 meters, such that at the ends the top of the pipeline is minimum 1.0 meter below the natural ground level.




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3.12.2 CONTRACTOR shall use a bending machine and mandrel (if required) and employ approved and accepted methods of bending of coated pipe in accordance with good pipeline construction practice. The procedure shall include amongst other steps- lengths, maximum degree per pull and method and accuracy of measurement during pulling of the bend. Cold field bends made from coated pipes shall be inspected visually and by holiday detector to locate damages which shall be repaired by CONTRACTOR as per COMPANY approved procedures. The ends of each bent pipe length shall be straight and not involved anyway in the bending. In no event shall the end of the bend be closer than 1.5 meters from the end of a pipe or within one meter of a girth weld. The ovality in the bent pipe shall not exceed 2.5% of the nominal diameter at any point. A check shall be performed on all bends in the presence of COMPANY by passing a gauge consisting of two discs with a diameter equal to 95 % of the nominal internal diameter of the pipe connected rigidly together at a distance equal to 300 mm. Miter bends are not permitted. 3.13

Hydrostatic testing

3.13.1 Pre-Installation Hydrostatic Testing CONTRACTOR shall hydrostatically test the complete pipe string of each river crossing before installation as per approved procedure. The section of the pipeline corresponding to the river crossing shall, before installation, be subjected to a minimum hydrostatic test pressure equal to 1.4 times design pressure for gas pipeline and 1.25 times design pressure for liquid pipeline. The combined equivalent stress in the pipeline due to bending and test pressure shall not exceed 90% of the SMYS of the pipe material. After the temperature has been stabilized, the pressure shall be maintained in the pipeline for at least twenty four hours and recorded by manothermograph. During the test CONTRACTOR shall check all welds for leakage. Failure, if any, during the test shall be rectified by the CONTRACTOR. If the same is due to failure on account of any cause other than defect in COMPANY supplied material, the repairs shall be done free of cost, to the satisfaction of COMPANY. 3.13.2 Final Hydrostatic Test The complete water crossing shall be tested after installation. The test procedure shall result in a hoop stress in pipe corresponding to 90% SMYS of the pipe material. After temperature stabilization, pressure shall be retained in the pipeline for a minimum 4 hours and recorded by manothermograph. The hydrostatic testing shall be carried out in accordance with approved procedures.




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3.13.3 CONTRACTOR shall prepare for COMPANY'S approval a hydrostatic test procedure manual for pre-testing and post-installation testing of pipeline. The test procedure manual shall include, but shall not be limited to, the following items: a.

For the pipe section to be tested, a diagram indicating all fittings, vents, valves, temporary connections, relevant elevations and ratings. The diagram shall also indicate injection locations and intake and discharge lines.

b.

Estimated amount of test water, water source, including required concentration of corrosion inhibitors and additives, procedure for inhibitor injection and control of concentration.

c.

Filling and flushing procedures, including a complete description of all proposed equipment and instruments (including spares), their location and set-up.

d.

The type and sequence of pigs and the pig tracking system for cleaning and removal of air pockets, pig inspection procedures, including procedure to be followed in case the gauging pig indicates damage.

e.

Procedures for leveling and stabilization after filling and for pressurization and to allow for temperature stabilization.

f.

Pressure testing procedure including a complete description of all proposed equipment and instruments (including spares), their location and set-up, and proposed system for observation and recording of data during the pressure test.

g.

Procedure for detection and location of leaks.

h.

Procedure for dewatering the pipeline section after testing, including a complete description of all proposed equipment and instruments (including spares), their location and set-up, the type and sequence of pigs and the pig tracking system along with the pig specifications. Forms for recording the testing data.

i.

3.13.4 CONTRACTOR shall furnish all necessary equipment & instrumentation for performing the work including all temporary piping and scraper launcher/receiver etc. 3.13.5 The test medium shall be fresh water to be arranged by the CONTRACTOR. The water to be used shall be filtered, shall not be contaminated, and free from sand of silt. CONTRACTOR shall submit laboratory test reports of water used for testing. CONTRACTOR shall provide COMPANY approved corrosion inhibitors, oxygen scavengers and bactericides to be added to the test water. CONTRACTOR shall furnish and install all temporary piping which may be necessary to connect from source of water to its pumps and manifolds / tankage.




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3.13.6 Before filling operation, CONTRACTOR shall clean the pipeline by air driven pigs provided with spring loaded brushes and cups to remove all mill scale, rust / sand from the internal of pipe sections. 3.13.7 The hydrostatic test shall be considered as positive if pressure has kept a constant value throughout the test duration, except for changes due to temperature effects, and there is no abrupt pressure drop throughout the test duration. If test section fails to maintain the specified test pressure after isolation, CONTRACTOR shall determine by search the location of leakage or failure. All leaks and failures within the pipe wall or longitudinal seam shall be repaired by replacement of entire joint or joints in which leakage or failure occurs. In those cases where leaks occur in circumferential welds the method of repair shall be determined by COMPANY. CONTRACTOR shall comply with instructions of the COMPANY whether to replace a section of the line pipe that includes the line leak or whether to repair the circumferential weld. This repair should, however, meet the requirements of welding specification contained herein. Where failures occur in pipeline field bends, bends shall be replaced with same degree of bends. After completion of repairs, the hydrostatic test shall be repeated in full, as per the approved procedures. All work of reinstating line pipe, to replace failures, shall be done in accordance with the specifications contained herein. CONTRACTOR shall haul and stockpile all damaged and defective pipes to storage locations designated by the COMPANY. All cracks and splits resulting from failures shall be coated with an application of grease to preserve the characteristics of failures from corrosion. Joints of failed pipes shall be marked with paint, with a tag indicating failure details, date and location of failure and pressure at which failure occurred. 3.13.8 After completion of successful hydro test of the above portion, the pipeline shall be capped and buried. Pipeline end position on the banks shall be marked on the ground by installing location markers on both banks approved by COMPANY. 3.14

Permanent Pipeline Markers On both banks of each river crossing, CONTRACTOR shall install a Navigable Waterway Pipeline Crossing Warning Sign, if in accordance with Std. No. S-04-01019. CONTRACTOR shall supply all materials and fabricate and install the markers as per reference drawing. Wherever feasible, the pipeline markers shall be installed on the embankments, however, exact location shall be decided based on site conditions and as directed by COMPANY.

3.15

Fencing CONTRACTOR shall supply all materials and install G.I. Wire Chain link security fencing of size 10mx10mx2.5m high with lockable steel gate around the pipe ends and test stations for temporary C.P. on both sides of each river crossing. GAIL (INDIA) LTD NEW DELHI



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3.16

Idle Time Preservation of Pipeline If directed by COMPANY, CONTRACTOR shall supply all materials and consumable including water and inhibitor and shall install all piping connections, valves, instrumentation, etc., and perform all works for preservation of pipeline by pressurization with inhibited water. CONTRACTOR shall use approved inhibitors and shall determine the required dosages of inhibitors and pressure for idle time preservation of the pipeline for a period of maximum six months from the date of completion of construction. Corrosion inhibitors and dosages shall be subject to COMPANY'S approval prior to use.

3.17 Final clean up After completion of construction, CONTRACTOR shall clear the sites of all balance material and debris. All balance pipe lengths supplied by COMPANY shall be returned to COMPANY'S designated stock yard(s). Site shall be cleared to the complete satisfaction of COMPANY and authorities having jurisdiction. All such works shall be done at no extra cost to COMPANY. 4.0

DOCUMENTATION

4.1

In addition to the documents specified elsewhere in this specification, CONTRACTOR shall submit to the COMPANY six copies of each of the following documents/ records: 

4.2

Complete record of pipes 'taken-over' from COMPANY, number of pipe lengths used, and record of return of balance pipe lengths to COMPANY'S designated stock-yard(s)

During the course of execution of the crossing, CONTRACTOR shall generate / compile the following data. It shall be obligatory on part of the CONTRACTOR to furnish this data to COMPANY in the event it is required for. 



Detailed drilling log and down hole data, including, but not limited to, the following: a)

Torque and pulling / pushing force

b)

Data on drilling fluid. i.

Density

ii.

Type of mud and additive employed.

iii.

Mixing, pumping and cleaning.

Wash and drill pipe data, viz.,




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a)

Dimension and material properties.

b)

Data on API classification.

C) Age of and type of inspection previously carried out on these pipes.

4.3

4.4



Copies of the permits obtained from authorities having jurisdiction for the various works.



Plan & profile of the drilled hole along with the water level variations.



Records of hydrostatic pre-testing and final testing.



Record of Non Destructive Testing of welds.



Clearance certificates form the landowners and Authorities having jurisdiction regarding satisfactory clean-up and restoration of pipeline ROU and work areas.

After completion of construction, CONTRACTOR shall prepare and furnish six sets of copies and two sets of reproducible of As-Built drawings for the crossings. As built drawings shall, as a minimum include the following information: 

True profile of the river bed and banks along the pipeline;



True profile of the pipeline as installed and the depth of cover to top of pipe at regular intervals



Location of entry and exit points and angles of entry and exit, along with lateral offset of exit point from the original pipeline alignment



Location and angle of field bends



Location of pipeline markers.

All documents shall be in English language.




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STANDARD SPECIFICATION FOR CONSTRUCTION OF PIPELINES CROSSING ROADS, RAIL ROADS AND MINOR WATER CROSSINGS


STANDARD SPECIFICATION FOR CNSTRUCTION OF PIPELINES CROSSING ROADS, RAIL ROADS AND MINOR WATER CROSSINGS


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1.0

SCOPE This specification covers the minimum requirements for the various activities to be carried out by the Contractor for or about the installation of pipelines crossing roads, railroads, minor watercourses and other services. The provisions of this specification are not applicable for pipelines crossing water courses, which are specifically designated as "Major Water Courses" in the CONTRACT.

1.2

This specification shall be read in conjunction with the conditions of all specifications and documents included in the CONTRACT between Company and Contractor. Unless specified otherwise, all sections of this specification shall apply to all specifications referred in this specification.

2.0

REFERENCE CODES, STANDARDS AND SPECIFICATIONS

2.1

Reference has been made in this specification to the latest edition (edition enforce at the time of floating the enquiry) of the following codes, standards and specifications. a)

ASME B 31.4 -

Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids

b)

ASMEB 31.8

Gas Transmission and Distribution Piping systems.

c)

API RP 1102 -

Recommended practice for Liquid Petroleum Pipelines Crossing Railroads and Highways.

d)

OISDB141 -

Design and Construction requirements for cross-country hydrocarbon pipelines

e)

2.2

Part 192, Title 49 - Transportation of Natural and other Gases by Pipe Line (US DOT - Pipe Line Safety Standards).

f)

Part195

Transportation of liquids by Pipe Line (US DOT - Pipe Line Safety Standards).

g)

GAIL Standard Specifications:

i)

Standard Specification for Pipeline Construction (Onshore)

ii)

Welding Specification for Onshore Pipelines for Transportation of Gas

In case of conflict between the requirements of above mentioned codes, standards, specifications and practices, the most stringent requirement shall govern. In case of conflict between the requirements of this specification and that of the above referred GAIL (INDIA) LTD NEW DELHI



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codes, standards, specifications and practices, the requirements of this specification shall govern. 2.3

For the purpose of this specification the following definitions shall hold: -

the words 'Shall' and 'Must' are mandatory.

-

the words 'Should', 'May' and 'Will' are non-mandatory, advisory or recommended.

3.0

GENERAL

3.1

Crossing of roads, railroads, buried services. canals and minor water courses with equipment and/or personnel is allowed only after acquiring approval from the authorities having jurisdiction and after making arrangements for safeguarding the roads, etc. and the verges and/or banks thereof and the buried services with appropriate provisions. Highways, Main-Roads and Railroads and their verges and banks of water crossings are not allowed to be used for loading, unloading or stacking of materials and/or equipment. For secondary roads, such loading/unloading is permitted only after prior approval from the concerned authorities. Contractor is not allowed to close or divert roads or watercourses without prior approval from the Company and the concerned authorities. Contractor shall never unnecessarily hamper the users of the roads, railroads, buried services and/or watercourses. The water flow shall not be obstructed in any way. All Civil and Mechanical works associated with or incidental to the installation of pipeline crossings shall be carried out in accordance with GAIL Specification "Standard Specification for Pipeline Construction (Onshore)".

3.2

Company reserves the right to demand for individual crossings from the Contractor a separate detailed report for approval, containing: -

Approval letter from concerned authorities

-

Time Schedule

-

Execution methodology with details of equipment

-

Test procedure

-

Manpower deployment

-

Calculations/Description of temporary works




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-

Design calculations for crossing

-

Soil investigations, etc.

Such works shall be without any extra cost to Company. 3.3

Pipeline crossings for road, railroad, canals and rivers etc., shall be hydrostatically pretested ex-situ, prior to joint coating, whenever, -

Crossing is executed by boring of carrier pipe:

-

Crossing is installed in casing pipe;

-

River Crossing pipes which are to be continuously concrete weight coated

-

Whenever, in Company's opinion, the repair of pipeline at crossing, in case of a leak during final hydrostatic testing, would require inordinate amount of efforts and/or time;

-

Whenever pretesting is insisted upon by the Authorities having jurisdiction over the utility crossed.

The section of the pipeline for the crossing shall be tested as a single string. Unless specified otherwise in the CONTRACT, the test pressure shall be the one resulting in hoop stress corresponding to 90% of SMYS of pipe material. Test pressure shall be retained in the pipeline for minimum period of four (4) hours. Test section shall be kept under surveillance by regular patrols during test and it shall be visually examined for leaks/defects, etc. 4.0

ROAD AND RAILROAD CROSSINGS

4.1

The work under crossings shall include necessary clearing, grading and trenching to required depths and widths, welding of casing (when required) and carrier pipes, lowering-in, back filling, clean-up, restoration to the original condition and further strengthening and protective works, testing, installation of assemblies, insulators and end-seals, and temporary works such as sheet piling, bridges, etc. The work shall be carried out in accordance with the approved drawings and job standards, as directed by Company and to the satisfaction of Company and the authorities having jurisdiction over the facility crossed. The work carried out for road and railroad crossings shall meet the minimum requirements of API RP 1 102. Before the installation work of crossings is started, the Contractor shall provide suitable barricades, temporary bridge / bypass work (especially where roads are open-cut) with GAIL (INDIA) LTD NEW DELHI



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railing, if required by Company for safety of traffic. Adequate traffic warning signals and/or traffic lights and suitable diversions shall be provided as directed by Company/Authority having jurisdiction over these areas. Such diversions shall not cross the pipeline where it has already been installed, unless proper safeguarding at Company's opinion is ensured. Prior approval from the statutory authorities shall be obtained to lay the pipeline across the highway/road either by boring or by open -cut method. Installation of the crossing shall be by the method (i.e., boring/open-cut) approved by Authorities having jurisdiction. Railroad crossings shall always be bored/ jacked. 4.2

Boring/ jacking of carrier pipes for crossings is allowed only if the pipes for boring/ jacking are provided with a suitable corrosion coating and Contractor remains liable for the suitability of the pipe and weld-coating of carrier pipes to be bored and type of coating and method of application are anyhow to be authorized by Company without prejudice to Contractor's liability. In all other cases the carrier pipes shall be cased. Before start of the boring/ jacking operation, Contractor shall execute soil investigations and determine the ground water table. Based on these investigations, Contractor shall prepare a construction drawing and submit to Company for approval including time schedule and soil investigation report. During the execution of the boring, the ground water table over the length of the boring shall be lowered up to at least 0.50 m below bottom of the pipeline. This water table is to be regularly inspected and maintained by Contractor and reported to Company. To safeguard the stability of the bore pit, contractor shall, if necessary in Company's opinion, use a closed sheet piling, which shall extend at least over 50% of the length in undisturbed soil. The length of the boring shall be in accordance with the width of the ROU of the crossing (road, railroad, etc.), with minimum 0.6 m extra on either side. If the soil conditions and ground water for a particular boring give reasons for this, Contractor is entitled to suggest to Company for a relaxation of one or more of the following requirements as defined here forth. Soil investigation Lowering of ground water table Sheet piling Length of boring, etc.




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In approaches to the crossing, Contractor shall eliminate unnecessary bending of pipe by conforming to the contour of the ground by gradually deepening the ditch at such approaches as directed by the company. 4.3

The bottom of the trench and/or the pit for at least twelve (12) meters at the approach to each end of a casing shall be graded and if necessary backfilled with clean sand and compacted up to atleast 95% Proctor Density to an elevation that will provide sufficient and continuous support to the pipeline so that the pipeline remains correctly aligned at casing ends during and after backfilling.

4.4

The diameter of the hole for a bored section shall have a hole diameter as close as practicable to the outside diameter of the carrier or casing pipe. If excessive void or too large hole results, or if it is necessary, in the opinion of Company, to abandon the bored hole, prompt remedial measures such as filling the hole with suitabie material shall be taken to the entire satisfaction of the company and Authorities having jurisdiction thereof at no extra cost to Company. Equipment used for installation of casing pipe shall be of the type approved by Company. An installation consisting of hydraulic jacks shall be provided with easily readable pressure gauges (in bar) and sealable pressure limits. Their proper operation shall be demonstrated before the work is started. Company can request that the maximum pressing force be limited. At the front of the pipe there may be a cutting ring, which may be 12 mm large than the outside diameter of the pipe or casing. A lubricating pipe can also be used in jacking, the nipples of which shall not protrude from the cutting ring. Said lubricating pipe shall not be fixed to the pipe or casing. When jacking, only biologically degradable lubricants shall be used (e.g. WRC Medlube or an emulsion of bentonite). Removal of soil from the pipeline during jacking shall be done mechanically by means of a standard, locked auger, which has to be safeguarded against jacking ahead of the pipe. If, in the opinion of the Company, fluid sand may arise, an inner pipe with funnel shall be used. During jacking, the progress of the pipe to be jacked and the cutting capacity of the auger shall be mutually adjusted, by regulating the speed of auger, to prevent the road from bulging (rpm too low) or cave-ins (rpm too high). In any case no more soil shall be removed than the volume of the pipe. The auger drive shall be provided with a clutch. The progress in the work, the readings of the gauge pipes, the jacking pressures observed, etc., shall be recorded in a log book, to be shown to Company upon request. All information shall be supplied to Company on completion of the work.




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If the jacking fails, the casing shall not be withdrawn. It shall be filled with sand and plugged at either end. The diameter of the casing pipe shall be as indicated in the job standards. Company reserves the right to inspect certain lengths of pipes to assess damages, if any, to the corrosion coating of the carrier pipe used for boring. Contractor shall weld additional lengths of pipe and pull the required extra lengths for Company's inspection. If during inspection any defects are noticed, Contractor, in consultation with Company, shall carry out the remedial measures, as required. 4.5

While welding of the casing and vent/ drain pipes, internal high or low is not allowed. Welding of casing and vent/drain pipes need not be radiographed, however, only normal visual checks shall be carried out. Before welding, the single length of pipe shall be inspected in order to check that there is no out of roundness and dents. When such defects are noticed, these must be completely removed before joining the pipes. If these defects cannot be repaired, the defective section shall be cut out.

4.6

In the case of crossings where excavation has been authorised, the welding for the casing pipe and for a continuous section of the pipeline corresponding to the expected length shall be carried out in the proximity of the crossing. Casing must be laid immediately after the trenching. Casing pipe must be laid with a single gradient in order to allow for an easy insertion and, if necessary at a future date, to allow for the removal or replacement of the pipeline, leaving the casing undisturbed. The direction of gradient shall be marked in the crossing drawings for future reference.

4.7

The installation of assembly of vent pipe units as approved by Company shall be carried out by direct insertion and welding to the ends of the casing pipe before introducing the carrier pipe to avoid damage to insulators from welding heat. The operation of assembling and extending the vent pipe shall be carried out in such a way that there is no contact with the carrier pipe. The painting/ coating of the vent pipes shall be applied before backfilling as per relevant specifications.

4.8

The casing pipe shall be considered ready for installation of the carrier pipe, after careful inspection and internal cleaning with the removal of soil, mud, stones and other foreign materials.

4.9

Insulators, as approved by Company, shal1 be securely fastened to the pipe with all bolts and fixtures firmly tightened. The number of insulators and spacing shall be as shown in the drawings or at 2.5 meters center (whichever is more stringent). At the end of both sides of the casing, a double set of insulators shall be installed.

4.10

Care must be taken in pushing or pulling carrier pipe into the casing so that the pipe is aligned correctly in the casing and that the pushing or pulling force is evenly and constantly applied to avoid damages to the insulators. A nose piece having a diameter equal to that of the pipe shall be welded on the front and back end of the carrier pipe




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to facilitate installation of the carrier pipe properly in the casing and to keep it dry and clean. 4.11

After installation of the carrier pipe section, the casing and the appurtenances, but prior to making tie-in welds and backfilling, an electrical test shall be conducted by the Contractor in the presence of the Company, to determine the resistance between the casing and the carrier pipe or the carrier pipe and the soil. These tests shall show at least a resistance of 100,000 ohm M2 . After backfilling and compaction, additional tests shall be conducted to determine if the casing is electrically shorted to the pipe. If the installation is found to be shorted, Contractor shall make the necessary corrections and repairs at his cost, unless a test to the satisfaction of the Company is obtained.

4.12

After successful installation of crossing to the satisfaction of Company/ Authorities having jurisdiction, the nose pieces/ pulling head welded to carrier pipe as an installation aid shall be cut/ removed and ends of carrier pipe shall be beveled/ prepared for further welding/ tie-in with the balance section of pipeline on either side of crossing. Casing end-seals shall be installed/ fitted prior to back filling.

5.0

CROSSINGS OF BURIED SERVICES

5.1

The pipeline under construction may pass above or below the existing buried facilities such as pipelines, cables, etc. Type of crossing shall be such that a minimum depth of cover as required in the drawings and specifications are guaranteed. The clearance required between pipeline and the existing facility shall be 500 mm (min.) as indicated in job standard.

5.2

Whenever buried services in the ROU are to be crossed by Contractor, Contractor shall safeguard the buried facilities and the required protecting precautions shall be executed as approved by Owners of the buried services and by Company. For buried services to be crossed by boring/ jacking, the relevant provisions of Section 4.0 shall apply.

5.3 6.0

MINOR WATER COURSE CROSSINGS

6.1

Minor water crossings are crossings of (future) ditches, canals, water courses, rivers, streams etc., whether the bed(s) contain(s) water or not, and such crossings are not being specified as "Major Water Crossings" in the CONTRACT.

6.2

For minor water crossings a standard drawing or a separate detailed approved drawing for individual crossing shall be applicable, and all further specifications are applicable.

6.3

Wherever minor water crossings in the ROU are to be crossed, Contractor shall install bridges and further comply with the provisions as laid down in this specification.




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6.4

In crossings of water courses with either moderate flow rate or of torrential nature with marked and unpredictable flooding, an adequate survey shall be carried out before starting the work with the object of determining what precautions are necessary and the most favorable period for executing the work.

6.5

In case of crossings of water courses for which no special methods of laying are required, a pipe section of a size as per the approved drawings shall be assembled and subsequently laid. Bends shall be of cold field type. Whenever required by Company, Contractor shall, before start of construction, execute soil investigations. Based on the soil investigations, the Contractor shall prepare a construction drawing, work method and time schedule for approval by Company. The depth of the existing bottom of a minor water course crossing shall be determined in relation to the adjacent ground level by taking the average of four measurements. Measurements shall be taken with a gauge rod and with dimensions 60x60 mm and having a flat bottom. The minimum force to be exerted shall be 360N (36 kgf). Contractor shall take special care to check with the responsible authorities for special conditions applying to working on, over, under or thorough minor water crossings and Contractor shall comply with any such conditions. Written arrangements with authorities shall be drawn up in cooperation with Company.

6.6

The minimum cover over the pipe shall be as specified in the relevant approved drawings and job standard.

6.7

For crossing beneath the bed of water courses, the pipe section shall be made in such a way that it conforms to the existing or future bed as indicated in the approved drawings. In crossings for which an individual drawing has not been prepared, the minimum cover of the pipeline shall not be less than that indicated in the standard drawings for a similar type of crossing.

6.8

Whenever the crossing requires a straight section of pipe between the lower bends coinciding with the river bed, this section shall be laid at a single horizontal level.

6.9

For crossings of ditches, canals, banked channels, etc. by boring, the pipe section shall be prepared, laid and tested in accordance with the applicable clauses of Section 4.0 of this specification.

6.10

The Contractor shall arrange temporary installation of diversions as may be necessary, to ensure the effective functioning of these watercourses crossed, to the entire satisfaction of the concerned local Authorities as well as the Company.

6.11

Banks and trenches of minor water crossings shall be backfilled with soil which is to be approved by Company and shall be thoroughly compacted to prevent soil and bank



SPECIFICATION

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erosion as per the drawings and standards to the satisfaction of authorities having jurisdiction thereof and the Company. Whenever boulders, rock, gravel and other hard objects are encountered, they shall not be placed directly on the pipe. Sufficient earth, sand or selected and approved backfill material shall be backfilled initially around and over the pipe to provide a protective padding or cushion extending to a minimum thickness of 300 mm around the pipe before backfilling remainder of the trench with excavated or other material as per approved drawings and standards. After the trench has been backfilled and during the clean up works, the minor water crossing shall be cleaned across the whole width of the ROU. When specified in the CONTRACT, Contractor shall repair the ditch bank with materials to be supplied by him as follows:

6.12

-

The excavation shall be backfilled with well compacted solid soil, followed by a minimum 0.25 m thick layer of properly shaped boulders (75- 150 mm) encased in a net of galvanized iron wire of dia 3 mm spaced at a maximum distance of 50 min to be laid over the backfilled, compacted and graded banks.

-

The lengths of the above protection shall be equal to the bank excavation and damage and extending 2 m on either side. The width of this protection on the slope shall be determined by the following: -

2 m plus the highest water level

-

Up to the bottom of the crossing or 20 m below the highest water level Which ever is smaller.

The crossing of any embankments shall be carried out strictly in accordance with approved drawings. No drilling work on embankments shall be permitted without prior written approval from the competent Authorities.



SPECIFICATION

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STANDARD SPECIFICATION FOR MAJOR WATER CROSSINGS (CONVENTIONAL TRENCHING)




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Abbreviations: ASME

:

American Society of Mechanical Engineers

API

:


OISD

:

Oil Industry Safety Directorate

ROU

:

Right of Use

US DOT

:

Unite States Department of Transportation




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1.0

SCOPE

1.1

This specification covers the minimum requirements for the various activities to be performed by contractor for the construction of pipeline major water crossings by conventional trenching method. Provisions of this specification are applicable only for "Major Water Crossing" specifically named as such in the CONTRACT.

1.2

This specification shall be read in conjunction with the conditions of all specifications and documents included in the CONTRACT between Company and Contractor.

1.3

Contractor shall, with due care and diligence, execute the work in compliance with all laws, by-laws, ordinances, regulation etc., and provide all services and labor, inclusive of supervision thereof, all materials, excluding the materials indicated as "Company Supplied Materials" in the CONTRACT, equipment appliances or other things of whatsoever nature required in or about the execution of the work, whether of a temporary of permanent nature.

1.4

Contractor shall take full responsibility for the suitability, stability and safety of all operations and methods involved in the work.

1.5

Contractor shall be deemed to have inspected and examined the work area and its surroundings and to have satisfied himself so far as practicable as to the form and nature thereof, including sub-surface conditions, hydrological and climatic conditions, the extent and nature of the work and materials necessary for the completion of the work, and the means of access to the work area.

1.6

Contractor shall be deemed to have obtained all necessary information subject as above mentioned as to risks, contingencies and all other circumstances, which may influence the work.

1.7

Contractor shall, in connection with the work, provide and maintain at his own costs all lights, guards, fencing, watching etc., when and where necessary or required by Company or by any duly constituted Authority for the protection of the work and properties or for the safety and the convenience of public and/or others.

2.0

REFERENCE DOCUMENTS

2.1

Reference has been made in this specification to the latest edition (edition enforce at the time of issue of enquiry) of the following codes, standards and specifications: a)

ASME B 31.4

-


b)

ASMEB31.8

-

Gas Transmission and Distribution piping systems.




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c)

API RP 1102

-

Recommended practice for Liquid Petroleum Pipelines Crossing Railroads and Highways.

d)

OISDB 141

-

Design and construction requirements for crosscountry hydrocarbon pipelines

e)

Part 192, Title 49

-

Transportation of Natural and other Gases by Pipe Line (US DOT - Pipe Line Safety Standards).

f)

Part195

-

Transportation of liquids by Pipe Line (US DOT - Pipe Line Safety Standards).

g)

GAIL Standard Specifications: i)


ii)

Welding Specification for Onshore Pipelines for Transportation of Gas

2.2

In case of conflict between the requirements of above mentioned codes, standards, specifications and practices, the most stringent requirement shall govern. In case of conflict between the requirements of this specification and that of the above referred codes, standards, specifications and practices, the requirements of this specification shall govern.

2.3



-


3.0

GENERAL

3.1

All works of the pipeline major water crossing shall be performed in accordance with the approved construction drawings, procedure, and other applicable documents as per the CONTRACT, good pipeline practices and as directed by Company.

3.2

Before start of the field construction, Contractor shall submit in triplicate to Company, for approval, for each major water crossing, a complete report containing at least: i)

Installation method.




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ii)

Proposed time schedule indicating start and finish dates and detailed break-up of time period for all critical activities associated with the work.

iii)

Required work area along with layout and location.

iv)

Equipment to be used (including number and capacity of equipment).

v)

Manpower deployment during construction.

vi)

Proposed sub-contractors and/ or vendors along with their scope of work.

The description of the installation method as a minimum shall include the following: a)

Study of water currents in relation to the method of launching (on bottom and on surface).

b)

Calculations for stability of pipeline during launching and final test.

c)

Buoyancy Studies.

d)

Preparation of fabrication yard and launching areas along with proposed layouts.

e)

Pipeline construction details (including hauling, stringing, welding, NDT, concrete coating, etc.).

f)

Pre-test procedure.

g)

Procedure for corrosion coating of field joint.

h)

Dredging, anchoring requirements, spoil deposit and trench survey method and Contractor's proposed methodology for execution of these activities.

i)

Pulling or other installation method and related calculations/analysis including rope test, checking of winch/crane pulling capacity etc.

j)

Pulling arrangement including launch way and anchoring and braking device.

k)

Trench correction before launching.

l)

Method of positioning and sinking/ lowering of pipeline.

m)

Method of rectification of damages to the pipeline/ coating, during launching.

n)

Method of backfilling, bank protection and survey.




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o)

Final test procedure after backfilling.

p)

Safety system adopted during rope/ winch capacity test and during construction including launching.

q)

Communication system adopted during construction/testing/survey.

r)

Abandonment and recovery procedures.

Company shall inform Contractor within 21 calendar days, if any objection against the document and procedures described requires resubmission by Contractor. Approval by Company of the methods used by Contractor shall in no way relieve Contractor from the sole responsibility for safe and satisfactory installation of the crossing. 3.3

Contractor shall comply with all the conditions and requirements issued by Authorities having jurisdiction in the area where the work is to be performed. Contractor shall, at his own responsibility, obtain necessary permits from the Authorities having jurisdiction, for performing its work. If no public roads exist, Contractor shall arrange at his own for access to work areas at no extra time and cost to Company.

3.4

Pre-construction surveys Prior to start of any work, Contractor shall carry out a survey of the major water crossings and acquaint himself with site conditions and to collect any data regarding the water velocity and the tidal variation in the flow pattern and shall verify the suitability of his equipment and the method of Construction.

4.0

TRENCHING

4.1

Dredging / Excavation

4.1.1 Contractor shall dredge or excavate the trench for the water crossing in conformity with the approved drawings. Dredging of the trench shall be executed as accurately as possible. 4.1.2 The trench shall be excavated to such depth as required to provide the minimum cover and the pipeline configuration as specified. The pipeline profile of the crossing shall be followed as accurately as possible. Before laying, the trench shall be cleaned and leveled. The trench shall be subject to inspection by Company prior to installation of the pipe. GAIL (INDIA) LTD NEW DELHI



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4.1.3 Navigational traffic shall not be obstructed, unless permission has been given thereto. Contractor shall issue all necessary publication according to the local requisitions. Instructions given by Authorities shall be followed accurately and immediately, so that traffic encounters no hindrance. Contractor can not request a compensation if his work is hampered or delayed due to weather conditions, any obstacles/or any traffic on the spot, where work is executed. 4.1.4 Contractor is fully responsible for the execution of the blasting (wherever permitted), the dredging and excavation work, hopping of the spoil, transportation, dumping on land or in water, all to be executed in agreement with Authorities, land owners and Company. 4.1.5 Contractor may be obliged to dredge or excavate a trench deeper or wider than indicated in the drawings in order to properly lay the pipeline in unstable (underwater) areas, or near and adjacent to the banks of water-courses. It shall be understood that Contractor is aware of such problems at the time of his Bid and that, when such additional excavation is required, it shall be done by Contractor as part of the work and that he will install the necessary provisions and/ or temporary works such as sheetpiling, special filling materials, etc. at no extra cost to Company. 4.1.6 During the execution of dredging work by Contractor, bearings, measurements and levels shall be taken by or on behalf of Company. Contractor shall render assistance for this purpose and make available for Company appropriate survey boats, fully manned and equipped, before the trench excavation work of the water crossing can be started Contractor, if so desired by Company, shall make cross profiles at intervals of not more than 10.0 m of the bottom of the watercourse along the surveyed centerline of the water crossing. In such a case, horizontal measurements shall be taken by triangulation or tapping between known points and shall be made with such accuracy that the location of each vertical measurements is known with 1.0 m. Vertical measurements shall be taken with a sonic recording device, or with line and rod, as directed by Company and shall be taken with such an accuracy that each depth is known within 0.2 m. Vertical measurements shall be taken at points averaging not more than 5.0 m apart and no two measurements shall be more than 7.0 m apart. The cross profiles shall extend at least 10 in on both sides of the top of the trench. All measurements shall be recorded by Contractor. Company may witness such measurements. The resulting profile, corrected to the elevation of the undisturbed watercourse, shall then be the reference profile. Said profile shall be plotted on a 1:200 vertical and horizontal scale. 4.1.7 Contractor shall keep the trench in good condition until the pipe is laid, and no claim is to be made to the Company by reason of its caving either before or after the pipe is laid. Contractor shall do whatever is required to excavate the trench, install the pipe in GAIL (INDIA) LTD NEW DELHI



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it and backfill the trench in accordance with the specifications at no extra cost to Company. 4.1.8 Immediately before installation of the water crossing in the excavated trench, Contractor shall prepare a profile of the trench bottom along the surveyed center line of the water crossing for comparison with the reference profile. Contractor shall also make cross sections of the trench at intervals of not more than 50 m. All profiles and cross section measurements shall be taken as specified and, if required, shall be witnessed by Company. These data shall be submitted to Company for approval and Company will approve or reject the trench excavation as completed within 24 hours after receipt of the profile and cross sections. 4.1.9 Contractor shall grade the trench in such a manner as to give the maximum amount of uniform support to the pipeline when it is lowered or pulled into place. The maximum unsupported span shall not exceed 10.0 m. 4.1.10 In submerged sections, where rock or gravel is encountered in the bottom of the trench, padding is required. The thickness of the padding under the concrete coated pipe shall at least be 0.5 m and after installation at least 0.5 m around the pipe. Blasting, if any, and padding shall be included in the contractor's work. 4.2

Pumping Line In case Contractor uses pumping lines to discharge the spoil, he shall take care of the necessary permits. Pumping lines, discharges and siphons shall be installed by Contractor and removed before the completion of the work. At crossing with existing roads, the pumping lines shall be led through a casing pipe boredljacket under the road or led through a porch over the road. A stress calculation must then be handed over to Company. The necessary provision to embank the dumping area and also the spoil-basins shall be made by Contractor. Contractor is responsible for transportation of the spoil and dumping on land and is liable for damage to works of third parties caused by leakage of pumping lines, etc. Contractor shall at all time prevent overflow of pumping water, spoil or sand over embankments, parcels or roads. Further more, Contractor shall safeguard Company from claims of compensation by third parties due to encountered damage.

4.3

Spoil Spoil which is not dumped on and including spoil acquired after cleaning the water crossing trench, shall be transported and dumped in places, designated thereto by agreement between Contractor and authorities and approved by Company. Spoil shall be transported in (split), barges; only those barges shall be used that avoid spilling during transportation due to incorrect closing of the flaps, etc. Spoil, which is dumped




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outside the designated places shall be removed by Contractor at first notice by company. 4.4

Dikes, Dams and weirs Contractor shall install temporary provision in the existing dikes, dams, etc. to prevent flooding of low areas. Therefore in general, in existing dikes, dams, etc. a double substituting weir must be installed before start of excavation in the existing dike or dam. Such a double substituting weir can be a closed wall of sheet piling, supported by soil. The provisions shall be such that the underwater profile of the dredged trench, the water movement caused by ships etc. cause no slide/ cave-ins of the dike or dam.

4.5

Pollution Control Measures Contractor shall take all necessary precautions not to pollute river water and banks during entire construction operation. Equipment deployed and construction methodology adopted shall be such that minimum damage is caused to the existing environmental conditions. Union and State Government requirements concerning pollution control and environmental protection shall be fully complied with.

5.0

CONTINUOUS CONCRETE COATING Contractor shall provide concrete coating over the pipeline including the bends in accordance with the specification issued for the purpose and approved procedure. Contractor shall coat the weld joints in order to arrive at the continuously concrete coated pipeline. However the concrete coating shall be applied after the hydrostatic pretest.

6.0

HYDROSTATIC PRE-TESTING Contractor shall hydrostatically pre-test the pipe string of each water crossing before installation as per approved procedure. Joint coating of the welds shall be done after this pre-test. The section of the pipeline corresponding to the major water crossing shall, before installation, be subjected to hydrostatic pretesting on a combined equivalent stress of 90% of the SMYS of the pipe material. After the temperature has been stabilised, the pressure shall be maintained in the pipeline for at least twenty-four hours and recorded by manothermograph. During test, the Contractor shall check all welds for leakage. Failure, if any, during the test shall be rectified -by the Contractor. If the same is due to failure on account of any cause other than defect in materials supplied by Company, the repairs shall be done free of cost, to the satisfaction of Company.

7.0

INSTALLATION



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7.1

Contractor shall submit a detailed scheme for the method he proposes to adopt for installing the pipeline to Company for approval. Contractor shall calculate all stresses in the pipeline while laying and check whether the stresses remain within permissible limits. A set of all calculations shall be submitted to Company for approval.

7.2

Contractor shall perform all work required to install the water crossings, including the possible appurtenances indicated in the drawings. The water crossings shall be installed in such a manner as to comply with the requirements and conditions stated by the Authorities issuing the permits. Contractor shall pay special attention to minimise any damage to embankments and dikes in the vicinity of water crossings.

7.3

The equipment for launching shall be arranged in such a way that the pipeline is laid without impact or jerking and is not subjected to stresses of any type other than those which are allowable. Minimum allowed radius of curvature shall be followed, particularly at the end of the launching way towards the water in the freely suspended section. During the launching the Pipe shall have a submerged weight of 30 kg/ meter with a tolerance of & ± l0%.

7.4

After the water-crossing section has been installed in place, Contractor shall fill this pipeline section including the pertaining land pipeline sections with water for the final testing.

7.5

Contractor shall check if the position and depth of the water crossing are in accordance with the approved drawing, by means of a profile of the pipeline, before and after the water-crossing section is filled with water. Contractor shall lower each pipeline section, which is not sufficiently deep by dredging or jetting the underlying ground.

7.6

The maxiinuin allowed horizontal deviation from the required center-line shall be limited by the following: -

For pipeline dia up to including 500 mm :

300 mm

-

For pipeline dia greater than 500 mm

500 mm

:

7.7

Prior to backfill the pipeline shall, when laid in the trench, conform to the bottom contour of the trench grade, so that it will be firmly, uniformly and continuously supported within the permissible limits of unsupported spans as specified in Para 4.1.9. Company may employ a diver or use other suitable methods to inspect the bottom of the trench and/or after the pipe is installed prior to backfilling of the trench. Contractor shall facilitate the work of the diver and shall furnish the necessary equipment and helpers necessary for the diver/ inspector to perform his work.

7.8

If the pipe does not properly fit the trench or does not rest at sufficient depth to satisfy the minimum requirements of cover as specified in approved drawings, the Contractor shall make necessary corrections to either trench or to the pipe alignment or to both so GAIL (INDIA) LTD NEW DELHI


SPECIFICATION

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that the pipe, when finally in position in the trench, shall fully meet the specification, failing which Contractor may be asked to remove the pipeline. This shall be done at no extra time and cost to the Company. 7.9

Installation of Parallel Pipelines When parallel pipelines are required to, be installed across major water crossing, Contractor shall further comply with the following requirements.

7.9.1 Depending on the diameter of the parallel pipelines, the characteristics of the crossing and the limitation of Contractor's equipment, Contractor may propose installation of the parallel pipelines either together in a combined operation or separately in a common trench. 7.9.2 If the pipelines are installed together, the minimum clear distance between the parallel pipelines (measured from the outside diameters of the concrete coated pipes) shall be 300 mm. Contractor shall provide spacers (at sufficient intervals along the length of the pipe sections), securely fixed to the pipes, or shall propose other suitable alternative methods, so as to ensure that the stipulated minimum clear distance is maintained. The buoyancy of the combined installation (pipes+spacers) shall be checked before installation. The spacers may be removed before the trench is backfilled. Contractor shall furnish detailed drawings/calculations for the pipe assembly, showing the details of spacers/ other arrangements for Company's approval before start of construction. 7.9.3 If the parallel pipelines are installed separately in a common trench, the minimum clear distance between the parallel pipelines in the trench shall be 5000 mm. Contractor shall ensure that this minimum spacing is maintained till the time the trench is backfilled. 7.10 Construction Equipment All critical construction equipment deployed shall have a factor of safety of 2 (minimum) over the calculated loads/capacities. 8.0

BACKFILLING AND BANK PROTECTION

8.1

Backfilling of the water-crossing section shall be performed as described in the following clauses.

8.1.1 The bottom of the water way shall be reinstated to its original level by backfilling the trench in a manner and with suitable material and as prescribed and approved by the Authorities and Company. In case material other than the original spoil is required, this shall be supplied and applied by Contractor.



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Wherever boulders, rock, gravel and other hard objects are encountered, they shall not be placed directly on the pipe. Sufficient earth, sand or selected and approved back fill material shall be backfilled initially around and over the pipe to provide a protective padding or cushion extending to a minimum thickness of 0.5 m around the pipe before backfilling remainder of the trench with excavated or other material. Wherever required by Company, Contractor shall cover the nearly backfilled trench with a layer of rock boulders to be approved by Company over a width equal to the width of excavated trench with an extra of 5m on either side at no extra cost to Company. 8.1.2 Backfilling progress of the trench shall be checked continuously and a daily progress report shall be made in three-fold and handed over to Company. 8.1.3 All embankments and/or dikes, bed and banks shall be reinstated to their original state and levels, unless otherwise prescribed in the drawings or by the competent Authorities or Company. 8.1.4 All remaining spoil-deposits shall be cleaned by Contractor to the satisfaction of Company. 8.2

Bank Protection Trenches in banks of major water crossing shall be backfilled with soil approved by Company. The fill at the banks shall be compacted firmly and reinforced with sacked earth, rip-rap, or by other means as directed by Company to the satisfaction of Authorities having jurisdiction thereof. In areas where the backfilled soil is expected to be of loose type, which is prone to flow, the trench shall be backfilled with crushed rock of size approved by Company and pipe shall be provided with adequate padding of soil of a quantity approved by Company. After the trench has been backfilled and during the clean up works, the water crossing shall be cleaned across the whole width of ROU. Unless stipulated otherwise by the Authority or by Company, Contractor shall protect the banks of the major water crossings by using gravel and boulders filled embankment mattresses of galvanized iron wire to be laid over the backfilled, compacted and graded banks. In case slope of the banks is 1:1 or more, bank protection shall be carried out using gabions. Bank protection works shall be carried out by Contractor in accordance with the drawings included in the CONTRACT. All materials required for such works shall be supplied by Contractor and all works carried out in accordance with specifications, approved drawings, instructions of Company and to the complete satisfaction of Authorities having jurisdiction at no extra cost to Company.



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The length of the above protection shall be equal to the bank excavation and damage and further extending 10 m on either sides. The width of the 'restoration on the slope shall be determined by the levels: -

2m above Highest Water Level, and

-

5m below Low Water Level or 60m along the slope from Highest Water Level, whichever is the smaller.

8.3

Before final hydrostatic testing, Contractor shall "prove" the Diameter of the pipeline by passing a gauging pig through the pipeline. The gauging pig shall be capable of locating and detecting defects permitted by governing code. Contractor shall supply and install all temporary scraper launchers receivers and other equipment, piping materials and other consumables for the purpose.

9.0

POST-INSTALLATION HYDROSTATIC TEST The complete water crossing must be tested immediately after the approved backfilling of the trench. The test procedure shall result in a hoop stress in pipe corresponding to 90% SMYS of the pipe material. After temperature stabilisation, pressure shall be retained in the pipeline for a minimum twenty four (24) hours and recorded by manothermograph. The hydrostatic testing shall be carried out in accordance with approved procedures.

10.0 POST-CONSTRUCTION SURVEY After laying of the pipeline, Contractor shalI carry out a post-construction survey jointly with Company. Any defects brought to the notice of Contractor shall be promptly corrected by contractor at his own expense to the complete satisfaction of Company. 11.0 FINAL CLEAN-UP After completion of construction, Contractor shall clear the site of all balance material and debris. All balance pipe lengths, in case supplied by company, shall be returned to Company's designated stock yard(s). Site shall be cleared to the complete satisfaction of Company and Authorities having jurisdiction. All such works shall be done at no extra cost to Company. 12.0 DOCUMENTATION 12.1

In addition to the documents specified elsewhere in this specification, Contractor shall submit to the Company six copies of leach of the following documents/records.



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12.2

-

Complete record of pipes "taken-over" from Company, number of pipe lengths used, and record of return of balance pipe length to Company's designated stock yard(s)

-

Copies of the permits obtained from Authorities having jurisdiction for the various works.

-

Records of Non Destructive Testing of welds.

-

Clearance certificates from the land owners and Authorities having jurisdiction regarding satisfactory clean-up and restoration of pipeline RoU and work areas.

After completion of construction, Contractor shall prepare and furnish six sets of copies and two sets of reproducible of As-Built drawings for the crossings. As-Built drawings shall be as a minimum, include the following information:

12.3

-

True profile of the bed and banks of water crossing along the pipeline after backfilling

-

True profile of the pipeline as installed and depth of cover at top of pipe at 10 m interval.

-

Location and angle of sag bends and over bends.

-

Cross section along the pipeline indicating nature and extent of backfill materials, thickness of concrete coating to pipe etc.

-

Method and extent of bank protection.

All documents shall be in English language.



SPECIFICATION

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STANDARD SPECIFICATION FOR PIPELINE CONSTRUCTION (ONSHORE)




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1.0

SCOPE

1.1

This specification covers the minimum requirements for the various activities to be carried out by Contractor for or about the construction of cross-country onshore pipelines.

1.2

The various activities covered in this specification include the following works of pipeline construction: -

Clearing, grubbing and grading of Right-of-Use;

-

Construction of all temporary facilities required in connection with the WORKS;

-

Staking of the pipeline route;

-

Handling, hauling, stringing and storing of all materials;

-

Trenching;

-

Field bending of line pipe;

-

Lining-up and Welding;

-

Pipeline laying;

-

Backfilling;

-

Tieing-in

-

Installation of auxiliary facilities and appurtenances forming a part of pipeline construction;

-

Clean-up and restoration of Right-of-Use;

-

Maintenance during defects liability period.

1.3

This specification shall be read in conjunction with Scope of Work and requirements indicated in specifications and documents included in the CONTRACT between Company and Contractor.

1.4

Contractor shall, with due care and diligence, execute the WORK in compliance with all laws, by laws, ordinances, regulations etc. of the land and provide all services and labour, inclusive of supervision thereof, all materials, excluding the materials indicated as "Company Supplied Materials" in the CONTRACT, equipment, appliances or other things of whatsoever nature required for the execution of the WORK, whether of a temporary or permanent nature.

1.5

Contractor shall take full responsibility for the stability, suitability and safety of all operations and methods involved in the WORK.




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1.6

Contractor shall be deemed to have inspected, examined and independently obtained all necessary information of WORK area(s) and its surroundings and shall have satisfied himself as practicable to the form and nature thereof, including sub-surface conditions, hydrological and climatic conditions, the extent and nature of the WORK and materials necessary for the completion of the WORK, and the means of access to the WORK area(s).

1.7

Contractor shall be deemed to have obtained and understood all necessary information with respect to risks, contingencies and all other circumstances, which may influence the WORK. Any neglect/omission/failure on the part of Contractor in obtaining necessary and reliable information for performance of WORK shall not relieve him from any liabilities or responsibilities for completion of WORK.

1.8

Contractor shall, in connection with the WORK, provide and maintain at his own costs, all lights, guards, fencing, watching etc., when and where necessary or required by Company or by any duly constituted authority and/or by the authorities having jurisdiction thereof for the protection of the WORK and properties or for the safety and the convenience of public and/or others.

1.9

Unless otherwise specified, all sections of this specification shall apply to all the specifications referred in this specification.

2.0

REFERENCE CODES, STANDARDS AND SPECIFICATIONS

2.1

Reference has been made in this specification to the latest edition of the following codes, standards and specifications: a.

API 1 104

-

Welding of Pipelines and Related facilities

b.

API 1105

-

Bulletin on Construction Practices for Oil and Products Pipelines.

c.

ASMEB 31.4

-

Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids.

d.

ASME B 31.8

-

Gas Transmission and Distribution Piping Systems.

e.

OISD B 141

-

Design and construction requirements for cross-country hydrocarbon pipelines

f.

Part 192, Title 49

-

Transportation of Natural and other Gases by Pipe Line (US DOT - Pipe Line Safety Standards).

g.

Part 195

-

Transportation of liquids by Pipe Line (US DOT - Pipe Line Safety Standards)

In case of conflict between the requirements of above mentioned codes, standards and practices, the most stringent requirement shall govern. In case of conflict between the requirements of this




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specification and that of the above referred codes, standards and practices, the requirements of this specification shall govern. 2.2

3.0



-


REQUIREMENT OF RIGHT OF USE AND ACCESS THERETO Contractor shall, before starting and clearing operations, familiarize himself with all the requirements of the Authorities having jurisdiction over the Right of Use (ROU) for WORK along the pipeline route or in connection with the use of other lands or roads for construction purposes. Contractor shall notify Company well in advance during WORK progress, the method of construction for crossing road, railway, pipeline, cable, canal, river and other existing obstacles. Contractor shall not commence WORK on such crossings before having obtained approval from the Authorities and landowners concerned to the satisfaction of Company. The crossings shall be installed to meet at all times, the requirements and conditions of the permit(s) issued by the Authorities concerned. In the absence of any specific requirements by Authorities, Contractor shall comply wit11 Company's instructions. The right of ingress and egress to the ROU shall be limited to points where such RoU intersects public roads. Arrangements for other access required by the Contractor shall be made by him (at his own cost and responsibility) and for such accesses the requirements of this specification shall also apply. Where the ROU comes within 30 meters of an existing line or facility, Contractor shall propose and provide methods to safeguard the existing line or facility (e.g. a demarcation fence). No work is allowed in such areas without Company's prior approval. Where the ROU comes within the area of influence of high voltage electrical installations, the following instructions shall be followed:

3.1

Instructions concerning high voltage influencing Safety measures during construction of pipelines inside the area influenced by high voltage lines.

3.1.1 General Pipelines, which are constructed inside the area of high voltage lines, may be electrically influenced by these high voltage lines. The voltage caused by the influence may at times be so high as to pose a danger to personnel working on the pipeline. It is imperative therefore, that the instructions given below shall be accurately followed: GAIL (INDIA) LTD NEW DELHI



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3.1.1.1 It is a prerequisite that all personnel involved in construction of the pipeline, which is being constructed in the area influenced by the high voltage system, must be given clear instructions on safety measures to be taken while execution of WORK. 3.1.1.2 Vehicles and equipment must be earth-connected. This may be effected by attaching an uninsulated cable or chain (which touches the ground) of adequate length to the underside of the vehicle. 3.1.1.3 If it is not impossible for plant and/or materials to come to within 50m of the centre of the high voltage system, special measures must be taken to prevent any approach beyond that distance, unless Clause 3.1.2 is complied with. 3.1.1.4 DURING THUNDERSTORMS OR WHEN DISCHARGES ARE OBSERVED ON INSULATORS ALL PERSONNEL MUST LEAVE THE AREA OF THE HIGH VOLTAGE LlNE AND PIPELINE. 3.1.1.5 To prevent electrical voltages in a non-buried section of the pipeline from rising to dangerous values, the length of the pipeline section which has been welded together before burial must not exceed the length at which the maximum admissible voltage may be induced. This length shall be calculated using an approved calculation method. 3.1.1.6 Before a pipeline section is lowered into the trench the structure's earth electrodes indicated in the drawings or determined with calculation method must have been installed and connected both to the pipeline section already buried and to the section, which is about to be buried. The electrical connections, which serve the purpose of preventing dangerous voltages, must have a min. area of 35 mm2. Said connections must not be interrupted until after the permanent safety earth connections have been installed and connected to the entire uninterrupted pipeline. 3.1.1.7 The welded connection between the pipeline section and the section already buried must be installed at a distance of at least 50m from the nearest point of a pylon base. 3.1.1.8 Personnel doing WORK inside the area influenced by the high voltage system must wear electrically insulating foot-wear (e.g. rubber knee boots) and wear insulating rubber or plastic gloves. 3.1.2 Additional measures for WORK to be done at a distance less than 50m from the centre of the high voltage system. If WORK is to be done at a distance less than 50m from the centre of the high voltage system, the measures indicated below must be complied with, in addition to the instructions specified in clause 3.1.1.




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3.1.2.1 The WORK must not be started until agreement has been reached with the Authorities, which control the high voltage system, about the implementation of the safety measures specified in this section. 3.1.2.2 Measures must be taken to prevent excavating and hoisting equipment from approaching high voltage lines to within any of the following distances. This distance depends on the voltage carried. For individual connections the distance must be:

The measures taken may be as follows: 1.

Special selection of equipment, or limiting or blocking certain directions of movement, or limiting the operational area, thereby mal
2.

In case the measures recommended in 1. above are not feasible, installation of clearly visible markers of sufficient height or laying out a 'no passage beyond this point' line of drums painted bright red and white must prevent any WORK being done inside the danger area. Furthermore, an inspector must be present all the time.

3.1.2.3 In the event that a vehicle, crane etc. should accidentally come into contact with a live cable of a high voltage system or flash-over of electrical charge occurs, the driver must not leave his vehicle because this will pose a serious threat to his life. The vehicle or crane must break the contact WITHOUT ANY HELP FROM OUTSIDE. The driver must not leave his vehicle until he has managed to leave the dangerous area, or alternatively, when the Electricity Authorities have given notice that the cable(s) have been put out of circuit. In case a serious fire starts in the vehicle, he is permitted to jump from the vehicle, clearing it as far as possible, while the jump should possibly be to a dry spot. 4.0

RIGHT-OF-USE The Contractor is required to perform his construction activities within the width of Right-ofUse (RoU) set aside for construction of pipeline, unless he has made other arrangements with the land owner and/or tenant for using extra land. Variation in this width caused by local conditions or installation of associated pipeline facilities or existing pipelines will be identified in the field or instructed to the Contractor by Company. The Right-of-Use boundary lines shall be accurately staked by the Contractor, so as to prepare the strip for laying the pipeline. GAIL (INDIA) LTD NEW DELHI



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4.1

Stakings Prior to clearing operations Contractor shall: 1.

Install Bench Marks, Intersection Points and other required survey monuments.

2.

Stake markers in the centerline of the pipeline at distances of maximum 100 metres for straight line sections and maximum 10 metres of horizontal bends. Wherever RoU centerline has been staked on ground, Contractor shall exercise care in accurately staking the pipeline centerline, in consultation with Company.

3.

Stake two ROU markers at least at every 100 metres.

4.

Set out a reference line with respect to pipeline centerline at a convenient location. Markers on reference line shall be at a distance of maximum 100 metres for straight line sections and maximum 10 metres for horizontal bends.

5.

Install distinct markers location and indicating special points, such as but not limited to: Contract limits, obstacle crossings, change of wall thickness, including corresponding chainage, etc.

6.

Chainage markers shall be installed at every 250 meter

ROU Markers shall be staked out at the boundary limits of Right-of-Use wherever possible. ROU Markers shall be painted red with numbers painted in white. Number shall be identical to centerline marker number with letters A (left side) and B(right side) added, (looking to flow direction). Reference markers shall also carry the same information as its corresponding centerline markers. Markers shall be of suitable material so as to serve their purpose and shall be coloured distinctly for easy identification. Contractor shall be responsible for the maintenance and replacement of the reference line markers until the permanent pipeline markers are placed and the as-built drawings are submitted and approved. Any deviation from the approved alignment shall be executed by Contractor after seeking Company approval in writing prior to clearing operations. 4.2

Monuments All shrines, monuments, border stones, stone walls and the like shall be protected and when required, removed for safe keeping and replaced in original condition after construction as directed by Company.

4.3

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Prior to clearing and grading of the Right-of-Use or stringing of pipe, Contractor shall open fences on or crossing the construction Right-of-Use and install temporary gates of sound construction made of similar materials and suitable quality to serve purpose of original fence. Adjacent posts shall be adequately braced to prevent slackening of the remainder of the fence. Before such fences are cut and opened, Contractor shall notify"t11e land owner or tenant, and where practicable, the opening of the fences shall be in accordance with the wishes of said owner and tenant. In all cases where Contractor removes fences to obtain WORK room, Contractor shall provide and install temporary fencing, and on completion of construction shall restore such fencing to its original condition. Contractor shall install temporary fencing on either side of ROU where in Company's opinion, it is considered essential to ensure safety and non-interference, especially in areas like grazing lands, villages etc. Fencing shall be removable type wherever necessary, to permit crossing of traffic. The type of fencing must be suitable for the situation in accordance with user. The pole distance shall not be greater than 6m. The minimum height of the fencing shall be 1.2 in above grade. Fencing can consist of one or more rows of smooth wire and/or of barbed wire. Fencing shall be continuously maintained and the through-ways inspected to be shut during the execution of the WORK. 4.4

ROU Clearing and Grading Any obstacle, which may hinder the construction and laying of the pipeline all along the pipeline route and for a strip of land of the size provided, shall be removed.

4.4.1 All stumps shall be grubbed on a continuous strip, with a width equal to trench top width plus two meters on either side centered on the pipeline centerline. Further, all stumps will be grubbed from areas of the construction Right-of-Use, where Right-of-Use grading will be required. Outside of these areas to be graded and the mentioned trench strip, and at the option of Contractor, the stumps may either be grubbed or cut off to ground level. Any stump cut off must be left in a condition suitable for rubber-tyred pipeline equipment traffic. 4.4.2 All grubbed stumps, timber, bush, undergrowth and roots cut or removed from the Right-of-Use shall be disposed off in a manner and method satisfactory to Company, land-owner and/or tenant, and Government Authorities having jurisdiction and as soon as practical after the initial removal. In no case shall it be left to interfere with the grading and laying operations. Whenever stumps are grubbed and a hole is left in the ground, Contractor shall back-fill the hole and compact it to prevent water from gathering in it and malting a big hole. 4.4.3 Contractor shall grade the pipeline Right-of-Use as required for proper installation of the pipeline, for providing access to the pipeline during construction, and for ensuring that the pipeline is constructed in accordance with the most up-to-date engineering and construction practices.



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4.4.4 Contractor shall grade sharp points or low points, without prejudice to section 6.0 (trenching) of this specification, to allow the pipe to be bent and laid within the limits set forth in these specifications and drawings as regards the minimum elastic curvature permitted, and shall drill, blast or excavate any rock or other material which cannot be graded off with ordinary grading equipment in order to make an adequate working space along the pipeline. 4.4.5 No temporary or permanent deposit of any kind of material resulting from clearing and grading shall be permitted in the approach to roads, railways, streams, ditches, drainage ditches and any other position which may hinder the passage and/or the natural water drainage. 4.4.6 The Right-of-Use clearing and grading operations shall in no case involve embankment structures of any type and class without prior approval of the authorities having jurisdiction over the same. 4.4.7 In the case of natural or artificial deposits of loose soil, sand, heaps of earth, or other fill materials, these shall be removed till stable natural ground level is reached so as to ensure the construction of the pipeline ditch in stable ground. 4.4.8 In the case of Right-of-Use clearing and grading on the hillside or in steep slope areas, proper barriers or other arrangement/structures shall be provided to prevent the removed materials from rolling downhill. The Right-of-Use cross fall shall not exceed 10%. Slope of side hill faces shall be stabilized to prevent landslides. 4.4.9 Wherever the pipeline Right-of-Use runs across, through or alongside farmyards, built-up areas, groups of trees, forests, groves, horticultural spreads, gardens, grass-fields, ditches, dikes, roads, paths, railways or any other area with restrictions of some kind, Contractor shall grade only the width of the Right-of-Use necessary for digging the pipeline trench and constructing the pipeline. In the said places Contractor shall carry out the works in such a way that damage resulting from the pipeline construction is kept to a minimum. 4.5

Provision of detours Contractor shall do all necessary grading and bridging at road, water and other crossings and at other locations where needed, to permit the passage of its men and equipment. It is understood that the Contractor has recognized such restrictive features of the Right-of-Use and shall provide the necessary detours and execute the works without any extra cost to Company. Public travel shall not be inconvenienced nor shall it be wholly obstructed at any point. Contractor at his own cost shall furnish and maintain watchman detours, lanterns, traffic lights, barricades, signs, wherever necessary to fully protect the public. Contractor shall be responsible for moving its equipment and men across or around watercourses. This may require the construction of temporary bridges or culverts. Temporary bridging required for Right-of-Use crossing water courses shall be constructed in consultation with concerned Authorities. Contractor shall ensure that such temporary works shall not interfere with normal water flow, avoid overflows, keep the existing morphology unchanged and shall not unduly damage the banks of water courses. No public ditches or drains shall be filled or bridged GAIL (INDIA) LTD NEW DELHI


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for passage of equipment until Contractor has secured written approval of the Authorities having jurisdiction over the same. Contractor shall furnish Company a copy of such approval. 4.6

Steep and rocky terrain Grading operations could normally be carried out along the Right-of-Use with mechanical excavators or manually. In certain areas, grading may have to be resorted to exclusively by blasting. In rough or steep terrain, Contractor may have to grade access roads and temporary bypass roads for its own use. Where such access roads do not fall on the Right-of-Use, Contractor shall obtain necessary written permission from land owners and tenants and be responsible for all damages caused by the construction and use of such roads, and at no extra cost to Company. Wherever rocky terrain is encountered, grading shall be carried out in all types of solid rocks which cannot be removed until loosened by blasting, drilling, wedging or by other recognized methods of querrying solid rocks. Where use of explosives is required in connection with Right-of-Use grading and trenching, Contractor shall comply fully with requirements of the use of explosives as provided under clause 6.3 of this Specification and as provided under "Rules for Blasting", as per “Specification for Blasting” issued for this purpose.

4.7

Off Right-of-Use Damages Contractor shall confine all its operations within limits of the Right-of-Use. Any damage to property outside RoU shall be restored or settled to the Contractor's account. Contractor shall promptly settle all off Right-of-Use damage claims. Should Contractor fail to do so, Company shall give written notice to Contractor that if Contractor does not settle such claims within seven days after such notice, Company shall have the authority to settle claims from the account of Contractor.

5.0

HANDLING, HAULING, STRINGING AND STORING OF MATERIALS

5.1

General The Contractor shall exercise utmost care in handling line pipe and other materials. Contractor shall be fully responsible for all materials and their identification until such time that the pipes and other materials are installed in permanent installation. Contractor shall be fully responsible for arranging and paying for temporary storage areas for the pipeline materials, however, method of storage shall be approved by Company. Contractor shall reimburse the Company for the cost of replacement of all Company supplied materials damaged during the period in which such materials are in the custody of the Contractor. It shall be Contractor's responsibility to unpack any packings for the materials supplied by Company. GAIL (INDIA) LTD NEW DELHI


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Pipe bevel protectors shall always be kept in position during all handling, transportation and stringing operations and shall be removed only prior to fit-up for welding. After fabrication and welding, the Contractor shall arrange to return all such bevel protectors at Company's designated storage yard and as instructed by Company. 5.2

"Taking-over" of line pipe The following stipulations shall apply in case CONTRACT provides for supply of line pipe, bare and/or corrosion coated, by Company. Contractor shall receive and 'take over' against requisition, line pipe from the Company’s designated place(s) of delivery as defined in the CONTRACT. Contractor shall perform visual inspection of the bare pipes and coating of the corrosion coated pipes, as the case may be, in the presence of Company and all damages shall be recorded. In the case of corrosion coated pipes Contractor at his option may carry out holiday detection at a prescribed set voltage and record such holidays, in the presence of Company, at the time of 'taking over'. HOWEVER, if Contractor proposes to perform only visual inspection of coating, then repair of all holidays found at the time of laying the pipeline shall be carried out by the Contractor at no extra cost to Company. The Contractor shall be entitled to extra compensation for repair and rectification of defects recorded at the time of 'taking over' as per the rate set fort11 in the "CONTRACT". Repair of all damages occurring after taking over the delivery of the materials shall be to the Contractor's cost. In case of delays in handing over of Company supplied materials, Contractor shall be fully responsible for stopping and rearranging means of transportation at no extra cost to Company.

5.3

Handling and hauling of line pipe

5.3.1

Bare pipes Contractor shall unload, load, stockpile and transport the bare pipes using suitable means and in a manner to avoid denting, flattening, or other damages to pipes. Pipe shall not be allowed to drop or strike objects, which will damage the pipe but shall be lifted or lowered from one level to another by suitable equipment. Lifting hooks when used, shall be equipped wit11 a plate curved to fit the curvature of the pipe. In loading pipe on trucks each length shall be lowered to position without dropping and each succeeding length shall rest on special supports on the truck and shall be separated from the adjacent pipes. After loading, suitable chains and padding shall be used to tie the load securely to each bolster. Pipe, when stock piled, shall be placed on suitable skid to keep it clear of the ground and flood water. Care shall be exercised in handling or stock-piling pipes in order to avoid distortion, flattening, denting or other damages. The Contractor shall provide all necessary timber or other materials required for the stock-piling. While stacking, the number of allowable layers of bare pipes shall be calculated as per API RP 5L1 and shall be agreed with Company. The stacks must be properly secured against sliding and shall consist of pipes of the same diameter and wall thickness. Adjacent stacks of pipes having different dimensional characteristics shall be clearly separated.



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Pipes which are damaged at the time of delivery or 'taking-over' (when line pipe is supplied by Company), particularly those which are dented, buckled, or otherwise permanently deformed, must be stacked separately and may be transported to the sites only when these defects have been repaired or eliminated. 5.3.2

Corrosion coated pipes The Contractor shall load, unload, transport and stockpile the coated pipes using approved suitable means and in a manner to avoid damage to the pipe and coating. Contractor shall submit to Company a complete procedure indicating the manner and arrangement used for handling and stacking of coated pipes for Company approval prior to commencement of handling operations. Use of vacuum lifting equipments is preferred. Hooks may also be used for handling the pipes provided they have sufficient width and depth to fit the inside of the pipe and covered with soft material like rubber, Teflon or equivalent, so as not to cause damages to bevel or pipe ends. During hoisting cables/wire ropes shall have sufficient inclination compared to pipe axis so that they do not come into contact with external coating. Coated pipes may be handled by means of slings and belts of proper width (minimum 60 mm) made of non-metallic/non-abrasive materials. In this case, pipes to be stacked shall be separated row by row to avoid damages by rubbing the coated surface in the process of taking off the slings. Use of round sectional slings is prohibited. During handling, suitable handling equipments with proper length of booms shall be used. Forklifts may be used provided that the arms of the forklifts are covered by suitable pads preferably rubber. Before lifting operations, it is essential to ensure that the pipe surface is free from foreign materials with sharp edges. Belts/slings when used shall be cleaned to remove hard materials such as stone, gravel etc. Coated pipes shall not be bumped against any other pipe or any other objects. Rolling, skidding or dragging shall be strictly forbidden. Coated pipes at all times shall be stacked completely clear from the ground so that the bottom row of pipes remain free from any surface water. The pipes shall be stacked at a slope so that driving rain does not collect inside the pipe. The coated pipes may be stacked by placing them on ridges of sand free from stones and covered with a plastic film or on wooden supports provided with suitable cover. This cover can, for example, consist of dry, germ free straw with a plastic film, otherwise foam rubber may be used. The supports shall be spaced in such a manner as to avoid permanent bending of the pipes, particularly in case of small diameter pipes with low wall thickness. The pipes shall be stacked so that the uncoated bevelled ends are in line at one end, thus making differences in lengths clearly noticeable. Stacks shall consist of limited number of layers so that the pressure exercised by the pipes own weight does not cause damages to the coating. Each pipe section shall be separated by means of spacers suitably spaced for this purpose. Stacks shall be suitably secured against falling down and shall consist of pipe sections having the same diameter and wall thickness. The weld bead of pipes shall be positioned in such a manner so as not to touch the adjacent pipes.



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Coated Pipes stacked in open storage yards/dump yards shall be suitably covered on top to decrease direct exposure to sunlight. The ends of the pipes during handling and stacking shall always be protected with bevel protectors. The trailers/rail wagons shall be equipped with adequate pipe supports having as many round hollow beds as the number of pipes to be placed on the bottom of the trailer bed. Supports shall be provided for at least 10% of the pipe length. These supports shall be lined with a rubber protection and shall be spaced in a manner as to support equal load from the pipes. The rubber protection shall be free from all nails and staples where pipes are in contact. The second layer and all subsequent layers shall be separated from each other with adequate number of separating layers of protective material such as straw in plastic covers or mineral wool strips or equivalent, to avoid direct touch between the coated pipes. All stanchions of trailers/rail wagons used for transportation shall be covered by non-abrasive material like rubber belts or equivalent. Care shall be exercised to properly cover the top of the stanchions and convex portions such as reinforcement of the truck/rail wagon body, rivets etc. to prevent damage to the coated surface. 5.4

Stringing of pipe Pipes shall be unloaded from the stringing trucks and lowered to the ground by means of Side boom/Hydra crane tractor or swinging crane or other suitable equipment using lifting devices as mentioned earlier. Dragging or sliding of pipe shall not be permitted. Special precaution shall be taken during stringing of corrosion coated pipes as per the special requirements of previous Para. Stringing of pipe shall only be carried out in daylight and after clearing and grading operations have been completed. Pipe shall not be strung on the Right-of-Use in rocky areas where blasting may be required, until all blasting is complete and the area cleared of all debris. The stringing of the pipe on the Right-of-Use shall be done in such a manner as to cause the least interference with the normal use of the land crossed and to avoid damage to or interference with the pipes. The sequence of pipes must be interrupted at suitable intervals, spaced to coincide with passages, roads, railways and water-courses crossings as well as at other places if requested by land Owner or tenants to permit use of the land. Also care shall be taken to provide safe working space between trench edge and the pipe. Pipe shall be strung on approved soft earth/sand filled bags and wedge. Bottom of pipe shall in no way touch the ground. There shall be sufficient clearance from bottom of pipe & the ground level. The pipe shall be supported at minimum two locations. In case line pipe supply is by different Manufacturers, Contractor shall string all line pipe of one Manufacturer before commencing the stringing of the line pipe of another Manufacturer. When parallel pipelines are being constructed, bumping against and contact with the strung sections of pipe shall be avoided, whether the stringing of the pipes for the individual lines is



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carried out separately or simultaneously. When parallel pipes of different sizes are to be laid, the pipe stringing shall suit the respective location of pipes in the trench. The pipe lengths must be properly spaced in order to make easier the handling during the welding phase. It shall be the responsibility of the Contractor to see that pipe is strung in accordance with the approved drawings for the proper placement of pipe by size, thickness, grade and other specifications. Any additional handling of pipes resulting from failure to, comply with these requirements shall be at the Contractor's expense. 5.5

Repair of damaged pipes After the pipe has been strung on the Right-of-Use, it shall be inspected by the Contractor and the Company and all defective pipe ends repaired. Defective pipes shall be repaired or rejected as the Company may direct as per the requirements of clause 5.2 of this Specification.

5.6

Materials other than linepipe Contractor shall receive and take over against requisition all Company supplied materials from Company's designated place(s) of delivery as defined in the CONTRACT. Contractor shall perform visual inspection and defects, if any noted, shall be recorded separately. The Contractor shall be entitled to extra compensation for repair and rectification of such defects at the rates set forth in the 'CONTRACT". The Contractor shall perform the necessary loading, unloading, hauling from points designated by the Company and storing, if necessary, of all materials. The Contractor shall exercise care in handling, hauling, storing and distribution of materials in order to avoid damage and deterioration of these materials and prevent their theft or loss. Materials excluding line pipe shall be stored in sheltered storage. Such materials shall not be strung on the Right-of-Use but shall be transported in covered conveyances for use only at the time of installation. Contractor shall ensure that all valves and whenever applicable, other materials are fitted with suitable end covers of the type approved by Company. Materials with worked surfaces such as / flanges, pipe fittings, etc. must be stacked and handled so as to avoid contact with the ground or with substances that could damage them. The Manufacturer's instructions regarding temperature and procedure for storing materials, which are subject to alteration of the original properties and characteristics due to unsuitable storage, must be strictly complied with and, if required, an adequate heat conditioning shall be provided for these materials. When material is supplied in containers and packages, it must not be thrown or dropped, nor handled using hooks which could damage the container or the materials, either during loading/unloading or during successive handling, until their final use. GAIL (INDIA) LTD NEW DELHI


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Coating materials, which are susceptible of deteriorating or suffering from damages especially due to humidity, exposure to high thermal excursions or other adverse weather conditions, shall be suitably stored and protected. These materials shall be kept permanently in store, supported above the ground in a dry place protected against the weather and transported for use only at the time and in the quantities necessary for immediate application. Deteriorated materials shall not be used and replaced with no extra cost to Company. 5.7

Identification Contractor shall provide all pipes, bends etc. greater than 50mm NB with serial numbers as soon as possible upon the receipt of such materials at site and measure their length and state it on the pipes, etc. Pipes to be bent shall be measured prior to bending. Identification (i.e. letter, number and length) shall be indelible. All serial numbers shall be recorded in a list, which shall also state appurtenant pipe numbers. Beside recording the stamped pipe numbers, length of pipe and painted-on serial numbers, the stamped-in numbers of T-pieces, bends, valves, etc. and the batch numbers of bends, T-pieces, valves, etc and the make of valves, shall also be recorded in said list. Before a pipe length, pipe end, etc is cut, the painted serial number and stamped-in pipe number shall be transferred by Contractor in the presence of Company to either side of the joint, which is to be made by cutting, and the changes shall be recorded in the above mentioned list stating the (new) length. The result shall be such that all pipes, pups, etc. of diameter greater than 501mm NB bear clear marks painted on. Contractor shall explicitly instruct his staff that parts which cannot be identified must not be removed, except after permission by Company. As a general rule parts shall be marked as described above before being moved. In no conditions may unmarked parts be incorporated into the WORK.

6.0

TRENCHING

6.1

Location Contractor shall excavate and maintain the pipeline trench on the staked centerline of the pipeline taking into account the curves of the pipeline. In case of common ROU, the centerline of the trench shall be established from the location of existing pipeline. In case of independent ROU, the centerline of the trench shall be established from the edge of ROU.

6.2

Excavation



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6.2.1 Contractor shall, by any method approved by Company, dig the pipeline trench on the cleared and graded Right-of-Use. In cultivable land and other areas specifically designated by the Company, top 300mm of the arable soil on the pipeline trench top width shall be excavated and stored separately, to be replaced in original position, after backfilling and compacting rest of the trench. Suitable crossings shall be provided and maintained over the open RoU, where necessary, to permit general public, property owners or his tenants to cross or move stock or equipment from one side of the trench to the other. Care shall be exercised to see that fresh soil recovered from trenching operation, intended to be used for backfilling over the laid pipe in the trench, is not mixed with loose debris or foreign material. The excavated material shall never be deposited over or against the strung pipe. 6.2.2 In steep slope areas or on the hillside, before commencing the works, proper barriers or other protection shall be provided to prevent the removed materials from rolling downhill. 6.2.3 On slopes wherever there is danger of landslide, the pipeline trench shall be maintained open only for the time strictly necessary. Moreover, the Company may require manual excavation of trench, local route detouring and limiting the period of execution of the works. The Contractor shall make adequate arrangements for safe working of the personnel involved in manual excavation of trench. 6.2.4 In certain sloppy sections, before the trench cuts through the water table, proper drainage shall be ensured both near the ditch and the Right-of-Use in order to guarantee soil stability. 6.2.5 All sewers, drain ditches and other natural waterways involved in the execution of the works shall be maintained open and functional. The same applies to canals, irrigation canals, and pipelines and buried facilities crossed by the ditch for which temporary pipelines shall be laid, if required, and proper temporary installations provided. 6.3

Blasting Blasting for trenching and the related removal of scattered rock and debris caused by the blasting from the Right-of-Use and/or adjacent property, shall be performed by Contractor as part of his WORK. Every possible precaution shall be taken to prevent injuries and damages to persons and properties during blasting operations, which shall be performed in accordance with Rules for Blasting in Standard Blasting Specification issued for the purpose.

6.3.1 All necessary precautions shall be taken to prevent stones from falling outside the Right-of-Use and in cultivated areas and to avoid any damage to the installations and properties existing nearby. 6.3.2 Blasting and removal of debris shall be carried out prior to stringing the pipes.



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6.3.3 Company reserves the right to refuse blasting where possible danger exists to property, existing utilities or other structures. In such locations other methods of extracting rock shall be proposed by Contractor and shall be approved by Company. 6.4

Normal cover and trench dimensions The trench shall be excavated to a minimum width so as to provide, on both sides of the installed pipeline, a clearance as indicated in the job standards/drawings and to a depth sufficient to provide the minimum cover as indicated below. The dimensions in the table below shall govern except as noted herein or as shown on the job standards or detailed construction document/drawings or as required by authorities having jurisdiction, whichever is greatest. Minimum depth of cover shall be measured from the top of pipe corrosion/concrete weight coating (as applicable) to the top of undisturbed surface of the soil or top of graded working strip or top of road or top of rail whichever is lower. Fill material in working strip shall not be considered to add to the depth of cover. However, surface of fill material placed to fill hollows may be used to determine the depth of cover subject to prior approval by Company. Location

Minimum Cover in meters

a)

Industrial, Commercial & Residential Area

1.0

b)

Rocky Terrain

1.0

c)

Minor water crossing/canals/drain/nala/stream

1.5

d)

River crossings for which scour depth is defined (below scour)

1.5

e)

River crossings (Bank width < 501n) (below lowest bed level)

1.5

f)

Other River crossings (Bank width > 5011-1) (below lowest bed level)

2.5 (for normal soil) 1.5 (for rocky strata)

g)

Water crossing by HDD (below lowest bed level)

2.5

h)

Uncased/Cased Road Crossing/Station approach

1.2

i)

Railways crossing

1.7

j)

Drainage, ditches at roads/railway crossings

1.0

k)

Marshy land and creek area

1.5

Notes:



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In case pipeline is located within 15 m from any dwelling unit, the cover shall be increased by 300 mm over and above that specified. 6.5

Cutting and removal of paving Whenever it is permitted by Authorities and/or Company to open cut a paved road crossing, or where the line is routed within the road pavement, Contractor shall remove the paving in accordance wit11 the restrictions and requirements of the Authorities having jurisdiction thereof or as directed by Company. The open cut for the road crossing shall be carried out only when the section of pipeline to be laid is complete. After laying the pipeline, backfilling shall be immediately performed and all the area connected with the works shall be temporarily restored. Throughout the period of execution of such works, Contractor shall provide and use warning signs, traffic lights or lanterns, barricades, fencing, watchman, etc. as required by the local authorities having jurisdiction and/or Company. For all roads, paths, walkways etc., which are open-cut, Contractor shall provide temporary diversions properly constructed to allow the passage of normal traffic with the minimum of inconvenience and interruptions. The paving shall be restored to its original condition after the pipeline is installed.

6.6

Extra depth and clearance At points where the contour of the earth may require extra depth to fit the minimum radius of the bend as specified or to eliminate unnecessary bending of the pipe according to customary good pipeline practice, or where a deep trench is required at the approaches to crossings of roadways, railroads, rivers, streams, drainage ditches, and the like, Contractor shall excavate such additional depth as may be necessary at no extra cost to the Company. Contractor shall excavate to additional depth where the pipeline approaches and crosses other pipelines, sewers, drain pipes, water mains, telephone conduits, and other underground structures, so that the pipeline may be laid with at least 50 centimeters free clearance from the obstacle or as specified in the drawings, or such greater minimum distances as may be required by authorities having jurisdiction. Where the pipeline crosses areas, whose easements specifically require greater than normal depths of cover, the trench shall be excavated to extra depth in accordance with the Right-of-Use Agreements or as required. Contractor shall excavate all such additional depths as may be necessary at no extra cost to the Company.

6.7

Grades, Bends and Finish of trench The trench is to be cut to a grade that will provide a firm, uniform and continuous support for the pipe. Bends shall be made in the pipe at significant changes in grade of the trench. Company GAIL (INDIA) LTD NEW DELHI


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reserves the right to set the grade of the trench and locate the bends if so desired, in which case Contractor shall excavate, at no extra cost, the trench and bend the pipe to such a grade. Company desires reduce to a minimum the required number of cold field bends to lay the pipe to conform to the general contour of the ground and maintain a normal cover. This can be accomplished by cutting the trench slightly deeper at the crest of ridges and by gradually deepening the trench in approaches to crossings. Such trenching WORK shall be done by Contractor at no extra cost to the Company. Company intends that there will be a minimum of hand grading of the trench bottom. However, to achieve this, Contractor will have to dig as square a bottom of the trench as possible with the equipment. This in part can be obtained by adjusting and adopting the crumbing shoe and digging teeth of the trenching machines and by use of a drag behind the trenching machines or manually dressing-up the same. Contractor shall do such hand WORK in the trench as is necessary to free the bottom of the trench from loose rock and hard clay and to trim protruding roots from the bottom and side walls of the trench. 6.8

Padding In all cases where rock or gravel or murum/hard soil is encountered in the bottom of the trench, Company will decide the exact extent of trench padding, that will be required. The thickness of the compacted padding shall not be less than 150mm. In those areas that are to be padded, the trench shall be at least 150snm deeper than otherwise required, and evenly and sufficiently padded to keep the pipe, when in place, at least 150mm above bottom of excavated trench. Acceptable padding shall be placed under the pipeline before its installation, and around after installation to establish at both sides and on top of the pipe a permanent layer of padding. The thickness of compacted padding on top of pipe corrosion coating shall be at least 150mm. Padding materials that are approved by Company shall be graded soil/sand and/or other materials containing no gravel, rock, or lumps of hard soil. Sand used for padding shall pass through sieve size ASTM C33 No. 16.

6.9

Protection of trench Contractor shall keep the trench in good condition until the pipe is laid, and no claim is to be made to the Company by reason of its caving either before or after pipe is laid. All lumber, sheet-piling jacks or other materials that may be necessary to shore the trench, in order to prevent caving are to be furnished and removed by Contractor. Contractor shall dewater if necessary, using well point system/concrete grouting for stabilization of trench wall or other suitable systems, shore or do what else might be required to excavate the trench, install the pipe in it and backfill the trench in accordance with the specifications at no extra cost to Company.

6.10

Protection of underground utilities and special methods



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Available details of underground utilities, as far as acquired by Company, shall be indicated in the Drawings. However, Contractor shall obtain plans and full details of all existing and planned underground services from the relevant Local Authorities and shall follow these plans closely at all times during the performance of WORK. Contractor shall be responsible for location and protection of all underground lines and structures. In special locations the use of trenching machine/backhoe may result in damage to property and subsurface structures likely to be encountered during excavation. At such places, Contractor shall excavate the trench manually to same specification at no extra cost. Where the pipeline crosses other underground utilities/structures, the Contractor shall first manually excavate to a depth and in such a manner that the utilities/structures are located. Temporary under pinning or any other type of supports and other protective devices necessary to keep the interfering structure intact shall be provided by the Contractor at his own cost and shall be of such design as to ensure stability & safety against their possible failure. Despite all precautions, should any damage to any structure/utility etc., occur, the Owner/Authority concerned shall be contacted by the Contractor and repair shall forthwith be carried out by the Contractor at his expense under the direction and to the satisfaction of Company and the concerned Owner/Authority. If Contractor fails to repair in reasonable time, Company reserves the right to have the repair executed at the cost of the Contractor. 6.11

Encroachments and working near other utilities In locations, where pipeline has to be laid in the body of a road, canal, dyke or other locations under jurisdiction of Government/Public Bodies, the Contractor shall perform such WORK without extra compensation, according to the requirement of concerned Authorities. When it becomes necessary that Contractor has to resort to hand digging, well point, erection of sheet piling or any other special construction method in these areas, no extra compensation shall be paid. Contractor shall contact the Authorities concerned in order to become familiar with their requirements. The facilities damaged during construction shall be restored to their original condition to the satisfaction of Company/Authority. In locations, where the pipeline has to be laid more or less parallel to an existing pipeline, cable and/or other utilities in the Right-of-Use, Contractor shall perform the WORK to the satisfaction of the Owner/Authority of the existing pipeline/cable/utility. In such locations Contractor shall perform WORK in such a way that even under the worst weather and flooding conditions, the existing pipeline/utilities remain stable and shall neither become undermined nor have the tendency to slide towards the trench. Contractor shall be liable for any damage occurring to, or resulting from damage to other pipelines, underground structures/utilities, as laid down in clause 6.10 of this specification.

6.12

Provisions for negative buoyancy to the pipe Contractor shall check if up-floating danger is present in open trench and then shall take appropriate measures to prevent up-floating such as applying soil dams and dewatering of trench or temporary filling of water into the line (in exceptional cases). GAIL (INDIA) LTD NEW DELHI


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In the case of water on the ditch bottom when the pipeline is being laid, the ditch shall be drained to the extent and for the time required to make a visual inspection of the ditch bottom. After this inspection, the presence of water will be allowed provided its level does not cause sliding of the ditch sides and pipe floating before backfilling when no concrete weighing is provided. The water pumped out of the ditch shall be discharged into a natural water course. Whenever up-floating of the pipeline after backfilling is to be reckoned with, anti-buoyancy measures shall be provided by Contractor for such areas of construction, using one or a combination of the following methods: -

weighing by applying a continuous concrete coating around the pipe;

-

weighing by installing gravel filled Geotextile bags/Saddle weight;

-

installing metal anchors screwed into the subsoil in pairs;

-

deeper burial of pipeline;

-

provision of select backfill material.

The above provisions shall be in accordance with the relevant specifications and/or job standards/drawings. Contractor shall indicate the option(s) selected to Company for review and approval along with calculations, wherever applicable. 7.0

BENDING Contractor shall preferably provide for changes of vertical and horizontal alignment in pipeline by malting elastic bends. Contractor may provide cold field bends, at its option for change of direction and change of slope. Company at its option, may authorise fabricated bends for installation at points where in Company's judgment the use of such bends is unavoidable. Overbends shall be made in such a manner that the centre of the bend clears the high points of the trench bottom. Sag bends shall fit the bottom of the trench and side bends shall conform and leave specified clearance to the outside wall of the trench.

7.1

Elastic bends The minimum allowable radius for elastic bends in the buried pipeline including that for continuous concrete weight coated pipe shall be in accordance with relevant job standards. The elastic bend shall be continuously supported over its full length. A radius smaller than permitted in elastic bending shall require a cold bend.



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7.2

Cold field bends

7.2.1 The radius of cold field bends shall not be less than 40 times the pipe specified diameter for pipe diameters 18 inch and above and shall not be less than 30 times the pipe specified diameter for pipe diameter less than 18 inch. 7.2.2 Contractor shall use a pipe bending machine of adequate capacity and employ recognized and accepted methods of bending of coated pipe in accordance wit11 good pipeline construction practice. However, bending machines shall be capable of making bends without wrinkles, buckles, stretching and with minimum damage to the coating. 7.2.3 Contractor shall, before the start of the WORK, submit and demonstrate to Company a bending procedure, which shall conform to the recommendations of the manufacturer of the bending machine. The procedure shall include amongst other steps- lengths, maximum degree per pull and method and accuracy of measurement during pulling of the bend. The bending procedure and the equipment used shall be subject to Company's approval. 7.2.4 Pipes with longitudinal welds shall be bent in such a way that the weld lies in the plane passing through the neutral axis of the bend, which shall be installed positioning the longitudinal weld in the upper quadrants. If horizontal deviations are to be achieved by joining more adjacent bends, the bending of the pipe lengths shall be made by positioning the longitudinal welds alternatively 70mm above and below the plane passing through the neutral axis in such a way that the bends are welded with the longitudinal welds displaced by about 150 mm and situated in the upper quadrants. In case of vertical bends formed from a number of pipe lengths, the longitudinal welds shall be positioned on the plane passing through the neutral axis of the bend to the right and left alternatively. 7.2.5 The pads, dies and rolls of the bending equipment shall have relatively soft surfaces to avoid damage to the pipe coating. Where applicable, fully retaining bending shoes shall be used. Roller type bending machines are preferred. 7.2.6 The ends of each bent length shall be straight and not involved anyway in the bending. The length of the straight section shall permit easy joining. In no event shall the end of the bend be closer than 1.5 m from the end of a pipe or within one meter of a girth weld. 7.2.7 The ovalization caused on each pipe by bending shall be less than 2.5% of the specified diameter at any point. Ovalization is defined as the reduction or increase in the internal diameter of the pipe compared with the nominal internal diameter. A check shall be performed on all bends in the presence of Company Representative by passing a gauge consisting of two metallic discs with a diameter equal to 95% of the nominal internal diameter of the pipe connected rigidly together at a distance equal to 300 mm. 7.2.8 The wall thickness of finished bends, taking into account wall thinning at the outer radius, should not be less than the design thickness. An indication of wall thinning as a percentage is given by the following empirical formula:



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50 Wall Thinning = __________ (n+1) Where 'n' is the inner bend radius divided by pipe diameter. Pipes with measured wall thickness greater than the nominal wall thickness (i.e. with +ve tolerance) shall normally be used for making cold field bends. 7.2.9 Cold bend pipes on site shall have the corrosion coating carefully checked with the aid of a holiday detector for cracks in the coating down to the pipe wall. It must also be checked whether the coating has disbonded from the pipe wall during bending by beating with a wooden mallet along the outer radius. Any defects or disbonding of the coating caused during bending (also forced ridges in the coating) shall be repaired at the Contractor's expense in accordance with Company approved procedures. 7.2.9 When pipelines are laid in parallel, the horizontal bends shall be concentric. 7.3

Miter and unsatisfactory bends All bends showing buckling, wrinkles, cracks or other visible defects or which are in any way in disagreement, in whole or in part, with this specification shall be rejected. No miter bends shall be permitted in the construction of the pipe line. Contractor shall cut out and remove any bend or bends, which do not meet the specifications and shall replace the same with bends complying with specification at no additional cost to the Company. In the event the CONTRACT provides for supply of line pipe by Company, the pipes required for replacement will be furnished by Company, but the cost of replacement of such pipes shall be borne by Contractor. Cutting of factory made bends and cold field bends for any purpose are not permitted.

8.0

LINING UP & WELDING Each length of pipe shall be thoroughly examined internally and externally to make sure that it is free from visual defects, damage, sever corrosion (sea water pitting), dirt, animals or any other foreign objects. Each length of the pipe shall be adequately swabbed, either by use of canvas belt disc of proper diameter, or compressed air blowing or by other methods approved by the Company. Damaged/corroded pipes shall be kept separate. Each length of pipe shall be pulled through just before being welded. All rust and foreign matters shall be removed from the beveled ends by power operated brush. This shall be affected inside & out side and for a minimum distance of 25 mm from edge of bevel. The bevel shall be thoroughly inspected at this stage. Should laminations, spilt ends or manufacturing defects in the pipe observed, the length of the pipe containing such defects shall be removed from the line in accordance with relevant specification.



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Contractor shall align and weld together the Joints of pipe so as to construct a continuous pipeline. All welds in the pipeline made by Contractor shall be of strength equal to that of pipe. All welding shall conform to Company's welding specifications enclosed with the Contract. 8.1

Pipe defects and repairs It is Contractor's responsibility to repair all internal and/or external defects.

8.1.1 Acceptability of defects in the pipe detected during inspection at the WORK site shall be determined in accordance with latest edition of Company's own material specification or code ASME B31.8 / B 31.4 whichever is more stringent. 8.1.2 The maximum permissible depth of dents in pipes shall be as per applicable linepipe specification issued by Company. 8.1.3 Dents, which contain a stress concentrator such as scratch, gauge, arc burn or groove, and dents located at the longitudinal, spiral or circumferential weld shall be removed by cutting out the damaged portion of pipe as a cylinder. 8.1.4 Repair on line pipe shall be executed as specified in Company's material specification or Code ASME B 31.8 / B 31.4, whichever is more stringent. A record of all repairs shall be maintained by Contractor. This record, provided with the pipe identification number shall be submitted to the Company. 8.1.5 If due to cutting or repairs, the pipe identification number is removed, it shall be reprinted immediately by Contractor in the presence of Company. In the event, the CONTRACT provides for supply of line pipe by Company, Contractor shall be charged for any pipe length due to loss of identification number. No pipe without identification number shall be transported and/or welded into the pipeline. 8.1.6 Repair of damaged pipe ends by hammering and/or heating is not allowed. If the dented area is minor and at least 200 mm away from the pipe end, and the steel is not stretched, severed, or split in the Company's opinion, the pipe may be straightened with a proper jack. 8.2

Pipe handling and skid spacing

8.2.1 When lifting pipe, care must be taken not to kink or overstress it. Proper pipe slings approved by Company shall be used. Contractor shall submit his method of skidding and skid spacing for Company's approval. A strip of soft material shall be placed in between skid and pipe to protect the external coating of the pipe. The material shall be approved by the Company. 8.2.2 The maximum skid spacing is not allowed before the stringer 'bead and the top and bottom reinforcements are completed, provided that the distance between the incomplete weld and the skid shall not exceed 9 (nine) percent of the skid spacing. 8.2.3 Skids shall be at least 1.20 meter long. For pipe with an O.D. of 324 mm and larger the skids in contact with the pipe shall have a width of at least 200 mm. For pipe with an O.D. of less than GAIL (INDIA) LTD NEW DELHI


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324 mm the skids in contact with the pipe shall have a width of at least 150 mm. Pipe supports shall be stable, so that pipe movement will not cause the supports to move. Skids shall not be removed under a string before lowering in. The welded pipe shall be maintained on skids at the minimum distance of 500 mm above ground. Crotches shall be installed at frequent intervals (at least every l0th support) with a greater number required at bends and undulating grounds. 8.3

Night caps At the end of each day's WORK or every time when joining and welding operations are interrupted, the open ends on the welded strings of pipes shall be capped with a securely closed metal cap or plug as approved by Company so as to prevent the entry of dirt, water, or any foreign matter into the pipeline. These covers shall not be removed until the WORK is to be resumed. The caps/plugs used shall be mechanical type and shall not be attached to pipe by welding or by any other means, which may dent, scratch or scar the pipe.

8.4

Temporary caps Whenever the welded strings of pipes are left open at intervals to be tied in later after an appreciable time lag, under roads, railroads, rivers, marshy crossings, etc., temporary caps approved by Company shall be welded to the ends of the pipe.

9.0

LAYING

9.1

Lowering in trench

9.1.1 Lowering can start after removal from ditch bottom of all off cuts, pipe supports, stones, roots, debris, stakes, rock projections up to 15 cm below underside of pipe and any other rigid materials which could lead to perforation or tearing of the coating. Sand padding, graded soil and/or other materials containing no gravel, rock shall be provided as required in accordance with clause 6.8 of this specification in such a way to get an even surface for pipe laying. 9.1.2 Lowering shall follow as soon as possible, after the completion of the joint coating of the welded pipe string In the case of parallel pipelines, laying shall be carried out by means of successive operations, if possible without interruption. 9.1.3 Before lowering in, a complete check by a full circle holiday detector for pipe coating and for field joint coating shall be carried out and all damages repaired at Contractor's cost. All points on the pipeline where the coating has been in contact with either the skids or with the lifting equipment during laying, shall be carefully inspected for damages, denting or other defects and shall be completely repaired. If, after checking, it becomes necessary to place the pipeline again on supports at the bottom of the trench, these must be padded in such a way as to prevent damage to the coating, thus avoiding necessity for further repairs when the pipe is finally raised and laid. Before the last operation, a check must be made of the coating at points of contact with the supports. 9.1.4 Before lowering in, short completed sections of the pipeline shall be cleaned with compressed air driven cup Pig or Foam pig in order to remove all dirt, etc. from the inside of pipe sections. In GAIL (INDIA) LTD NEW DELHI


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case such cleaning is proposed by Contractor after lowering, the Contractor shall obtain approval from the Company. 9.1.5 The pipeline shall be lifted and laid using, for all movements necessary, suitable equipment of non-abrasive material having adequate width for the fragility 'of the coating. Care shall be exercised while removing the slings from around the coated pipe after it has been lowered into the trench. Any damage caused to the coating shall be promptly repaired. Lowering-in utilizing standard pipe cradles shall be permitted if Contractor demonstrates that pipe coating is not damaged. No sling shall be put around field joint coating. 9.1.6 Wherever the pipeline is laid under tension, as a result of an assembly error (for example, incorrect positioning of bends, either horizontal or vertical), the trench shall be rectified or in exceptional cases a new assembly shall be carried out, to be approved by Company, so that it fits the excavation and the laying bed. 9.1.7 Laying shall be carried out under safe conditions so as to avoid stresses and temporary deformations of the equipments, which may cause damage to the pipeline itself and to the coating. In case of localised points where the right-of-use is restricted to the minimum necessary for the transit of mechanical equipment, the laying shall be carried out using other suitable means. The pipe shall be placed on the floor of the excavation, without jerking, falling, impact or other similar stresses. In particular, care must be taken that the deformation caused during the raising of the pipe from the supports, does not exceed the values for the minimum allowable radius of elastic curvature, so as to keep the stresses on the steel and on the coating within safe limits. The portion of the pipeline between trench and bank shall be supported by as many sidebooms as required and approved by Company for holding the line in gentle S-curve maintaining minimum elastic bend radius as specified in job standard. Lowering in and backfilling shall preferably be carried out at the highest ambient temperature. 9.1.8 The pipeline must be laid without interruption for the whole or the length of section available. 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 inspections, the presence of water will be permitted, provided that it is not so high as to cause cave-in of the walls of the trench or floating of the pipeline before backfilling, when weighing is not provided for the pipe. 9.1.9 Contractor shall take precautions immediately after lowering in to prevent the movement of the pipe in trench. 9.1.10 Contractor shall close the two ends of the lowered section with night caps against ingress of Water/mud or any foreign material in the section. 9.1.11 In laying parallel pipelines in the same trench, the minimum distances between the pipelines indicated in the approved drawings shall be observed. Once the first pipeline has been positioned, it shall in no way be disturbed by laying of the subsequent pipelines.



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At every seven meters along the trench sand/earth filled bags shall be placed between the parallel pipelines so as to ensure maintenance of the minimum stipulated distance between the parallel lines. 9.2

Overhead sections and sections in tunnel

9.2.1 The following works shall be completed before proceeding with the assembly and laying of overhead pipelines: -

Construction of the pipe support structures

-

Paints and/or coating of the pipe WORK, as indicated in the engineering specification.

9.2.2 The erection of the supports shall be carried out taking care that the elevation and alignment is in accordance with the drawings. In the case of metal work supports, pre-fabrication and/or assembly shall take into account the maximum allowed free span and the supports shall not interfere with the pipeline welds. 9.2.3 In case roller supports are used, the rollers shall be lubricated, then checked for smooth rotation and, in case of seizure, the defect shall be repaired or roller shall be replaced. In the case of overhead section where the pipeline is slanting, the alignment of the end supports shall be made after placing the pipeline in position. Before installation of the pipe section, all the rollers shall be perfectly centered acting on the seat of the supports plates. The above alignment operations shall be carried out before connecting the overhead section with the end of the buried section. 9.2.4 Lifting, moving and laying of the pipeline shall be carried out in accordance with the provisions of clause 9.1.5. An insulation sheet shall be installed to isolate the pipe from the support or support from the earth. The sheet shall be hard polyethylene at least 5mm thick. It shall extend at least to 1 cm outside the saddles or clamps. 9.2.5 Moving supports, if any, shall be centered on their support and allow for a movement of at least 300mm in both directions. 9.2.6 A comprehensive report/method statement on the laying operation to be used shall be submitted to the Company well in advance for approval. The report as a minimum shall include, but not limited to the following: a.

Method of installation by lifting (as a preferred method).

b.

Pulling method and related calculations, whenever lifting method cannot be used.



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c.

Pulling device and its characteristics including available pull force and FOS/margin available w.r.t. calculated pulling load.

d.

Method of anchoring the pulling device

e.

Characteristics of the pulling rope

f.

Braking device, if any

g.

Pipeline assembly system.

10.0

BACK-FILLING

10.1

Backfilling shall not be done until the pipe and appurtenances have the proper fit and the pipe is following the ditch profile at the required depth that will provide the required cover and has a bed which is free of extraneous material and which allows the pipe to rest smoothly and evenly. Before any such WORK is done, it shall be Contractor's responsibility to first secure the approval of Company. If any backfilling is done without Company's approval, Company will have the right to require removal of the backfill for examination, and the cost of such uncovering and refilling shall be borne by Contractor. Backfilling of trench in water courses shall be carried out as per the relevant specifications issued for the purpose.

10.2

Backfilling shall be carried out immediately after the pipeline has been laid in the trench, inspected and approved by the Company, so as to provide a natural anchorage for the pipeline, thus avoiding long exposure of coating to high temperature, damaging actions of adverse weather conditions, sliding down of trench sides and pipe movement in the trench. If immediate back filling is not possible, a covering of at least 200mm of earth, free of rock and hard lumps shall be placed over and around the pipe and coating. On no account the top soil from the ROU be used for this purpose. In general, the trench shall be dry during backfilling. Deviations thereof must have prior approval of the Company. The backfill material shall contain no extraneous material and/or hard lumps of soil, which could damage the pipe and/or coating or leave voids in the backfield trench. After the initial backfill has been placed into the trench to a level slightly above the surrounding ground, Contractor shall compact the backfill material. The surplus material shall be neatly crowned directly over the trench and the adjacent excavated areas on both sides of the trench as per clause 6.2.1, to such a height, which will, in Company's opinion, provide adequately for future settlement of the trench backfill during the maintenance period and thereafter. The crown shall be high enough to prevent the formation of a depression in the soil when backfill has settled into its permanent position. Should depression occur after backfill, Contractor shall be responsible for remedial WORK at no extra cost to Company. Surplus material, including rock, left from this operation shall be disposed of to the satisfaction of land owner or authority having jurisdiction at no extra cost to the Company. For Further requirements reference shall be made to section 14.0 "Clean-up and Restoration of Right-of-Use" of this specification.

10.3

Rock, gravel, lumps of hard, soil or like materials shall not be backfield directly onto the pipe unless padding and/or rock-shield has been provided as per Section 6.8 of this specification. GAIL (INDIA) LTD NEW DELHI


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When "Padding" as described in Section 6.8 of this specification is to be used, the following shall be applicable. Where rock, gravel, lumps of hard soil or like materials are encountered at the time of trench excavation, sufficient earth, sand or select backfill materials shall be placed around and over the pipe to form a protective cushion extending at least to a compacted height of 150111m above the top of the pipe. Select backfill materials for padding that are acceptable to Company shall be soil, sand, clay or other material containing no gravel, rock or lumps of hard soil. Whether such padding material would be taken from the adjacent spoil bank or imported from elsewhere shall be directed by Company. All these works shall be carried out by Contractor at no extra cost to Company. Loose rock may be returned to the trench after the required selected backfill material has been placed, provided the rock placed in the ditch will not interfere with the use of the land by landowner, or tenant. 10.4

When the trench has been dug through drive ways or roads, all backfills shall be executed with sand or a suitable material as approved by Company and shall be thoroughly compacted. In certain cases, special compaction methods, such as moistening or ramming of the backfill in layers may be required by Company. Company and any public or private authority having jurisdiction over a road, street or drive way may require that the surface of the backfill be gravelled with crushed rock or some other purchased material and the road shall be repaved. In such instances, Contractor shall comply with said requirements at no extra cost to Company.

10.5

Trenches excavated in dikes which are the property of railways or which are parts of main roads shall be graded and backfiled in their original profile and condition. If necessary, new and/or special backfill materials shall be supplied and worked-up. The materials required may include gravel, special stabilization materials or stabilized mixtures. Moreover, special processing and/or compacting methods shall require the approval of Company and/or competent authorities. Stone-pitching/cement lining of Dyke walls, if dismantled during excavation shall be restored to its original condition after backfilling and compaction to the entire satisfaction of Company and concerned Authorities.

10.6

The trench in irrigated and paddy fields shall be backfield to within 300mm of the top, then rammed and further backfield until the trench is completely backfield. Surplus material remaining after the operation shall be spread over the RoU as specified in Section 14.0 "Cleanup and Restoration of Right-of- Use", of this specification.

10.7

At the end of each day's WORK, backfilling shall not be more than 500 meters behind the head end of lowered-in pipe, which has been padded and approved for backfill. The backfill shall be maintained by Contractor against washouts and spreading etc., until the completion and final acceptance of the WORK by Company.

10.8

Contractor shall furnish materials and install breakers in the trench in steep areas (slope generally 10% and more) for the purpose of preventing erosion of the back fill. The type of breakers installed shall be as per the approved drawings. Breakers shall be constructed of grout bags filled with a mixture of 4: 1 Sand : Portland cement at Company's direction. Contractor may propose other methods such as foam dams etc. which shall be subject to approval by Company. Such GAIL (INDIA) LTD NEW DELHI


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works shall be at no extra cost to Company. Contractor shall pay attention to the direction of backfilling in such steep areas. 10.9

When backfilling the trenches in sloping terrains or steep areas, where in the opinion of the Company the backfill may be washed out of the trench, sheet piling or other effective water breakers across the trench shall be provided by Contractor. This is to divert the flow of water away from the trench into normal drainage followed before laying of the line. In no case, the water is to be drained via the trench or via channels other than those followed before the line was laid.

10.10 Contractor shall leave the pipe uncovered at certain locations to allow Company to survey the top of the pipe and the level of the pipeline in the backfield trench. Within 48 hours after backfilling, Company shall have carried out such survey and informed Contractor of any realigning, if required. Thereafter Contractor shall compact the backfill. The maximum allowable deviation from the centerline for land sections as staked out by Company and as referenced by Contractor after backfilling is limited to following: Pipeline dia upto and including 600 NB

:

200mm

Pipeline dia greater than 600 NB

:

300mm

10.11 Before backfilling of the trench, Contractor shall comply with the requirements of Clause 6.12 of this specification. 10.12 Stabilization of backfill shall be carried out by the Contractor in sandy areas and other such places, as directed by the Company. Contractor shall carry out the stabilization to have a consolidated cover over the pipeline at no extra cost to Company. The backfill shall be stabilized preferably with 150 mm layer of marl, mattresses of gatch other than straw or other stable materials. The width of stablisation shall be at least 3.0 meters on either side of the pipeline, plus one meter for every 10 meters height of dune (where the line passes through the dune areas). 10.13 Temporary markers shall be installed during backfilling and the survey as per clause 10.10 to locate the pipeline axis. These markers shall then be replaced with permanent pipeline markers. 10.14 Backfilling shall be preferably carried out at the highest ambient temperature. 10.15 In certain areas like U/G pipeline crossings, overhead power cable crossings etc, special care to be taken by putting concrete slab/plastic grating before backfilling. Size and thickness of concrete slab/plastic grating shall comply applicable job standard and approved by Company. 11.0

TIEING-IN



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11.1

The unconnected sections of the pipeline at various locations have to be tied in after the sections are coated, lowered and backfield. The sections to be connected shall have at the ends, sections of over lapping, uncovered pipe of sufficient length to absorb, without inducing excessive stresses in the steel, small displacements necessary for perfect alignment and connection of the ends.

11.2

Tie-in shall preferably be carried out at ambient temperatures corresponding to the average operating temperature in the case of a pipeline conveying fluids at normal temperatures and at the maximum ambient temperature in the case where the pipeline is carrying fluids at high temperature.

11.3

Contractor shall carry out tie-in-welding (including necessary cutting, bevelling, grinding of pipe weld seams and line-up etc.) cleaning, priming, coating and backfilling for the tie-in portion as per relevant specifications. Contractor shall also excavate the required bell-holes for the welding. Bell holes made to facilitate welding shall provide adequate clearance to enable the welders to exercise normal welding ability and skill. All tie-in welds shall be radiographically examined.

11.4

The tie-in should be done in such a way as to leave a minimum of strain in the pipe. If necessary, with respect to the trench, realigning of the pipe shall be done to eliminate force or strain in the pipe by the Contractor at no extra cost to Company.

11.5

If a pup end cannot be avoided for tie-in, the minimum length that shall be added is 1.0 meter and two or more such pups shall not be welded together. All cut-off lengths greater than 1.0 meter shall be moved ahead in order to be welded into the pipeline at a suitable location. Tie-in with two or more pups may be used provided that they each have minimum length of 1.0 meter and are separated by an entire length of pipe. In no case more than three (3) welds shall be permitted on a 10 meter length of pipeline.

11.6

In connecting pipes, special items, fittings and equipment where different wall thicknesses are to be welded, Contractor shall follow the procedures indicated in ASME B3 1 .WASME B3 1.4, as applicable. The required tapering shall be done by Contractor at no extra cost to Company.

11.7

For tie-in of adjacent sections of pipeline already pressure tested, the pup used for tie-in shall be of single length or off-cuts of pipe, which have already been hydrostatically tested. Contractor shall take care that sufficient number of pretested pipes with different wall thicknesses are readily available.

12.0

SPECIAL INSTALLATIONS ON THE PIPELINE

12.1

General

12.1.1 In addition to constructing the pipeline, Contractor shall also install certain other auxiliary facilities and appurtenances. Contractor shall do all WORK necessary at each of the installations to provide facilities, which are complete in all respects and ready for operations.



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Without limiting the generality thereof, the WORK required to complete the installations shall, where applicable, include all site surveys, site preparation, filling, grading, fencing, foundations, installation of block valves, side valves, pipe work, pipe supports, pressure gauges, mechanical facilities, civil work, painting, installation of all electrical equipments, motors, cables, conduit, wiring and fixtures and hooking up of same; installation of all instruments, piping, valves and fittings; mounting of all instruments and malting all piping and electronic connections, etc. On completion, all elements of each entire installation shall be checked out and tested for full and correct operation in the presence of, and to the satisfaction of Company. All WORK shall be carried out strictly in accordance with the appropriate codes, the approved drawings, and this and other related specifications. Contractor shall fabricate all piping and install valves and fittings as required by the detailed engineering fabrication drawings prepared by him and approved by Company. Piping fabrication drawings shall be prepared by Contractor based on AFC drawings and approved by Engineer In charge at site. Stainless steel lines will he "swaged" using permanent fittings installed with a hydraulic device. Cold bending for the fitting of 12 mm NB and 6 mm NB pipes is allowed when special bending tools are used with guides to prevent flattening. The minimum radius allowed shall not be less than R=10 D, where D = outside diameter of pipe. The bending tools shall be subject to Company's approval. Contractor shall ensure that the piping assemblies are not in a strain prior to the final bolting or welding. Contractor shall also ensure that all equipment and piping are thoroughly swabbed clean of all dust, refuse, welding-spatter, scale, or any potentially detachable matter prior to the tie-in or final bolting. 12.1.2 Dimensional Tolerances These tolerances apply to inline items and corrections for other lines. These tolerances can be exceeded on items such as vents, drains, dummy supports, field supports, temperature and pressure connections, where the deviation will not affect another spool. a.

General dimensions such as face to face, face or end to end, face or end to centre, and center to centre: + 3 mm.

b.

Inclination of flange face from true in any direction: 4mm per meter.

c.

Displacement of branch connection from indicated location: ±1.6mm. When multiple branches are involved, the displacement of the branches shall not exceed 3mm from a common point.

d.

Rotation of flange bolt holes shall not exceed 1.6mm



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12.1.3 Flanged connections Contractor shall ensure that prior to final bolting, all flange faces are parallel and centered, according to standard practice. Contractor shall not use bolting forces as a means for attaining alignment. A gasket of required size and quality shall be installed between the flanges at each joint. Bolts shall be tightened in diagonal sequence and shall be centered with equal amounts of thread visible on both sides. Bolts shall be uniformly tightened to produce a leak-proof joint. Bolts that yield during tightening shall be removed and discarded. It is mandatory that a torque wrench is used for bolt tightening. 12.1.4 Threaded connections Damaged threads shall be cut from the end of a run and the pipe shall be rethreaded. Contractor shall properly align all threaded joints. Pipe entering unions shall be true to centerline so the union will not be forced during make-up. The threaded pipe shall not project through fittings to cause interference with valves or other operating mechanisms. Except for the threaded connections of instruments, which will require periodic testing and maintenance, all threaded joints shall be seal welded. The latter joints shall be made up without pipe joint compound and with a minimum of oil from the thread cutter. Seal welds should taper into the pipe with as little discontinuity as possible, and should cover all threads. All seal welds shall be tested with DP, MP testing. 12.1.5 Welded connections Where the ends of the piping components being welded have an internal surface misalignment exceeding 1.6mn-1, the wall of the component extending internally shall be trimmed by machining so that the adjoining internal surfaces will be approximately flush. All welding shall be performed in accordance with GAIL Specification of “Welding Specification for Onshore pipeline for Transportation of Gas” and other applicable Jobs Specifications and Welding Specification Chart. Tie-ins between fixed points shall be made at maximum ambient temperature. 12.1.6 Civil Work Civil work shall be performed in accordance with Specifications issued for the purpose. 12.1.7 Painting All exposed surfaces like piping, valves, structures, and miscellaneous appurtenances shall be painted in accordance with the specifications issued for this purpose. The corrosion coating on pipe surface will end approximately 300 mm above the finish grade and it will be necessary for Contractor to provide a clean interface at the junction of the protective coating and the paint. GAIL (INDIA) LTD NEW DELHI


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12.1.8 Coating of buried Installations, etc. All buried valves, insulating joints, flow tees, bends, other in-line fittings and appurtenances shall be coated with 100 % solid high build epoxy (minimum 500 micron thk.) or any other equivalent suitable Company approved coating at no extra cost to Company. For buried pipes and LR bends, heat shrink sleeves / cold applied tapes conforming to Company's specification for Field Joint Coating shall be used. Contractor shall submit to Company a report regarding the method of application and the materials used along with all test certificates. Only after obtaining written approval from the Company, Contractor shall commence the work of coating. 12.1.9 Clean-up After all required tests have been concluded satisfactorily, Contractor shall clean up the Site as laid down in the specifications issued for the purpose. The Site shall be graded in accordance with the approved drawings. 12.2

Installation of valves and valve stations

12.2.1 Block and sectionalizing valve stations shall be installed as shown on the approved drawings. It is Contractor's responsibility to have the units completely assembled, tested and made fully functional including all related instruments etc. 12.2.2 The civil and structural work shall be carried out in accordance with the relevant specifications issued for the purpose and in accordance with the approved drawings as directed by Company. This work as a minimum shall include clearing, grading, fencing, foundations etc. as required. All above ground structures shall be painted as per the specification and color code given by the Company. 12.2.3 Suitable concrete foundation as directed by Company shall be constructed on which the valve shall be firmly installed, after embedding an insulating sheet of hard polyethylene with a thickness of at least 5min or equivalent. Such insulating sheet is also to be installed under pipe clamps, etc. 12.2.4 Valves with flow arrows shall be installed according to the normal flow in the pipeline. During welding, the valves shall be in fully open position. In addition, all manufacturer's instructions shall be followed. Care shall be taken to avoid entry of sand particles etc. to valve body, seals etc. during transportation, storage, assembly and installation. 12.2.5 For valves and piping installed below ground and/or above ground the anti-corrosion Coating/painting shall be as per the requirements of the relevant specifications issued for the purpose. The anti-corrosion below ground coating shall extend upto 300mm above grade at the lowest point.



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12.2.6 Sectionalising valves shall be installed on sections of the pipeline in the horizontal position only or with an inclination not greater than that allowed by the valve manufacturer. Installation shall be done in such a way that there is no strain in the welded joint while the pipeline at upstream and downstream side are straight. 12.2.7 All valves shall always be handled using appropriate equipment and methods so as to avoid impact, shaking and other stresses. In particular, the equipment and tools used for lifting and handling shall never be hooked through hand wheel, valve stem, flange joints and other parts, which may suffer damage/misalignment. 12.2.8 All sectionalising valve and any other inline assemblies shall be prefabricated and tested hydrostatically ex-situ as per applicable specification. All such assemblies shall be installed at the locations shown in the drawings only after successful completion of the hydrostatic test and dewatering. Thereafter the ends of the assembly shall be closed off, Contractor shall carry out necessary excavation, cutting, beveling of pipe ends and welding of the tie-ins required for the installation of such assembly. The tie-in joints shall be radiographically examined over 100% length and also 100% ultrasonically examined prior to backfilling. All works shall be executed in accordance with the relevant specifications issued for the purpose. 12.3

Installation of scraper launchers and receivers

12.3.1 Scraper stations shall be fabricated and installed as per the approved drawings and whenever applicable as per the requirements of clause 12.2 of this specification. It is Contractor's responsibility to have the units completely assembled tested and made fully functional including all instruments and related piping. 12.3.2 The Civil and structural works for the scraper stations shall be carried out as per the relevant specifications, in accordance with the drawings and as directed by the Company. The WORK as a minimum shall include site survey, site preparation, clearing, grading, fencing, foundations, etc. as required. 12.3.3 It shall be Contractor's responsibility to maintain elevations shown on the approved drawings and to carry out any pipe work adjustments, necessary for this purpose. Field cuts shall be square and accurate and field welds shall not be performed under stress of pipe ends. 12.3.4 The painting for the scraper stations shall be carried out as per "Specifications for Painting". The underground sections shall be coated as specified for the pipeline upto at least 300mm above grade. 12.3.5 The hydrostatic testing of the scraper stations shall be executed after installation in accordance with the relevant specifications issued for the purpose. 12.4

Installation of insulating joints

12.4.1 Insulating joints shall be installed at the locations shown in the drawings. Contractor shall obtain approval from the Company before installation of the insulating joints.



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12.4.2 Handling and installation of the insulating joints shall be carried out with all precautions required to avoid damage and excessive stresses and that the original pup length is not reduced. 12.4.3 The insulating joints and the welded joints shall be protected by external coating as per relevant specifications issued for the purpose. 12.4.4 When the in-line inserting is made on the buried pipeline, care shall be taken to weld at an external temperature as close as possible to the pipeline operating temperature. The joint shall be inserted on straight sections and laid on a fine sand bed. 12.4.5 During the execution of the in-line connection welding, the propagation of heat shall be avoided. To achieve this, the joint shall be kept cold by means of rags continuously wetted. 12.4.6 Insulating joints shall be e1ectrically tested before welding into the pipeline. The electrical resistance/conductance test shall be carried out using a Megger. Measurement of the insulation resistance across the joint shall be approx. one (1) Mega Ohm. The tests shall be repeated after installation and welding of the joint into the pipeline to verify that the assembly is undamaged. 13.0

WORKING SPREAD LIMITATIONS Contractor shall, in general, observe the following maximum distances between the working mainline spread: Between ROU grading, clearing and backfilling

:

25 Kms

Between backfilling and final clean-up

:

05 Kms

The spread limitations do not apply to point spreads such as rock blasting, river crossing and bored crossings of roads, railways and canals and HDD crossings. Any deviations from the above shall meet prior approval of Company. Company reserves the right to stop the WORK, in case the approved spread limitations are exceeded and Contractor shall not be paid any compensation for stoppage of WORK. 14.0

CLEAN-UP AND RESTORATION OF RIGHT OF USE

14.1

Contractor shall restore the RoU and all sites used for the construction of pipelines, water crossings and other structures in accordance with Company's instructions, and deliver them to the satisfaction of Company.

14.2

Surplus materials For Company supplied materials, after completion of WORK, the Contractor shall return all surplus materials at Company's designated areas.



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The reconciliation of surplus free issue line pipes shall be as per the requirement of commercial condition of contract. 14.3

Disposal

14.3.1 All surplus and defective materials supplied by Contractor and all trash, refuse and spoiled materials shall be collected and disposed off by Contractor. 14.3.2 The ROU shall be cleared of all rubbish, broken skids, empty cans, card board, sacks, stumps, trash, and leftover construction material. All burnable matter shall be burned, but only after obtaining appropriate permits for such burning. If burning is not allowed, Contractor shall haul the clean-up material to an approved dumping area. All scrap metal and unburnable material shall be disposed of, in an appropriate manner, but never be buried in the ROU. 14.3.3 Surplus soil can only be removed from the Owner's plot after authorisation by Company. 14.3.4 All dumping fees connected with the disposal of materials shall be to the account of Contractor. 14.3.5 All loose stones and rock exposed by the construction operations and scattered over the ROU or adjacent grounds shall be removed by Contractor and be transported to a location considered suitable by the land-owner and/or tenant, or by authorities have jurisdiction, for satisfactory disposal. For stones, gravel or other hard material, which may be buried in the trench the provisions of the specifications shall apply with the understanding that the use of the land by the land-owner and/or tenant will not be interfered with. 14.4

Temporary structures All auxiliary structures such as bridges, culverts, sheet piling, posts, signs, etc., which were erected or installed by Contractor as temporary measure, shall be removed. However, it may be necessary to remove the fence of ROU during the maintenance period.

14.5

Repair of damages Damages to roads, bridges, and private property shall be repaired by Contractor. All fences and other structures, which are damaged during construction, shall be restored to original. Slopes, water course sides or banks which have been partially or totally demolished during the execution of the works shall be properly consolidated and restored (without waiting for their natural consolidation and settling) complying to requirement of the concerned Authorities. The bed of water-courses shall be restored to the original level. The banks and any excavated areas shall be restored to the original levels and contours. The banks shall also be stabilized. All boundary stones, which have been moved or removed during the WORK must be reset in their original location to the satisfaction of the landowner concerned.

14.6

On completion of clean-up, the ROU shall be restored to such stable and usable condition as may be reasonably consistent with the condition of the RoU prior to laying the pipeline. The GAIL (INDIA) LTD NEW DELHI


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Company shall be completely indemnified and held harmless by Contractor from any and against all claims, demands, losses, expenses etc. that may arise in this behalf or the Company may anyway suffer or sustain, relative to, arising out of, or in connection with same. The Company may require from the Contractor signed Releases from landowners regarding satisfactory indemnification and restoration of their lands. 14.7

Special precautions shall be taken near steep slopes prone to erosions and landslides. All necessary steps shall be taken to ensure the rapid growth of grass by providing wicker barriers and by regulating the drainage of surface waters.

14.8

All cadastral or geodetic markers, which may have been removed during the execution of the WORKS, shall be restored in their exact position.

14.9

Ditches for which no instructions for their restoration have been issued, or restoration cannot be done due to absence of banks, shall be restored as instructed by Company. The bed of ditches crossed by the pipeline shall be cleaned over the full width of the ROU, also outside the ROU if necessary. This restoration might contain but is not limited to the supply and installation of proper materials for backfill and protection, the sodding or other precautions to prevent erosion or guarantee the stability. All work has to be done after deliberation and acceptance of the authorities and Company. Other field drains have to be restored over full width of ROU and if necessary also outside the ROU by hand and/or special equipment as soon as possible.

14.10 Any subsidence, cave-ins, wash-outs, which have been caused during the pipeline construction and maintenance, caused by whatever reason within the edge of ditches and open drains, shall be repaired by Contractor immediately or at first notice given by Company. 14.11 After the clean-up, the ROU of pastures has to remain fenced considered suitable by the tenant and to be removed during the maintenance period. When agricultural and other traffic (requested by tenant) have to cross the ROU the cross-overs have to be fenced with the same material as the ROU. If necessary, special materials have to be used to allow traffic on the cross-over. Fencing of the right-of-use as specified shall not be removed until Contractor has obtained written permission by Company. In general this has to be done during the maintenance period. 14.12 All openings in or damage to the fences or enclosures shall be repaired by installing new fencing of a quality, which shall be at least equal to the parts damaged or removed. Provisional gates shall be removed and replaced with new fencing. All repairs to fences and enclosures shall be carried out by Contractor to the complete satisfaction of Company, landowner and/or tenant. 14.13 If, in the opinion of Company, the sod in pasture land has been damaged by vehicles and wheel tracks are visible, the ROU shall be tilled with a disc-harrow or rotary cultivator several times. The damaged sod shall be firmly cut up and thoroughly mixed through the top-soil. In general, the ROU has also to be ripped. After this procedure no closed-in layers must be found and sufficiently loose top-soil 25 to 30 cm thick must be present. The whole procedure must be approved by Company. Subsequently, the entire ROU, which is part of pasture land, shall be prepared for seeding and fertilized by Contractor according to the instructions of Company.



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14.14 In crop fields the tillage shall consist of passing over the land several times with a disc harrow, cultivating with a spading machine, or plow, to a depth of approx. 20 cm. In general the ROU has also to be ripped. After this cultivation process no closed-in layers must be found any more in the ROU. The equipment used and methods adopted shall require the approval of Company. Ripping has to be done with rippers with a distance of 50 cm between the ripper blades. The type to be used shall be approved by Company. 14.15 Adequate numbers of saplings of any plant/tree uprooted or cut during construction shall be planted along the route as per the direction of the Company and in accordance with the requirement of Authorities. The cost of sapling and its plantation shall be to Contractor's account. 14.16 The ROU and the backfilled trench in particular has to be finished in such a way that after settlement of the soil the fields are at their original level. If during the maintenance period certain parts of the ROU are lower than the original level, Company can order Contractor to bring these parts to the original level. In cases where heavy damage has occurred to the structure of the subsoil as a result of adverse circumstances, Company reserves the right to order Contractor to carry out special restoration work. Said special work can include: -

Spading with dragline (depth 30-80 cm);

-

Spading with dragline (depth 80-100 cm);

-

fertilizing;

-

cover with sand.

If during clean-up operations soil shortages become apparent outside the trench, Contractor shall supplement said soil shortage using suitable materials, approved by Company. If site and/or climatic conditions should render this necessary, Company shall have the right to order Contractor to suspend certain parts of the work related to the clean-up and postpone it to a later date. 14.17 Soil surplus If on site, as a result of the WORK and after careful backfilling and compacting, a sub-soil surplus exists, this shall be worked up by grading and compacting below the sub-soil top layer and as a rule this shall be done in the same plot of land. It shall not be permitted to remove the surplus from the plot concerned, unless it concerns rejected soil, which has to be removed. Working up surplus soil or removal of rejected soil shall be considered to pertain to the WORK. To work a soil surplus into the ground, Contractor shall remove an additional strip of top soil beside the trench. Next, the upper layer of sub-soil shall also be removed. Both soil types shall be GAIL (INDIA) LTD NEW DELHI


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stored separately across a width depending on the size of the soil surplus. The soil surplus shall then be distributed across the trench thus widened, after which it shall be graded and compacted and subsequently the top layer of sub-soil and the top-soil shall be replaced in the correct order, in accordance with the Specifications. In case Company has given prior permission for mixed excavation of the sub-soil as well as in cases where Company deems mixed excavation permissible, the above provision of separate storage of the upper layer of sub- soil shall not apply to the working up to the soil surplus. In cases where the soil surplus can be worked up in others plots where soil shortages have arisen due to the WORK, this shall only be done after prior permission by land-owner, land-user and Company. 14.18 Soil shortages If due to unforeseen circumstances during backfilling and compacting there should not be enough soil to fill the trench properly, or to install the crown height as stipulated, Contractor shall supply the necessary backfill material. Soil shortages shall be supplemented and applied before the top-soil is replaced. The soil to be supplied shall be worked up in those locations and into those layers where a soil shortage has been established. The quality of the supplemented soil shall be equal to that of the shortage. 15.0

MAINTENANCE DURING DEFECTS LIABILITY PERIOD Defects Liability Period (defined as period of liability in the CONTRACT) means the period calculated from the date certified in the Completion Certificate. Company reserves the right to carry out instrumented pigging survey of the completed pipeline. Contractor shall be responsible for making good with all possible speed at his expense any defect in or damage to any portion of the Work which may appear or occur during the Defects Liability Period and which arises either: a.

From any defective material (other than supplied by Company), Workmanship or design (other than a design made, furnished or specified by Company and for which Contractor has disclaimed responsibility in writing), or

b.

from any act or omission of Contractor done or omitted during the said period.

If such defect shall appear or damage occur, Company shall forthwith inform Contractor thereof stating in writing the nature of the defect or damage.



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If any such defect or damage be not remedied within a reasonable time, Company may proceed to execute the WORK at Contractor's risk and expense provided that he does so in a reasonable manner. Such defect or damage can be, but is not limited to: -

Clean-up of ROU, including water courses

-

Sagging or sinking of site level or pipe supports

-

Sliding of ditch banks

-

Repair of fencing or removal of construction fencing

-

Repaving of pavements, repair of pavements, repair of Roads

-

Repair of coating, painting

-

Realigning markers, signs

-

Leak/burst of pipe, leaking of flanges, washouts

-

Short-circuit in casings

-

Construction defects such as dents, ovality, welding offsets/defects, etc. detected during intelligent pigging survey, etc.

Company reserves the right to have the required Computerised Potential Logging Test executed during the DEFECTS LIABILITY PERIOD and whenever weather conditions are more favorable for this job. The work shall (at or as soon as practicable after the expiration of the Defects Liability Period) be delivered to Company in the conditions required by the CONTRACT, fair wear and tear excepted, to the satisfaction of Company. Contractor shall finish the work, if any outstanding, at the date of completion as soon as possible after such date and shall execute all such work.



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STANDARD SPECIFICATION FOR HYDROSTATIC TESTING OF ONSHORE PIPELINE


STANDARD SPECIFICATION FOR HYDROSTATIC TESTING OF ONSHORE PIPELINES


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Abbreviations: ASME

:


API

:


OISD

:

Oil Industry Safety Directorate

SMYS

:

Specified Minimum Yield Strength




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1.0

SCOPE

1.1

This specification covers the minimum requirements of supply, work and operation to be performed by Contractor for hydrostatic testing of cross-country steel pipelines transporting hydrocarbons in liquid or gaseous phase under high pressure. This specification does not cover the requirements of caliper pigging, drying/ pre-commissioning of the tested pipelines.

1.2

. 2.0 2.1

This specification shall be read in conjunction with the conditions of all specifications and documents included in the CONTRACT between Company and Contractor. Unless specified otherwise, all sections of this specification shall apply to all specifications referred in this specification.

REFERENCE CODES, STANDARDS AND SPECIFICATIONS Reference has been made in this specification to the latest edition (edition enforce at the time of floating the enquiry) of the following codes, standards and specifications. a)

ASME B 31.4

-


b)

ASMEB 31.8

-

Gas Transmission and Distribution Piping systems.

c)

API RP 1110

-

Pressure Testing of Liquid Petroleum Pipelines.

d)

ASME Sec. VIII Div. 1 -

Boiler and Pressure Vessels Code.

e)

OISDB141

Design and construction requirements for cross-country hydrocarbon pipelines

f)

GAIL Standard Specifications:

-

(i)


ii)

Welding Specification for Onshore Pipelines for Transportation of Gas.

2.2

In case of conflict between the requirements of above mentioned codes, standards, specifications, practices, the most stringent requirement shall govern.

2.3


The words "Shall" and "Must" are mandatory.




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-

the words "Should', "May" and "Will" are non-mandatory, advisory or recommended.

3.0

GENERAL

3.1

Hydrostatic test shall be performed on the entire length of the pipeline. Hydrostatic test shall be performed in accordance with approved Hydrostatic Test Diagrams clearly indicating the number of test sections and minimum and maximum test pressures in each test sections. The maximum length of each test section shall not exceed 50 Kms.

3.2

For pipeline sections which in Company's opinion, once installed would require an inordinate amount of effort for repair in case of a leak, a provisional pre-test shall be conducted. However, after installation, such pre-tested sections shall be tested again along with the entire pipeline.

3.3

Hydrostatic test shall commence only after mechanical and civil works completion, i.e., all welds have been accepted and the pipeline has been laid and backfilled. Hydrostatic test shall include those sections which have been previously tested viz. Rail/ road crossings, major water crossings including test on banks and in place after installation, and scraper traps at the terminals. Contractor shall perform all works required for hydrostatic testing after obtaining prior written approval from the Company.

4.0 HYDROSTATIC TEST PROCEDURE MANUAL Contractor shall prepare for Company's approval a hydrostatic test procedure manual. The procedure shall strictly comply with the requirements of this specification and shall be submitted to Company for approval well in advance. The procedure manual shall include all temporary materials and equipment, but not be limited to the following items: a)

A diagram for the system to be tested, indicating all fittings, vents, valves, temporary connection, relevant elevations and ratings. The diagram shall also indicate injection locations and intake and discharge lines.

b)

Estimated amount of test water, water source, including required concentration of corrosion inhibitors and additives, procedure for inhibitor injection and control of concentration.

C)

Filling and flushing procedures, including a complete description of all proposed equipment and instruments (including spares), their location and set-up.

d)

The type and number of pigs to be used, gauging plate parameters, sequence of pigs to be launched during pig tracking system for cleaning and removal of air pockets. Pig inspection procedures, including procedure to be followed in case the caliper pig indicates damage to pipeline in access of the values specified in governing codes.

e)

Procedure for levelling and stabilization after filling and for pressurization and to allow for temperature stabilization.




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f)

Pressure testing procedure including a complete description of all proposed equipment and instruments (including spares), their location and set-up and proposed system for observation and recording of data during the pressure test.

g)

Procedure for detection and location of leaks.

h)

Procedure for dewatering the pipeline sections(s) after testing, including a complete description of all proposed equipment and instruments (including spares), their location and set-up, the type and sequence of pigs and the pig tracking system along with the pig specification.

i)

Forms for recording the test data.

5.0

TEST DURATION AND PRESSURE

5.1

The duration of hydrostatic test shall be minimum 24 hours after thermal stabilization.

5.2

Unless specified otherwise in the Contract, the hydrostatic test pressure shall be as follows: For pipeline handling hvdrocarbon in gaseous phase: a)

1.25 times the design pressure for pipeline located in Class-1 and Class-2 locations as per ASME B 3 1.8.

b)

1.4 times the design pressure for pipeline located in Class-3 and Class-4 locations as per ASME B 31.8.

For pipeline handling hydrocarbon in liquid phase: a)

1.25 times the design pressure for pipeline handling liquids including Liquefied Petroleum Gas (LPG).

The test pressure, as calculated above, shall be generated at the highest point in the section under test. At any point in the test section hoop-stress due to test pressure and static head shall not exceed 95% of the SMYS of pipe material. 6.0

EQUIPMENT AND INSTRUMENTATION The Contractor shall furnish all necessary equipment for performing the work as stated in cleaning, flushing, filling, stabilising, testing and dewatering procedures. This shall include, but not be limited to the following equipment and instruments: a)

Pigs for cleaning, filling and gauging

-

Cleaning pigs with spring loaded steel wire brushes. For internally coated pipes, the pigs shall be provided with nylon/ polyurethane brushes.




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-

Four cup batching pigs.

-

Gauging pigs fitted with gauge plate.

The Contractor shall provide a sufficient number of pigs, including spares. b)

Fill pumps: The Contractor shall determine the type and number of fill pumps in order to guarantee the following: -

differential head 20% greater than the maximum required

-

Flow rate : Minimum 400 m3/h; Maximum 1000 m3/ h

If a single pump is used, a standby unit must be available. c)

Variable speed positive displacement pumps equipped with a stroke counter to pressurize the pipeline. The pump shall be capable of exceeding the maximum test pressure by at least 20 bar.

d)

Two positive displacement meters to measure the volume of water used for filling the line. These meters shall be provided with a calibration certificate not older than one month.

e)

Portable tanks of sufficient size to provide a continuous supply of water to the pump during filling and pressurizing.

f)

Bourdon pressure gauges of suitable pressure range and accuracy.

g)

Dead weight testers with an accuracy of 0.01 bar measuring in increment of 0.05 bar provided with a calibration certificate not older than one month at the time of the first hydrostatic test in the pipeline.

h)

Two 48 hours recording pressure gauges complete with pressure recording charts and ink, duly tested with dead weight tester prior to use. These shall be installed at the test head.

i)

Pressure recording charts.

j)

Two temperature recorders for fill water.

k)

Thermocouples duly calibrated for measuring the pipe wall temperature.

l)

Two laboratory thermometers of range 00C to 600C and with accuracy of ± 0.10C to be used in thermowells.

m)

Means to measure the volume of water necessary to drop the line pressure by 0.5 bar (container on scales or graduated cylinder)




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n)

Injection facilities to inject additives into the test medium in the required proportions.

o)

Communication equipment suitable for a continuous connection between the beginning and the end of the test section and with the inspection team along the line, in accordance with the requirements of Local Authorities.

p)

The temporary scraper traps shall be installed according to the test section fixed in the test procedure manual. Proper piping and valving arrangements shall be available to allow lunching and receiving of each pig independently. The test heads shall be sized in conformity with ASME specification Section VIII, Division 2 with particular reference to Appendices 4 and 5.

q)

Thermocouples for measuring the temperature of the pipe wall shall be installed on the pipeline to be tested: -

One (1) thermocouple at about 500 m distance from the pumping head.

-

One (1) thermocouple every 2500 m of the pipe. The spacing may be increased to maximum 5000 m depending on the terrain and nature of sub soil along the alignment of test section.

-

One (1) thermocouple at about 500 m distance from the terminal head.

Thermocouples shall be attached on the external surface of the pipe after removal of external coating and shall be adequately protected and Company's coating instructions shall be followed. After successful testing, the thermocouples shall be removed and damaged coating shall be repaired as per applicable coating repair procedure, approved by Company. 7.0

PROCEDURES

7.1

Equipment andlor parts which need not or must not be subjected to the test pressures or which must not be tested with water, must be disconnected or separated from the pipeline to be tested.

7.2

If the difference of minimum and maximum atmospheric temperature should cause thermal instability on the pipe section directly exposed to atmospheric condition, the scraper traps and above ground pipeline shall be properly protected. The pipeline test shall exclude long segments of line exposed to atmospheric conditions, viz. aerial lengths on piers, suspension bridges, etc. Such sections shall be tested separately.

7.3

The test medium shall be soft non-aggressive water furnished by the Contractor. The water to be used shall be filtered, shall not be contaminated and free from sand of silt. Contractor shall submit laboratory test reports of water used for testing. The possible use of sea water shall be subjected to its degree of cleanness, the possibility of obtaining a pre-determined salinity neutralisation and the use of corrosion inhibitors, this at the sole discretion of Company. Contractor shall provide Company approved corrosion inhibitors, oxygen scavengers and GAIL (INDIA) LTD NEW DELHI



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bactericides to be added to the test water. The Contractor shall furnish and install all temporary piping, which may be necessary to connect from source of water to its pump and manifolds/ tankages. The following products are acceptable for corrosion inhibition of the water used for hydro testing: -

REMIDOL 4000 of M/s Chemtreat India Ltd., Navi Mumbai.

-

HIBITOL 2000 of M/s Renkal Chemical, Navi Mumbai.

-

INDION 175 of M/s Ion Exchange India Ltd., Hyderabad.

-

VISCO 3900 of MIS NALCO EXXON.

Dosage for inhibitor shall be as follows: -

Upto 6 months 500 mg/l Above 6 months 750 mg/l

Contractor shall note the following: a.

All chemicals for hydrotesting shall be procured from approved vendors. Chemicals older than three months shall not be used.

b.

Company representative shall inspect the chemical containers and take random samples prior to its use. Contractor shall get the samples tested in an GAIL nominated Govt./PSU/other competent laboratories. Testing shall be carried out for accelerated % corrosion inhibition efficiency, % SRB and TBC killing efficiency test. Company reserves the right to witness the testing. The test report shall be submitted to Company for approval prior to undertaking hydro testing works.

c.

Only those chemicals which have passed the above tests shall be used for hydrotesting.

7.4

Before filling operation, the Contractor shall clean the pipeline by air driven pigs provided with spring loaded brushes and chisels to remove all mill scale, rust, sand, etc. from the internal of pipe section. For this purpose, temporary headers for air cleaning shall be attached to the pipeline. The number of pig runs is depending upon the cleaning results and shall be determined by the Company at site.

7.5

After cleaning the pipeline by using air and acceptance by Company, gauging shall be carried out by using gauging pig. The gauge plate diameter shall be equal to 95% of inside diameter of the heaviest all pipe in the test section. While computing the ID of heaviest wall pipe, pipe manufacturing tolerances shall not be considered. A 10 mm thick aluminium plate shall be used for making gauge plate.




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After receipt of gauging pig at the other end, the gauge plate shall be inspected in the presence of Company representative. A deformed, bent or severally nicked plate or damaged pig shall be evidence of gauging pig run failure and the same shall not be acceptable to COMPANY. In such cases the Contractor shall repair and rectify the line and repeat the gauging pig run to the satisfaction and approval of the Company Representative. Any obstruction and/ or faults such as dents, buckles, flat spots, etc. analysed and noted during gauging pig run shall be located and any necessary repair work shall be performed to rectify the same to the satisfaction of the Company. A written approval shall be obtained from Company regarding successful completion of gauging pig run. After acceptance of gauging operation, air header shall be cut and removed. Pre-tested test headers loaded with three numbers of four cup batching pig shall be welded to test section. Joints between test header and pipeline shall be radiographed. Un-inhibited water equal to 10% of the volume of test section shall be introduced in front of the first pig. The first pig shall be launched by introducing about 1.5 km un-inhibited water. Then the second pig shall be launched by pumping the inhibited water till the second pig is received at the other end. Subsequent to receipt of second pig, the pressurization and thermal stabilization operation can commence. 7.6

Thermal stabilization After a check has been made to confirm if the pressure has attained at least 1 bar (g) on the highest section, the thermal stabilization can be started. Thermal equilibrium between the pipeline and environment shall be checked through the Thermocouples installed on the pipeline. Temperature readings shall be made at 2 hours-intervals. Thermal stabilization shall be considered to have been achieved when a difference not higher than 1•‹C is attained between the average values of the last two readings. Thermal stabilization completion shall be approved by Company.

7.7

Pressurisation

7.7.1 The pressurization shall be performed in the presence of Company at a moderate and constant rate not exceeding 2 bars/ min. One pressure recording gauge shall be installed in parallel with the dead weight tester. Volume required to reach the test pressure shall be recorded periodically throughout the pressurization as follows: a) b) C)

each 5 bar increments up to 80% of test pressure as recorded by the dead weight tester; each 2 bar increments between 80% to 90% of test pressure as recorded by the dead weight tester; each 0.5 bar increments between 90% of the test pressure to full test pressure as recorded by the dead weight tester.

7.7.2 The pressurisation shall be cycled according to the following sequence:



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a) b) C) d) e)

Pressurise to 50% of test pressure, hold pressure for 1 hour, Drop pressure to static head of test section at test head, Pressurise to 75% of test pressure, hold pressure for 1 hour Drop pressure to static head of test section at the test head Pressurise to test pressure.

During the pressurisation to each test pressure, two tests shall be carried out for the calculation of air volume in the pipeline under test. In case, during the hold pressure periods indicated above, a decrease in pressure in observed, the above operations shall not be repeated more than twice, after which the line shall not be considered capable of test, until the Contractor has isolated and eliminated the cause for the lack of water tightness. 7.9

Air Volume Calculation. In order to check the presence of air in the pipeline, two separate consecutive pressure lowering of 0.5 bar shall be carried out after pressurizing to test pressure. For calculation of air in the pipeline the second pressure lowering shall be used, and the relevant drained water shall be accurately measured (V1). This amount measured shall be compared to the theoretical amount (Vp) corresponding to the pressure lowering that has been carried out, by using the procedure outlined in clause 12.1 of this specification. If no air is present in the length under test:

In order that the above ratio is acceptable, it shall not differ from 1 by more than 6% (i.e.1.06). If the air found in the pipeline is within the above established tolerance, then the pressurising can continue. If the ratio VINP exceeds 1.06, the hydrostatic testing cannot go on and additional pig passages shall be performed to remove the air pockets. The test shall be repeated as per the above procedure until above estimated tolerances are satisfied. The pressurising can then continue, to reach the value of the test pressure. 7.10

Testing After the section has been pressurised and the air volume test has given acceptable results the test pressure shall be held for a minimum of 24 hours after stabilisation. After temperature and pressure has stabilished, the injection pump shall be disconnected and all connections at the test heads shall be checked for leakage. The pressure recorders shall then be started with the charts in a real time orientation for continuous recording throughout the test. During the testing period the following measurements shall be recorded/ reported



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-

every one hour pressure measurements from dead weight testers.

every two hour the ambient temperature and the pipe temperature at the thermocouples. All data shall be recorded on appropriate forms attached to the hydrostatic test procedure manual. Care shall be taken that the maximum test pressures are not exceeded. Bleed-off water shall be accurately measured and recorded. 8.0

ACCEPTANCE

8.1

The hydrostatic test shall be considered as positive if pressure has kept a constant value throughout the test duration, except for change due to temperature effects. Such changes shall be evaluated as described under clause 12.2 of this specification. The pressure change value as a function of temperature change shall be algebraically added to the pressure value as read on the meters. The pressure value thus adjusted shall be compared with the initial value and the test shall be considered as acceptable if the difference is less than or equal to 0.3 bar. Incase of doubt the testing period shall be extended by 24 hours.

8.2

If test section fails to maintain the specified test pressure after isolation, Contractor shall determine the location of leakage or failure by suitable means. All leaks and failures within the pipe wall or weld seams shall be repaired by replacement of entire joint or joints in which leakage or failure occurs. In those cases where leaks occur in circumferential welds the method of repair shall be determined by the Company. Contractor shall comply with instructions of the Company whether to replace a section of the line pipe that includes the line leak or whether to repair the circumferential weld. This repair should, however, meet the requirements of applicable welding specification enclosed with the Contract. Where failures occur in pipeline field bends, bends shall be replaced with same degree of bends. After completion of repairs, the hydrostatic test shall be repeated in full, as per this specification.

8.3

The cost of repairs or replacements, followed by refilling and repressurising the line, due to poor workmanship, shall be borne by the Contractor. In the event of leaks or failures resulting from faulty Company furnished materials, Contractor shall be reimbursed as per the provisions of Contract. All work of reinstalling line pipe, to replace failures, shall be done in accordance with the relevant specifications included in the CONTRACT.

8.4

Contractor shall haul and stockpile all damaged and defective pipes to storage location designated by the Company. All cracks and splits resulting from failure shall be coated with an application of grease to preserve the characteristics of failures from corrosion. Joint of failed pipes shall be marked with paint, with a tag indicating failure details, date and location of failure and pressure at which failure occurred.

9.0

TERMINATION After the positive result of testing and all the data have been gathered, the test shall be terminated upon written approval given by the Company. The pipeline shall be slowly depressurised at a moderate and constant rate as instructed by Company. Subsequent operations such as caliper



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pigging, swabbing, drying, purginghnertising and commissioning shall be carried out as per the applicable specifications enclosed with the Contract. 9.1

Contractor shall dewater the tested line as per the following requirement after test acceptance. The dewatering shall be carried out by using four cup pigs and foam pigs driven by compressed air. The detailed dewatering procedure shall be deployed by the Contractor in such a way as to provide adequate control of pigs during dewatering. Pigs and equipment required for dewatering the line shall be furnished by Contractor and shall be approved in advance by the Company. Four cup pigs shall first be passed through the line to displace the water. Foam pigs shall then be passed in order to complete the line dewatering. Contractor shall use a number of foam pigs each in different colours/numbered for this purpose. The line shall be considered dewatered when a negligible amount of water is flushed out by the last foam pig and approval is given by the Company.

9.2

During dewatering, care shall be taken to properly dispose the discharging water in order to avoid pollution, damages to fields under cultivation and/ or existing structures and interference with the traffic. Before the start of dewatering and disposal of hydrotest water, a procedure for treatment of inhibited water to prevent pollution shall be submitted by Contractor to Company for review and approval.

9.3

Upon completion of the testing and dewatering operation, any provisional traps for pigs and all other temporary installation relating to the test shall be removed. Subsequently, the individual sections of the line already tested shall be joined in accordance with the requirements of relevant specifications issued for the purpose.

10.0

TEST REPORT

A complete report signed by Contractor and the Company shall be submitted upon completion of the hydrostatic test for each test section. This report shall contain as a minimum: - the cleaning, flushing, filling and testing procedures used; - schematic layout of cleaning, filling and testing facilities; - instruments calibration certificate; - a profile of the pipeline that shows the test sites, all instrument and injection connections; - pipe filling logs and records; - additive specification, required concentration and additive injection records; - pig specifications; - pig inspection records including photographs of the damages; - records of gauging pig survey and photographs; - pressurisation and stabilisation records; - pressure and temperature recording charts with appropriate information inscribed thereon; - temperature data along the pipeline; - dead weight tester logs and recordings; - air volume calculations; - pressure change due to temperature change calculations; GAIL (INDIA) LTD NEW DELHI


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- environmental data; - depressurisation logs and records; - dewatering procedure and schematic layout of relevant facilities; - dewatering logs and records; - records and photographs of all leaks, if applicable. 11.0

MEASUREMENTS

1 1.1

Water Amount Measurements The water volume added to the section to be tested shall be measured during the filling stage through a positive displacement meter (a turbine meter may also be used). In the calculation, as per clause 12.1 of this specification, use shall be made of the geometrical volume of the section in question. The water amount that has been let into the section shall be measured during the pressurisation stages thorough positive displacement meters or turbine meters.

1 1.2

Pressure Measurement Pressure shall be measured with a dead weight tester that shall permit readings of at least 0.05 bar. During the test, the pressure shall be recorded by means of a recording pressure gauge featuring the following specifications: Accuracy Recording Feed Recording range

: : : :

±0.1% of the full-scale value continuous on tape or disk, graph width l00 mm 20mm/h for tape diagrams, 7.50 /h for disk diagrams to be such as to record pressure between 50% and 90% of the diagram width. The recording pressure gauge shall be checked by means of dead weight test at the beginning, during and at the end of the hydrostatic test. 11.3

Temperature Measurements

a)

Water temperature shall be taken at every 2 hours through the thermocouples that have been installed along the section under test on the pipe wall. Further, the temperature measurement shall be taken: -

during the filling operation during the thermal stabilisation stage during the hydrostatic test

The thermocouples' sensitivity shall enable temperature readings with the accuracy of ±0.20C.



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b)

Water temperature shall also be measured on the pump delivery by means of a recording thermometer throughout the filling stage. The recording thermometer shall feature the following characteristics: Accuracy : ± 1% of the scale range Scale : -100 to +400C Recording : Continuous on tape or disk, diagram width l00 mm Feed : 20mm/ h for tape diagrams, 7.50 /h for disk diagram

c)

Ground temperature shall be taken by measuring pipe temperature at the thermocouples prior to starting the filling operation.

d)

Environmental temperature shall be recorded from the beginning of pressurization to the end of the test by means of a recording thermometer featuring the following characteristics: Accuracy Scale Recording Feed

: : : :

± 1% of the scale range 00 C to +60 0C Continuous on tape or disk, diagram width l00 mm 20 mm/ h for tape diagrams, 7.50 / h for disk diagrams.

12.0

CALCULATIONS

12.1

The theoretical water amount that is necessary for filling the section to be tested shall be obtained from the geometrical volume of the section considering the pipe tolerances. The theoretical water amount that is necessary for pressurizing the section shall be calculated by means of the following formula:

Where



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12.2

The pressure change due to a water temperature change shall be calculated through the following formula:

Where

13.0

PRECAUTIONS DURING THE TEST In addition to all that has been expressly described in the procedures for carrying out the tests, the following additional requirements shall be complied with:

13.1

Provision shall be made for the installation of no-admittance signs to unauthorised personnel from the roads to the R.O.U.

13.2

Signs stating 'PIPE UNDER TEST-KEEP OFF" with local language translation shall be placed where the pipeline is uncovered, and particularly where the provisional traps and stations are located. Such areas shall be suitably fenced in such a way as to prevent access of unauthorised personnel. No unauthorised personnel shall be closer than 40M to the pipeline or equipment under test.

13.3

Provisional scraper traps shall be installed in compliance with methods and suitable location so that their rupture cannot cause any injuries to the personnel or third parties.

13.4

The test station shall be placed in such a location as to prevent it from being affected by a catastrophic failure in the test head. GAIL (INDIA) LTD NEW DELHI


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13.5

Once dewatering is over the sectionalising valves and other valve assemblies tested previously, shall be installed at locations shown in the drawings and in accordance with the procedures contained in the relevant specifications. All thermocouples installed in the pipeline shall be removed and damage corrosion coating shall be repaired using Company approved materials and procedure.

14.0

PRESERVATION OF PIPELINE When so stated in the CONTRACT, to preserve/conserve the pipeline for a specified duration, Contractor shall completely fill the pipeline with water, with sufficient quantity of corrosion inhibitors depending upon quality of water and the period of conservation, at a pressure to be agreed upon with the Company at a later stage. Contractor shall obtain necessary approval from the Company of the procedure, type and quality and quantity of inhibitors used before commencement of the works.



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SPECIFICATION

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STANDARD SPECIFICATION FOR PIPELINE MARKERS




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CONTENTS 1.0

SCOPE

2.0

REFERENCE CODES AND DRAWINGS

3.0

GENERAL

4.0

AERIAL MARKERS

5.0

KILOMETER MARKERS

6.0

PIPELINE WARNING SIGN

7.0

ROW BOUNDARY MARKERS

8.0

DIRECTION MARKERS

9.0

NAVIGABLE WATER WAY PIPELINE CROSSING WARNING SIGN

10.0

SPECIAL MARKERS REFERENCE DRAWINGS GAIL STANDARD DRAWINGS S-04-01-014

K.M. POST

S-04-01-015

TYPICAL ROW BOUNDARY MARKER

S-04-01-016

AERIAL MARKER

S-04-02-017

DIRECTION MARKER

S-04-02-018

PIPELINE WARNING SIGN

S-04-02-019

NAVIGABLE WATERWAY PIPELINE CROSSING WARNING SIGN




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1.0

SCOPE:

1.1

This specification covers the minimum requirements for supply, fabrication and erection of pipeline markers to be installed by CONTRACTOR at various locations along the route of a cross-country pipeline.

1.2

This specification shall be read in conjunction with the conditions of all specifications and documents included in the CONTRACT between COMPANY and CONTRACTOR.

2.0

REFERENCE CODES:

Reference has been made in this specification to the latest edition of the following code: API RP 1109

Recommended Practice for Marking Liquid Petroleum Pipeline Facilities.

3.0

GENERAL:

3.1

CONTRACTOR shall supply, fabricate and install the Pipeline Markers along the pipeline route. The location of markers as indicated in the approved drawings shall be treated for guidance purpose only and the exact location of the markers shall be based on AS BUILT drawings and as directed by COMPANY.

3.2

The pipeline markers shall be fabricated and installed in accordance with the GAIL standard drawings included herein. Before start of fabrication of the markers, the CONTRACTOR shall prepare and submit for COMPANY'S approval, the detailed scheme for the marker plates as applicable for the project. All the markers shall be painted in accordance with the requirements of Standard Specification for Shop and Field Painting (Specification No. S-05-02-014). The painting scheme shall be suitable for Normal Corrosive Environment.

3.3

The pipeline markers shall be installed, as far as possible, at locations such that they do not cause any hindrance to the regular use of the land or to the traffic.

4.0

AERIAL MARKERS:

Aerial Markers shall in general be installed along the pipeline at every five (5) kilometers intervals and at places specified by COMPANY. Refer GAIL Standard Drawing No. S-04-01016 for details. 5.0

KILOMETER MARKERS:

Kilometer Markers shall in general be installed along the pipeline at every one (1) kilometer interval. Markers shall indicate cumulative distance in kilometers from the reference station, as directed by COMPANY. A kilometer marker is not required, if the relative distance between its location and any pipeline warning sign is less than 200 meters. Refer GAIL Standard Drawing No. S-04-01-014 for details. GAIL (INDIA) LTD NEW DELHI



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6.0

PIPELINE WARNING SIGN:

Pipeline Warning Sign shall in general be installed at: 

National and State Highway crossings

-

2 Nos. min.



Other Road crossings

-

1 No. min.



Railway Crossings

-

2 Nos. min.



Minor Water Crossings (less than 15 m width) -

1 No. min.



Minor Water Crossings (above 15 m width)

-

2 Nos. min.



Major water crossings

-

2 Nos. min.



Valve station

-

1 No. min.



Any other location as shown in the approved drawings and as directed by the COMPANY

Pipeline Warning Sign shall identify the existence of the pipeline and display the name of the COMPANY, with an emergency telephone number, as shown in GAIL Standard Drawing No. S-04-01-018. 7.0

ROU BOUNDARY MARKER:

Right-of-Use boundary markers shall be fabricated as per the drawings and shall be installed at every 250 meters interval along the entire pipeline route. These shall be installed on either side of the pipeline alignment to define the ROW boundary limits. These shall also be installed at pipeline turning points to maintain the continuity of the ROW limits. Refer GAIL Standard Drawing No. S-04-01-015 for details. 8.0

DIRECTION MARKERS:

Direction Markers as shown in GAIL Standard Drawing No. S-04-01-017 shall be installed to identify the significant Turning Points of the pipeline during serial traverse. One direction marker shall be installed at each Turning Point, two more direction markers shall be installed along the pipeline alignment, one on either side of the Turning Point at 200 m from the Turning Point. 9.0

NAVIGABLE WATERWAY PIPELINE CROSSING WARNING SIGN:

The Navigable Waterway Pipeline Crossing Warning Sign shall be fabricated in accordance with GAIL Standard Drawing No. S-04-01-019. Such Warning Sign shall be installed one on each bank of navigable water courses at the pipeline crossing location, in lieu of the Pipeline Warning Sign described in Clause 6.0 of this specification. GAIL (INDIA) LTD NEW DELHI



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10.0 SPECIAL MARKERS: As directed by COMPANY, special markers shall be installed at location where following changes take place: 

Change in pipeline diameter and wall thickness.



Change in type of pipe



Change in class / zone locations for pipelines conveying gas and HVP products.

The above data may be provided on other types of marker (except ROU boundary marker), if the relative distance between the two does not exceed 100m.




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STANDARD SPECIFICATION FOR DOCUMENTATION FOR PIPELINE CONSTRUCTION




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CONTENTS 1.0

SCOPE

2.0

RECORDS

3.0

AS-BUILT DRAWINGS AND PIPE BOOK




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1.0

SCOPE:

1.1

This specification covers the minimum requirements of various records, reports and drawings for all aspects of pipeline construction to be prepared by the CONTRACTOR and submitted to the COMPANY at intervals as described in this specification and as directed by the COMPANY.

1.2

All documents required to be prepared and submitted by the CONTRACTOR as per this specification shall be in addition to the various reports, records, methodology statements, calculations, drawings etc. to be submitted by the CONTRACTOR for COMPANY'S record, review or approval as per the requirements of all other specifications included in the CONTRACT between the COMPANY and the CONTRACTOR.

1.3

This specification shall be read in conjunction with the conditions of all specifications and documents included in the CONTRACT between COMPANY and CONTRACTOR.

2.0

RECORDS:

The CONTRACTOR shall submit daily, weekly, monthly and after completion, to the COMAPANY, various records and reports for COMPANY'S documentation purpose during and immediately after the construction. This shall as a minimum include, but not limited to the following: 2.1

2.2

Daily 

Separate progress reports of all crews



Daily welding results and repairs



Actual weather conditions



Application for deviations, if any



Accidents



Damages



Activities required from COMPANY



Materials Receipts

 Urgently required materials Weekly 

Up-to-date list of confirmed Site Instructions issued by COMPANY



Materials 'taken over'




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2.3



Materials defects and repairs



Outstanding activities of COMPANY



List of installed markers, chainage



Required approval form COMPANY



Progress planned



Reports of manning of all crews, equipment and plant



Reports of equipment and plant



Reports of accidents



Reports of damages



Reports of Acquired Releases, Permits etc.



Prices variations



Required materials for next month

Monthly 

2.4

Progress report for payment, safety report, report of accidents, security reports, health and environment report, material balance, approved deviations.

Further, CONTRACTOR shall supply for approval, if required, to the COMPANY with document such as but not limited to: 

Organogram for construction of work



Bio-data of key personnel (including foremen)



(Revised) list of address of personnel in particular of medical staff, safety and security officers.



(Revised) list of approved coaters



(Revised) list of approved sub-contractors



Time schedule



Acquired permits and/or approval from Authorities, if any.




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

Minutes of meeting with COMPANY with comments, if any.



Material certificates, material receipt.



Guarantees from Vendors and sub-contractors



Calculations, temporary works, buoyancy, blasting.



Drawings issued by CONTRACTOR.



Vendor drawings.



As-built drawing of route maps, alignment sheets, detail drawings and isometric drawings,



Procedures such as surveying, stacking, fencing.



Welding procedure qualification record, radiographic procedure qualification, welder qualification



Coating procedure.



Installation of crossings.



Hydrostatic testing



Blasting



Radiographic report along with original radiographs



Pipe and welding book

 

Material records and Accounting book Reports



Material tests (coating, welding, painting)



Computerized Potential Logging Test



Water samples



Cleaning, Pigging Report before hydrostatic test



Hydrostatic test



Calibration test



Blasting trials




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

Equipment certificates (dead weight tester, instruments, vessels, equipment)



Manuals



Major water crossings -



Waste disposal



Disposal of water after hydrostatic test.

2.5

The CONTRACTOR shall submit to COMPANY, colour photographs (hard copy as well as digital format) taken through digital camera (having resolution > 1 million pixels) of various construction activities/operations at regular intervals. Size, number and frequency of the photographs shall be mutually agreed upon between the CONTRACTOR and the COMPANY. The CONTRACTOR shall make video recordings of all operations right from the start of construction till the completion of the work, covering to the extent as instructed by COMPANY and submit to COMPANY. Upon completion of the work, the CONTRACTOR shall submit edited master tape plus six copies of video recording in VCD / DVD formats or any other format ordered by the COMPANY. The duration of video recording shall be of ½ hour and shall cover all aspects of the job.

3.0

AS-BUILT DRAWING AND PIPE BOOK:

3.1

General The CONTRACTOR shall prepare "As-built' drawings of all by or on behalf of COMPANY issued drawings and of all CONTRACTOR work drawings including vendor drawings, such as but not limited to: For pipeline section: 

Route maps



Alignment sheets



Detail drawings (road, railway, minor water crossings, major water crossing, valley crossings)



Isometric drawings of installations



Special installation.

Further CONTRACTOR shall prepare a pipe Weld Book. If required by the COMPANY, the CONTRACTOR shall update the diskettes for drawings issued for construction of the job. -




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3.2

"As-built" Drawings: The CONTRACTOR shall prepare a complete set of "As-built" drawings. From the start of construction, the CONTRACTOR shall, on daily basis, process any changes in two sets of drawings. Deleted parts shall be indicated in red, new parts in blue, remarks in green and unchanged parts in yellow. Said drawings shall be kept at site and shall be available to COMPANY at all times. The CONTRACTOR shall prepare "As-built" drawings based on these data. On completion of the work, one revised film transparency of all drawings made "As-built" by CONTRACTOR containing the "As-built" information as well as one complete set of CD ROM containing "As-built" drawings shall be handed over to COMPANY. The CONTRACTOR shall prepare and submit a specimen of the layout of the drawings for COMPANY'S approval. The required measurement for "As-built" drawings shall be executed by the CONTRACTOR by experienced and qualified surveyors. The surveyors shall daily take care of all measurements required such as but not limited to: 

Horizontal location of pipeline with regard to deviation and Permanent Grid Pillars.



Vertical level with regard to Mean Sea Level of pipeline and grade.



Location and type of bends, fittings etc. and grades, points of intersection.



Changes of wall thickness, materials.



Location and details of valves, insulating joints, fencing.



Location and details of road, railway, water crossing, suspension bridges.



Location and details of crossing pipes, vents.



Location and type of coating.



Location and type of weighing, anchoring.



Location and type of markers.



Location of further appurtenances (Pig-signalers).



Location of ROU and of pipeline with respect of ROU.



Type of soil.



Type of rock.




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

Type of blasting and ripping



Sand Padding



Type of Road Pavement



Details of Bank protection, No. of Insulators, seals

The CONTRACTOR shall also prepare isometric drawings of installation (facilities) etc. for which the data as mentioned in or required for the Pipe and Welding Book can be identified and these drawings can also be used for material accounting. 3.3

Name plates of Equipment: All permanent equipment supplied and installed by CONTRACTOR shall be provided with plates by CONTRACTOR. All texts shall be submitted to COMPANY for approval before plates may be manufactured.

3.4

Pipe Book: Every page of the Pipe and Welding Book shall mention: 

Data relevant to the project and section thereof



Sequential number



Length brought forward (for pipes and other materials)



Length to bring forward (for pipes and other materials)



Alignment sheet number and at least the location thereon of two welds on every page of the Pipe Book.

Further, 

Diameter of pipeline



Length of each pipe



Wall thickness



Pipe number



Heat number, certificate number



Cut and re-numbered pipe ends



Coating




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

Date of stringing



Data of welding



Direction of working



Weld number

 

Welder number Type of welding, electrodes, diameter of electrodes etc.



Heat treatment



Equipment used for radiography



Limits of water crossings.



Test pressure and date of test.

In order to achieve this, the CONTRACTOR shall identify all pipe elements. Sample format of Pipe Book shall be submitted for COMPANY approval. 3.5

As-Built Documents: The CONTRACTOR shall prepare all documents in the prescribed format as indicated below. In addition to the hard copy, three copies of final documents shall also be submitted in electronic media i.e. CD ROM. Software used for the preparation of these documents shall be as follows: Type of document Software a) Reports MS Word (Windows 98 / 0ffice 2000 / office 2003 / XP) b) Drawings AutoCAD Release 14 and above. For the purpose of preparation of As-built drawings, CONTRACTOR shall update the "Issued for Construction" drawings issued by the COMPANY. It shall be the CONTRACTOR'S responsibility to convert the drawings furnished by the COMPANY in hard copy into CAD drawings including scanning, digitizing and converting the drawings into a suitable format compatible with the AutoCAD Release 14 and above. As-built drawings shall be prepared only on AutoCAD.




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STANDARD SPECIFICATION FOR BLASTING




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1.0

SCOPE

1.1

This specification covers the minimum requirements for materials, personnel, transportation, storage and use of explosives for grading of Right of Use (ROU) and excavation of trenches for the burial of pipelines in rocky terrain.

1.2

This specification does not cover the construction or operation of permanent magazines.

1.3

This specification applies to on-shore pipeline installation.

2.0

REFERENCE DOCUMENTS

2.1

The following National and International regulations and codes shall be used: BS 5607 NFPA-495

:

Safe use of explosive in construction Industries :Manufacture, Transportation, Storage & Usage of Explosive Materials.

National and Local Laws/Regulations Applicable Safety Rules of Chief Inspector of Explosives, Nagpur IS 4081

:

Safety Code for Blasting and related drilling operations

3.0 GENERAL 3.1

The CONTRACTOR shall acquaint himself and comply with all the applicable local laws and regulations concerning storing, handling and the use of explosives. All such laws, regulations and rules etc., as enforced from time to time shall be binding upon the CONTRACTOR. National/Local Laws and Regulations shall take precedence over this specification in the event of conflict. All conflicts shall be brought to the notice of the COMPANY.

3.2

The requirements stated herein however in no way relieve the CONTRACTOR of this responsibility of carrying out safe blasting operations and shall be solely responsible for damages and claims thereof.

3.3

The use of explosives requires an approval from the Chief Inspector of Explosives and/or his authorized Inspector. It shall be the responsibility of the CONTRACTOR to obtain all such permits and observe all requirements regarding the safe storage, handling and use of explosives. All expenses incurred in this regard shall be to CONTRACTOR'S account. GAIL (INDIA) LTD NEW DELHI



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3.4

Contractor shall inform the COMPANY in writing at least four(4) weeks prior to planned use of explosives.

3.5

Contractor shall notify the COMPANY prior to any blasting in the proximity of overhead power lines, roads, communication lines, pipelines, utility services or other services and structures above and below ground. Before, starting blasting operations, local authorities and owners of utilities shall be consulted to check on the presence of services which could be damaged and their approval obtained to undertake blasting operations. The distances to nearest structures(houses, offices, factories) or service shall also be taken into consideration when planning blasts so that ground vibration and air-over pressure is kept within acceptable levels as given in section 11.0 of this specification.

3.6

CONTRACTOR shall prepare an Explosives Handling and usage Procedure for the information of the COMPANY which shall incorporate the following: -

Individual procedure and calculations

-

Nature of blasting operations, including hole diameter, depth and presence of cavities

-

Rock characteristics

-

Type of explosives

-

Temperature likely to be encountered in use

3.7

No blasting is allowed within 20 m of any above ground or underground structure or facilities. No blasting is allowed within 200 m of overhead power lines/cables unless specifically approved by the Authorities having jurisdiction over it and COMPANY.

4.0

MATERIALS

4.1

All materials such as explosives, detonators, fuses, tamping materials etc. that are proposed to be used by the CONTRACTOR in blasting operations, shall be as Approved for use in the Country.

4.2

All electric detonators used in the blast shall be of the same electrical sensitivity and be produced/procured from the same manufacturer.

4.3

The detonators used shall be capable of giving effective blasting of the explosives. Damaged explosive materials shall be destroyed by a responsible person as per manufacturer's instructions or returned to the manufacturer.




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4.4

No explosive material shall be abandoned.

4.5

All blasting materials and testing equipment shall be regularly tested for correct performance. The intervals between test shall be decided after consideration of the local factors, but tests shall always be carried out if the blasting materials and/or test equipment have been subjected to abnormal conditions, or following misfires. Guidelines/recornrnendations of the manufacturer shall be adhered to.

4.6

All packaging and.other waste materials gathered together during blasting operation shall be burnt after the blast has been fired.

The burning site shall be chosen at a safe distance with due respect to prevailing wind strength and direction, at least 100 meters from explosives stores and other premises. A minimum of two fire extinguishers shall be on hand during burning activities. 5.0

PERSONNEL

5.1

Excavation by blasting will be permitted only under personal supervision of competent and licensed persons and by trained workmen.

5.2

The storage of explosives shall be in the charge of a person approved by the COMPANY. COMPANY may, if necessary, ask police inquiries being made as to his reliability, antecedents etc.

6.0

STORAGE OF EXPLOSIVES

6.1

The CONTRACTOR shall build a magazine for storing the explosives. The site of the magazine, its capacity and design shall be subject to approval by the COMPANY and the inspector of Explosives before the fabrication is taken up. As a rule the explosives should be stored in a clean, dry, well ventilated, bullet proof and fire proof building, at an isolated site. Adequate security shall be provided to ensure no unauthorized entry into the magazine. A notice shall be hung next to magazine entrance prohibiting entry of unauthorized persons.

6.2

CONTRACTOR shall comply with National/Local Regulations and specifications for truck mounted mobile explosives store. Mobile stores shall only carry ONE DAY'S Explosives requirements and shall be parked overnight inside the compound at the authorized magazine.

6.3

All safety precautions and necessary equipment for maintenance, operation of mobile stores, as required by local authorities or regulatory bodies shall also be installed/provided on the Mobile Store.

6.4

A careful and day-to-day account of all explosives shall be kept by the CONTRACTOR in a register and in an approved manner. The register shall be produced by the GAIL (INDIA) LTD NEW DELHI



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CONTRACTOR, for the inspection of the COMPANY/Inspectorof Explosives when so required by the later. Any loss, damage or theft shall be reported immediately to the necessary local authorities and to the COMPANY. 6.5

The magazine shall on no account be opened during or on the approach of a thunderstorm and no person shall remain in the vicinity of the magazine during such period.

6.6

Magazine-shoes without nails shall, at all times, be kept in the magazine, and a woodtub or cement trough, filled with water shall be fixed near the door of the magazine.

6.7

Persons entering the magazine must put on the magazine-shoes. 1)

not to put their feet on the clean floor unless they have magazine-shoes on.

11)

not to allow the magazine-shoes to touch the ground outside the clean floor.

111) not to allow any dirt or grit to fall on the clean floor. 6.8

No matches or inflammable material shall be allowed in the magazine. Light shall be obtained from an electric storage battery lamp.

6.9

No person having articles of steel or iron on him shall be allowed to enter the magazine. No tools or implements other than those of copper, brass, gun metal or wood shall be allowed inside the magazine.

Oily cotton, rags, waste and articles liable to spontaneous ignition, shall not be allowed inside the magazine. 6.10

Boxes of explosives shall not be thrown down or dragged along the floor and shall be stacked on wooden trestles. Open boxes of explosives shall never be expcsed to the direct rays of the sun. Empty boxes or loose packing materials shall not be kept inside the magazine.

6.11

The magazine shall have a lightning conductor, which shall be got tested at least periodically, by an officer authorized by the COMPANY, the testing fee shall be to the CONTRACTOR'S account.

6.12

The magazine shall be inspected periodically by an officer representing the COMPANY, who will see that all the rules are strictly complied with. He will notify all omissions etc. to the CONTRACTOR, who shall rectify the defects within a period of 3 days from the




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date of receipt of the notice, failing which the COMPANY mat take whatever actions it considers suitable. 7 .O

PREPARATION OF EXPLOSIVES

7.1

CONTRACTOR shall submit the following procedure for INFORMATION of the COMPANY as a minimum. -

Loading of explosives

-

Drilling of new holes and extending existing holes

-

Handling of explosives at site

-

Tamping explosives into holes

-

Machines, tools and cables required

-

Initiation of blasting Safety of personnel

-

Vibration control

-

Blast pattern and shot size establishment

-

Misfires

-

Emergency procedures

7.2

Trial blasts in conjunction with vibration recording shall be carried out for each rock and trench type, in order to assess rock breakability and vibration levels. These trial blasts shall be carried out prior to actual trench blasting of the pipeline route.CONTRACTOR shall conduct trial digs as directed by COMPANY in order to check suitability of the lasting pattern and to measure vibration levels to ensure vibration levels are below the allowable maximum.

7.3

"Weight per Distance Tables" shall be drawn up from these trials.

7.4

The detonators shall never be forced into the primer cartridge. It shall be inserted in a hole made by a wooden, copper, brass or aluminum pricker. The detonator shall be firmly embedded in the primer so that it is not pulled out of place during loading.

7.5

Detonators shall be activated electrically. In proximity of electric over-head power lines, CONTRACTOR may use non-electric system with the approval of COMPANY. Fly rock




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shall be minimized by the use of approved blast mats and by careful selection of shot size and drill hole configuration. 7.6

Use of explosives is prohibited in areas exposed to flammable gasses or dust.

7.7

Explosive and detonators shall be carried in separate boxes, tightly closed, and transported separately. For the conveyance of primers special containers shall be used.

7.8

Explosives shall be stored and used chronologically to ensure that the ones received earlier are being used first.

7.9

A make-up house shall be provided at each working place in which cartridges shall be made up by experienced men as required. The make-up house shall be separated from other buildings. Only electric storage battery lamps shall be used in this house.

7.10

No smoking shall be allowed in the make-up house.

8.0

PREPARATION OF PRIMERS The primers shall not be prepared near open flames or fires. The work of preparation of primers shall always be entrusted to the qualified and approved personnel. Primers shall be used as soon as possible after they are ready.

9.0

CHARGING OF HOLES

9.1

The work of charging shall not commence before all the drilling work at the site is completed and the COMPANY has satisfied itself to that effect by actual inspection.

9.2

The lead wires shall be kept away from conductors or sources of stray current While charging, open lampslflames shall be kept away.

9.3

Only wooden tamping rods without any kind of metal on them shall be used.

9.4

Only one cartridge shall be inserted at a time and gently inserted to the required depth with the tamping rod. The sand, clay or other tamping material used for filling the hole completely shall not be tamped too hard.

9.5

Blasting shall not take place after sunset or before sunrise unless specific approval is first obtained by CONTRACTOR from local authorities and the COMPANY.

9.6

The site of blasting operations shall be prominently demarcated by red danger flags. The order of fire shall be given only by the supervisor-in-charge of the work and this order shall be given only after giving the warning signal three times, so as to enable all the labor, watchmen etc. to reach safe shelter and after having ascertained that nobody is within the danger zone. GAIL (INDIA) LTD NEW DELHI



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9.7

A buegle with a distinctive note shall be used to give the warning signals. The buegle shall not be used for any other purpose. All the labor shall be made acquainted with the sound of the buegle and shall be strictly warned to leave their work immediately at the first warning signal and to take safe shelters, and not to leave the shelters until the all clear signals have been given.

9.8

All the roads and foot-paths leading to the blasting area shall be watched

10.0

ELECTRICAL FIRING

10.1

Only the Supervisor-in-charge shall keep the key of the firing apparatus and shall keep it always with himself.

10.2

Special apparatus shall be used as source of current for the firing operations. Power lines shall not be tapped for the purpose.

10.3

The firing cable shall have a proper insulating cover so as to avoid short circuiting due to contact with water, metallic parts or rock.

10.4

The use of earth as a return line shall not be permitted.

10.5

The firing cable shall be connected to the source of current only after ascertaining that nobody is in the area of blasting

10.6

Before firing, the circuit shall be checked by a suitable apparatus.

10.7

After firing, whether with or without an actual blast, the contact between the firing cable and the source of current shall be cut off before any person is allowed to leave the shelter.

10.8

During storms, charging with electrical detonators shall be suspended. The charges already placed into the holes shall be blasted as quickly as possible after taking all the safety precautions and giving necessary warning signals. If this is not possible, the site shall be abandoned till the storm has passed.

11.0 VIBRATION RECORDING 11.1

CONTRACTOR shall use COMPANY approved vibration recording system capable of measurement in three axes (tri-axial). The device shall have an accuracy of 0.0025 mm and a resonance of 2 Hz. The device shall measure both frequency and amplitude of vibration.

11.2

All the measurement devices shall be calibrated by an APPROVED certification




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body. 11.3

Particle velocity shall not exceed the following:

11.3.1

Areas not with 500 m of existing facilities -

11.3.2

50 mm/sec at a surface measured distance of 15 m from trench center line. Areas with existing buried or above ground facilities within 500 m.

-

20 mm/sec. At a surface measured distance from the trench center line towards the nearest existing facilities.

11.4

The particle velocity levels are provided for the guidance only, CONTRACTOR shall be responsible and liable for any injury to life or damage to property/facilities.

11.5

Air-over pressure/sound levels shall be limited to 100 db in inhabitated areas.

12.0 MISFIRES 12.1

If it is suspected that part of the blast has failed to fire, or is delayed, sufficient time shall be allowed to lapse before entering the danger zone. When fuse and blasting caps are used, a safe time should be allowed and then the Supervisor alone shall leave the shelter to see the misfire.

12.2

Drilling near the hole that has misfired shall not be permitted until one of the two following operations have been carried out by the Supervisor: I)

The Supervisor should very carefully (when the tamping is of damp clay) extract the tamping with a wooden scraper or jet of water or compressed air (using a pipe of soft material) and withdraw the fuse with the primer and detonator attached. A fresh primer and detonator with fuse shall then be placed in this hole and fired.

II)

The Supervisor shall get one foot of the tamping cleaned off and indicate the direction by placing a stick in the hole. Another hole may then be drilled at least 9" away and parallel to it, this hole should then be charged and fired. The balance of the cartridges and detonators found in the muck shall be removed.

12.3

The Supervisor shall at once report to the office all cases of misfire, the cause of the misfire and the steps taken in connection therewith.

12.4

If a misfire has been found to be due to defective detonator, or explosive, the whole quantity from the box from which the defective articles were taken must be returned to



SPECIFICATION

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the manufacturer for inspection to ascertain whether the whole box contains defective materials. 12.5

Re-drilling the holes that have misfired either wholly or partly shall not be permitted.



SPECIFICATION

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STANDARD SPECIFICATION FOR DETAILED PIPELINE ROUTE SURVEY (ONSHORE)




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CONTENTS 1.0

SCOPE

2.0

REQUIREMENTS

3.0

PRELIMINARY AND LOCATION SURVEYS

4.0

BENCH MARKS

5.0

CROSSINGS

6.0

ACCURATES IN MEASUREMENT

7.0

CHAINAGE

8.0

MEASUREMENT OF HORIZONTAL ANGLES

9.0

PROFILES

10.0

BUILT-UP AREAS

11.0

AZIMUTH OBSERVATIONS

12.0

SURVEY NOTES, OBSERVATIONS & COMPUTATIONS

13.0

MAPS AND DRAWINGS

14.0

PRESENTATION OF FIELD SURVEY DATA ANNEXURE – I

-

SPECIFICATION FOR SOIL INVESTIGATION

ANNEXURE - I1

-

ADDITIONAL REQUIREMENT FOR GAS PIPELINES DETERMINATION OF POPULATION DENSITY INDEX & CLASS LOCATION

ANNEXURE - I11 -

ADDITIONAL REQUIREMENT FOR HIGH VAPOUR PRESSURE (HVP) LIQUID PETROLEUM PIPELINES ZONE LOCATION

ANNEXURE – IV

-

PIPELINE ROUTE SURVEY DATA SHEET

ATTACHMENTS

-

SAMPLE FORMATS


1.

PIPELINE ROUTE MAP

2.

ALIGNMENT SHEET



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1.0

SCOPE:

This specification covers the minimum requirements of topographical survey along the pipeline route including locating the centre-line of pipeline alignment on the ground, constructing survey monuments, field measurements for planimetry and profiles and preparation of drawings and documents. This specification also covers the minimum requirements for soil investigation for the purpose of visual engineering classification of soil along the pipeline route. 2.0

REQUIREMENTS:

2.1

All survey works shall be performed by or under the supervision of a qualified land surveyor.

2.2

All measurements shall be in metric units.

2.3

The readings and noting shall be neat, legible and scorings and over-writing shall be duly initialed by the Surveyor.

3.0

PRELIMINARY AND LOCATION SURVEYS: The Surveyor is expected to make himself aware of the general conditions of the terrain before starting detailed survey.

3.1

Alignment and location surveys: A preliminary survey for locating the centre-line of pipeline alignment on the ground shall be carried out as follows:

3.1.1 Surveyor shall make a preliminary survey along the route of the proposed pipeline to establish and flag control points. 3.1.2 Surveyor shall locate and identify the existing features or obstructions along the route that are not shown in available maps or drawings. Archeological sites, reserved forests, environmentally sensitive areas, mining sites and built up areas shall be avoided. 3.1.3 Where it becomes apparent that a better route could be followed, the Surveyor shall consult the COMPANY / ENGINEER for authorization to make a change. 3.1.4 Turning Points (TPs) shall be located by Surveyor in consultation with COMPANYIENGINEER considering the following:  To avoid obstruction along the line, by ranging on ground and shifting the Turning Points if need be. 

Check for terrain gradient by using hand clinometer




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

Ensure proper angle of crossing by keeping as nearly right angle (to road /rail / streams, etc.) as possible. The right angle may be laid on ground by using a chain or string lengths in ratio of 3,4 and 5.



To check from construction point of view and avoid objects like power, telephone and telegraph poles, walls, tube wells or such other structures falling in the strip of land, 25M on either side of pipeline alignment.

3.2

Staking of pipeline route

3.2.1 The pipeline defining trench centre line shall be staked by placing suitably painted marker stakes at Turning Points (TPs) and at Intermediate Points (IPS) between consecutive TPs. All Turning Points (TPs) and intermediate points are referred as Intersection Points. The pipeline centre line shall be staked on the ground as follows: First, the Turning Points (TPs) shall be staked on the ground. After locating and marking the TPs, the intermediate points shall be staked while measuring slack distance. The staking shall normally be done at intervals of 500 M along the centre line of the pipeline. 3.2.2 The Intersection Points shall be serially numbered form the starting point. The serial number of each Intersection Point shall be boldly inscribed on the marker stake. In addition, the Turning Point (TP) marker stake shall identify the Turning Point reference number from the starting point. 3.2.3 For Intermediate Points (IPS) letter "P" shall precede the serial number of the intersection Point marker. For Turning Points, the letters "TP" shall precede the Turning Point reference number, and the letter "P" shall precede the serial number of the Intersection Point. 3.2.4 The marker stakes at Turning Points (TPs) shall be referred with three reference stakes around the TP. The reference stakes shall carry the Turning Point reference number and their respective distance from the TP marker stake. 3.2.5 Change in direction of line shall be marked on the TP marker stakes. In addition, direction markers near TPS and other locations shall be placed wherever necessary. 3.3

Stakes and Markers

3.3.1 All marker stakes shall be pre-cast reinforced concrete blocks having dimensions 150 x 200 x 800 MM deep, and shall be buried to a depth of 500 MM. The exposed surface of the blocks shall have a smooth finish and shall be painted with 'Post Office' red paint. All letters and figures shall be paint marked on the surface of the blocks in white. GAIL (INDIA) LTD NEW DELHI



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3.3.2 On the top surface of the reinforced concrete blocks, a cross inside a circle shall be engraved at the centre or a nail shall be put centrally inside an engraved circle, to indicate the exact position of the Intersection Point. The circle shall be of approximately 50MM diameter. 3.3.3 Surveyor can, however, propose to the COMPANYIENGINEER other types of stakes / markers which are better suited to site conditions. 4.0

BENCH MARKS:

4.1

Permanent Bench Marks (BM) approx. every 5 KMs or permanent structures on or off the Right-of-Use (ROU) shall be established and described.

4.2

Additional permanent bench marks shall be established near the major pipeline crossing sites.

4.3

Location of Bench Marks shall be established in the field by using reinforced concrete blocks similar to pipeline marker stakes described in clause 3.3.1 of this specification. Exact position of BM shall be marked by a cross inside a circle or a nail put centrally inside an engraved circle on the top surface of the concrete block. The reduced level of the BM shall be paint marked on the concrete block. Letters "BM" shall precede the reduced level of bench mark recorded to the second place of decimal.

4.4

Accuracy of the reduced levels of the Bench Marks shall be verified wherever possible by checking levels with the nearest permanent Bench Mark established by Survey of India.

5.0

CROSSINGS:

5.1

General As far as possible, crossings shall be made at right angles. The Surveyor shall record the angles of crossing for all fences, property lines, utilities, roads, railways, canals, streams, etc. that are crossed. In addition, the true bearings of the centerline of the road, railway, canal, as well as that of the pipe centre-line shall be recorded. Turning Points (TPs) provided near crossings shall be located, at least 50m from the crossing's boundaries, in stable and firm ground.

5.2

Railway Crossings The angles for all railway crossings shall be as close to 90 degrees as possible, but in no case less than 85 degrees to the centre-line of the railway.

5.3

Primary Road Crossings Primary roads are the National & State Highways, all-weather roads (paved / unpaved) and roads providing access to major installations. The angle of crossings




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shall be as close to 90 degrees as possible, but in no case less than 80 degrees to the centre line of the road. 5.4

Secondary Road Crossings The angles of crossing for secondary roads shall be as close to 90 degrees as possible, but in no case less than 45 degrees to the centre-line of the roads. All seasonal roads, unpaved village roads, cart-tracks, etc. come under this category.

5.5

River / Stream / Nala Crossings These crossings shall be established as close as possible to the locations shown on the route map. Crossings shall be located in a comparatively straight reach of the river where the banks are stable and there is sufficient area for construction. Angle of crossing shall be as close to 90 degrees as possible.

5.6

Canals / Drainage Ditch Crossings The angle of crossing shall be as close to 90 degrees as possible but in no case less than 60 degrees to the centre-line of the canal / drainage ditch. Crossings shall be located where there is no evidence of slumping or erosion of banks, or bed.

5.7

Utility Crossings Utilities crossed shall be located at their centerlines with stakes containing station numbers in the survey. The angle or crossings shall be measured and locations established relative to their above-ground facilities. The names and sizes of all utility lines shall be included in the survey notes. In the cases of overhead power and telephone lines, the distance to the poles and towers on each side of the survey line shall be measured, and the numbers of poles or towers noted. Line voltage shall also be recorded. Where possible, the survey shall be established so that there is a minimum distance of 50 meters from the survey line to the nearest High Tension pole or tower. Underground utilities shall be located as far as possible and staked for a minimum distance of 25 meters on each side of the survey line.

6.0

ACCURACIES IN MEASUREMENT:

6.1

Surveyor shall incorporate corrections to the linear ground measurement due to standard errors, variations from standard temperature and pull.

6.2

The error for angular closure for the work shall not exceed one minute per station and for linear measurements it shall be read to the nearest 0.005 M.

6.3

The error on closure for measurements on vertical distance to establish bench marks shall not be more that 24K millimeters (where 'K' is the linear distance in KM). The observations for measurement of vertical distances on bench marks shall GAIL (INDIA) LTD NEW DELHI



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be read to accuracy to the nearest 5 MM and for Inter section Points and other points along the pipeline route and at crossings to the nearest 10 MM. The error of misclosure in vertical distance shall be distributed linearly. 6.4

Azimuth checks shall be made by observations of the sun or Polaris at intervals of 15-20 Km. These observations of bearings together with deflection angles shall be recorded in survey notes. Azimuth misclosure based on bearings with observed angles at Turning Points shall be equally distributed over the number of stations observed in between. Accuracy of azimuth observations shall be acceptable if the three deductions agree within one minute.

7.0

CHAINAGE:

7.1

Slack distance measurement will be made using 50 M steel tape or 30 M chain. However, in case of abrupt slope change the tape / chain is straightened parallel to the probable grading.

7.2 7.3

Distance between Intersection Points staked along the pipeline route shall be measured and recorded. In addition, distance between level points shall also be measured and recorded. Chaining will be continuous in the direction of survey.

7.4

The true bearing of all straights shall be observed and recorded.

7.5

Data on nature of terrain, viz. sandy, stony, vegetation, etc. and type of ground will also be recorded along with chainages of change points.

7.6

Check on distance measurements will be by stadia method at the time of levelling.

7.7

Standard chain survey format will be used for record keeping.

8.0

MEASUREMENT OF HORIZONTAL ANGLES: Horizontal angles are measured to indicate the change in direction of alignment and specify the horizontal bend at the Turning Points.

8.1

Theodolite, reading direct to 10 seconds or better, shall preferably be used. Angles shall be measured clockwise from back station to fore-station. Mean of two readings-one on face left and other on face right shall be taken as the horizontal angle.

8.2

The line at both ends shall be tied to the grid control system being used for end facilities. True bearing at the beginning, end and every 15-20 KM shall be observed to keep a check on errors in angular measurements.

9.0

PROFILE:




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9.1

The continuous profile of the proposed pipeline route shall be established from the reduced levels taken. i)

At the starting point

ii)

At all Turning Points (TPs)

iii)

At all Intermediate Points staked on the ground,

iv)

At all points on the pipeline route where there is a change in slope.

9.2

When the terrain is flat, reduced level shall be additionally recorded along the pipeline route at 100m interval.

9.3

When the terrain is undulating observation of reduced level shall be made at a sufficient number of points so as to give an accurate plotting of the ground profile along the route.

9.4

For road and railway crossings, the reduced levels shall be recorded at all points along the pipeline alignment wherever there is a change in slope within the entire width of the Right of-Use of the road/ railway. CONTRACTOR shall prepare a detailed drawing for the crossing in scale 1:100 (in both horizontal and vertical directions) which shall be truly representative of the crossing profile.

9.5

For river / stream/ nalla / canal crossings, levels shall be taken at intervals of 5M up to 30M beyond the highest banks on both sides. Levels shall be taken at closer intervals, if there is a change in slope. CONTRACTOR shall prepare a detailed drawing for the crossing in scale 1 : 100 (in both Horizontal and Vertical directions) which shall be truly representative of the crossing profile.

9.6

In right-of-use having slope across the pipeline alignment, as encountered in hilly areas, Ghat regions, ravines and other similar areas as directed by COMPANY, cross-sections at 50 M interval and for a length of 25 M on either side of the pipeline alignment shall be observed and recorded.

9.7

For major water crossing sites, cross section as above shall be observed at both banks.

9.8

Method of RISE and FALL shall be used to compute reduced levels of various points. Check on computation shall be made by using the following formula: Back site - Fore Site = Σ Rise - Σ Fall = First R.L. - Last R.L

9.9

Maximum misclosure shall not exceed 24K MM where 'K' is the distance in KMs. Maximum length of line of sight shall not exceed 100 M.

9.10

All levels shall be with respect to Mean Sea Level (MSL).

10.0 BUILT-UP AREAS: GAIL (INDIA) LTD NEW DELHI



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10.1 Monuments and Properties The pipeline alignment shall run clear of the existing monuments, properties and structures etc., as indicated in Pipeline Route Survey Data Sheet (Annexure-IV). For congested areas, closer distance may be adopted; however, location shall be approved by COMPANY / ENGINEER. 10.2 Parallel Alignment The pipeline alignment wherever runs parallel to an existing or planned under / above ground facility will be treated as parallel alignment. For underground facilities surveyor shall identify and locate them with suitable special ground laths. The following clearances shall be observed in case of parallel alignment defined above. 

Between existing/planned electrical power cables / lines and the proposed line - 50.0 meters



Between existing / planned communication cables / lines and the proposed line - 25.0 meters

10.3 Parallel Encroachment Unless otherwise stated, when the pipeline alignment runs generally parallel to a road or railway it shall be kept sufficiently clear of the Right of Way limits of the facility. 11.0 AZIMUTH OBSERVATIONS Azimuth control shall be maintained by observation of azimuth at every fifteen to twenty kilometers by closing the traverse on existing control points. Azimuth may be obtained by making observations to sun or star depending upon the location of the area and direction control. In case of azimuth from sun, the computed values must be within one minute. Incase of stars the computed values should agree within 10 to 15 secs. Horizontal misclosure between two azimuth stations shall be equally distributed among TPs in between. 12.0 SURVEY NOTES, OBSERVATIONS AND COMPUTATIONS: 12.1

The procedures followed both for field and office calculations shall be such that the results obtained shall be readily understood and retraceable.

12.2

All up-to-date notes and observations related to the basis for determination of boundary lines and corners shall be maintained by surveyor.




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12.3

Survey records must contain schematic diagrams of all horizontal controls pertinent to the project showing all existing and established control points, bench marks, any triangulation station and boundary lines.

12.4

Geo-graphical and UTM co-ordinates of all Turning Points and starting / end points of the pipeline shall be computed and furnished to the COMPANY / ENGINEER.

13.0 MAPS AND DRAWINGS: 13.1

All maps and drawings shall be made on standard format furnished by the COMPANY. Surveyor shall perform mapping and drawing work so as to contain all relevant data consistent with the survey notes and observations. The drawings shall also contain details of roads, streets, highways, structures, all types of crossings, terrain, surface vegetation and all other details which will be required for the purpose of engineering design.

13.2

Following types of detailed survey drawings will be made.



Right-of-Use Planimetry in UTM grid

-

1:5000 along the line 1:1000 across the line



Ground Profile

-

1:5000 Horizontal 1:500 Vertical



Crossing Details (Road & Railway Crossings)

-




Crossing details (River / Stream / Nala / Canal Crossings)

-




Detailed Route Map

-

1:50,000

Additional Route Map for Hilly, Ghat and ravenous regions

-

1:15,000

Cross Section for sloping Right-of-Use

-


 

14.0 PRESENTATION OF FIELD SURVEY DATA: Survey drawings shall contain the following data as a minimum requirement. 14.1

Pipeline Route Map Pipeline route map shall show all features including, but not limited to roads and railroads, canals, streams, lakes, rivers, villages, towns, and cities that are located within a distance of 5 Krn from the pipeline centre-line on either side of it. For the entire region, contours shall be plotted on the route map at 20 M contour interval. Additional information like cultivated areas, barren land, areas prone to flooding, GAIL (INDIA) LTD NEW DELHI



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rocky areas and forests including access paths / roads to Right-of-Use shall also be shown on the route maps. Additionally for areas which are undulating such as hilly areas, Ghat regions, ravines, and other areas as directed by COMPANY, Pipeline route map to a scale 1: 15,000 shall be drawn over a distance of 1.0 Km from the pipeline centre-line on either side of it. For such areas, contours shall be plotted at 10m contour interval. 14.2

Right-of-Use Planimetry drawings shall show all objects within 50 meters on either side of the Pipeline in Plan.

14.3

In case of all rail, road, river, stream, canal and utility crossings, the angle of crossing shall be mentioned.

14.4

In case or rail, road, river, stream and canal crossings wider than 10m, the distances at the start and at the end of the crossing from the nearest IP shall also be mentioned. For crossings less than 10m, the distance of the centre line of crossing from the nearest IP shall be given.

14.5

For all river, stream and nalla crossings, the level of water at the time of survey and the approximate surface velocity of the flowing stream shall be observed and recorded and reported in the survey drawings. Also, the general nature of the surface soil (soft / hard, normal soil or rock/boulders) at the bed and banks of the river / stream / nalla shall be observed and mentioned in the drawings.

15.0 DOCUMENTS / DATA SUBMISSION: All drawings, reports, formats etc. submitted to COMPANY shall be prepared on electronic media. All drawings shall be prepared using Autocad Release 12/13 (or later version) software operating under Disk Operating System (DOS) environment. The documents shall be prepared using Word Perfect / Microsoft Word / lotus softwares. In addition, hard copies of documents shall also be submitted.




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ANNEXURE - I SPECIFICATION FOR SOIL INVESTIGATION 1.0

GENERAL: The purpose of soil investigation is to be obtain visual engineering classification of soil along the pipeline route.

2.0

SCOPE: The scope of soil investigation includes boring, collection of disturbed samples from boreholes and visual engineering classification of soil along the pipeline route, and submission of detailed report to COMPANY. Visual classification of soil shall be in accordance with IS-1498; "IS Classification and Identification of Soils for General Engineering Purposes".

3.0

BORING:

3.1

Boreholes shall be made at intervals of 500 M along the pipeline route, at all intermediate points where there is apparently a change in the type of soil and at any other place as directed by COMPANY.

3.2

For canal, stream and river crossings, boreholes shall be made one on either bank and one on the bed.

3.3

Minimum diameter of borehole shall be 150 MM. Auger boring shall be resorted to above the water table, whereas below water table the boreholes shall be advanced by shell and auger.

3.4

The boring shall be either terminated at a depth of 3 M below NGL or on top of bed rock if rock is encountered at a depth of less than 3 M.

4.0

SAMPLING: Disturbed representative samples shall be collected from boreholes to classify the subsoil visually at site.

5.0

DETAILED REPORT:

5.1

The report shall include proper visual engineering classification of soils encountered along the pipeline route in bore log form. Depth of Ground Water Table (GWT) below NGL shall also be mentioned if encountered.

5.2

Soil profiles along the pipeline route shall also be prepared and attached with the report.




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5.3

Regions along the pipeline route where special excavation techniques like blasting, etc. needs to be adopted for excavation of pipeline trenches shall be clearly indicated in the report.




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ANNEXURE-II ADDITIONAL REQUIREMENT FOR GAS PIPELINES DETERMINATION OF POPULATION DENSITY INDEX AND CLASS LOCATION 1.0

When survey is performed for gas pipelines, the class locations based on population density index as per code ANSI B3l.8 "Gas Transmission and Distribution Piping Systems" shall be recorded along with chainages at change points of each class location.

2.0

Population density index along the pipeline route shall be determined as follows: As zone, 400 M (one quarter mile) wide, shall be considered along the pipeline route with the pipeline in the centre-line of this zone. Then the entire route of the pipeline shall be divided into lengths of 1600 M (one mile) such that the individual lengths will include the maximum number of dwellings intended for human occupancy. The number of such dwellings which are intended of human occupancy within each 1600 M (one mile) zone shall be counted and reported along with other survey data.

3.0

Areas shall be classified based on guidelines as given below:

3.1

Class 1 Location A Class 1 location is any 1600 M (one mile) section that has 10 or fewer dwellings intended for human occupancy Class 2 Location A Class 2 Location is any 1600 M (one mile) section that has more than 10 but less than 46 dwellings intended for human occupancy. Class 3 Location A Class 3 Location is any 1600 M (one mile) section that has 46 or more dwellings intended for human occupancy except when a Class 4 Location prevails. Class 4 Location

3.2

A class 4 Location includes areas where multi-storey buildings are prevalent, and where traffic is heavy or dense and where there may be numerous other utilities under ground. In addition to the criteria contained in Clause 3.1 above, while classifying areas, additional consideration must be given to possibilities of increase in concentration of population along the pipeline route such as may be caused by the presence of schools, hospitals, recreational areas of an organized character, places of assembly, places of worship, etc. If one or more of these facilities are present, the area shall be classified as a Class 3 Location. GAIL (INDIA) LTD NEW DELHI



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3.3

Notwithstanding the provisions of Clause 3.1 and 3.2 above, while determining class location of an area due consideration shall be given to the possibility of future development of the area during the design life of the pipeline. If it appears likely that future development may cause a change in the location class, this shall be taken into consideration while determining its class location.




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ANNEXURE-III ADDITIONAL REQUIREMENT FOR HIGH VAPOUR PRESSURE (HVP) LIQUID PETROLEUM PIPELINES - ZONE LOCATION 1.0

When survey is performed for High Vapour pressure (HVP) liquid petroleum pipelines, zone location shall be recorded along the pipeline route along with chainages at change points of each zone location. (For definitions refer Oil Industry Safety Directorate (OISD) Standard 141 Design and Construction Requirements by Cross Country Hydrocarbon Pipelines)

2.0

A zone, 200M wide on either side of the centre-line of the pipeline route, shall be considered. Then the entire route of the pipeline shall be divided into lengths of 1 Km such that the individual lengths will include the maximum number of dwellings intended for human occupancy within each 1 Km zone shall be counted and reported along with other survey data.

3.0

Zone locations shall be determined as follows:

3.1

A zone 1 Location is an area extending 200 meters on either side of the centre-line of any continuous 1 KM length of pipeline that contains 5 or fewer dwelling units intended for human occupancy.

3.2

A Zone 2 Location is an area as defined in clause 3.1 above that contains more than 5 dwelling units intended for human occupancy, or a facility that contains 20 or more persons during normal use.

3.3

Each dwelling unit in a multiple dwelling unit building shall be counted as a separate unit.

3.4

When a facility creates Zone-2 location requirements, the Zone 2 area shall extend at least 200 meters from that facility.

4.0

Notwithstanding the provisions of clause 3.0 above, while determining zone location of an area due consideration shall be given to the possibility of future development of the area during the design life of the pipeline. If it appears likely that future development may cause a change in the zone location, this shall be taken into consideration while determining the zone location of the area.




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ANNEXURE-IV PIPELINE ROUTE SURVEY DATA SHEET Pipeline size

:

MM OD

Gradient (ROU)

:

(max) Along pipeline alignment

Bend radius

:

Minimum distance between TPs

:

Maximum deflection angle at TPs

:

Permissible variation in pipeline length

:

ROU width to be acquired

:

Pipeline location in the ROU

:

Minimum distance from existing Buildings / structures / monuments

:

Co-ordinates of starting point

:

Habitable dwellings

:

Structures

:

Property corners / monuments

:

To be established by Contractor

Note: Number of TPs / Bends in the pipeline, whether in horizontal or in vertical direction shall be kept to a minimum




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WELDING SPECIFICATION FOR FABRICATION OF PIPING




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CONTENTS

--

1.0

GENERAL

2.0

APPLICABLE CODES & STANDARDS

3.0

BASE MATERIALS

4.0

WELDING CONSUMABLES

5.0

SHIELDING & PURGING GAS

6.0

EQUIPMENTS & ACCESSORIES

7.0

WELDING PROCESSES

8.0

EDGE PREPARATION

9.0

ALIGNMENT & SPACING

10.0

WEATHER CONDITIONS

11.0

WELDING TECHNIQUE

12.0

HEAT TREATMENT

13.0

CLEANING OF THE WELD JOINT

14.0


15.0

REPAIRS OF WELDS

16.0

DOCUMENTS TO BE SUBMITTED BY CONTRACTOR FORMATS

EXHIBIT A TO EXHIBIT H




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(This specification shall be used in conjunction with Welding Specification Charts). 1.0

GENERAL: This specification shall be followed for the fabrication of all types to welded joints of piping system within the battery limits of the plant. The welded pipe joints shall include the following: a) b)

All pipe joints, longitudinal butt welds, circumferential butt welds and socket welds. Attachments of forgings, flanges and other supports to pipes.

c)

Welded manifold headers and other sub-assemblies.

d)

Welded branch connections with or without reinforcing pads.

e)

Joints in welded/fabricated piping components.

f)

The attachments of smaller connections for vents, drain drips and other instrument tapings.

Any approval granted by the Engineer-in-Charge or Owner's inspector, shall not relieve the Contractor of his responsibilities and guarantee. This specification shall not be applicable for welding of pipelines for transportation of liquid petroleum and other similar products. 2.0

APPLICABLE CODES & STANDARDS: All welding work, equipments for welding, heat treatment, other auxiliary functions and the welding personnel shall meet the requirements of the latest editions of the following accepted standards and procedures unless otherwise specified in the Welding Specification Chart and the Technical notes attached thereof. In the case of conflicting requirements, the requirements mentioned in welding Specification Chart/Technical Notes shall be applicable. i)

ASME Code for Pressure Piping - ASME B31.3

ii)

ASME Boiler & Pressure Vessel Code, Sec II Part C, Material Specifications: Welding Rods, Electrodes and Filler metals.

iii)

ASME Boiler & Pressure Vessel Code, Section V, Non destructive examination.

iv)

ASME Boiler & Pressure Vessel Code, Section VIII, Rules for Construction of Pressure Vessels.




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v)

ASME Boiler & Pressure Vessel Code, Section IX, Welding and Brazing Qualifications.

vi)

The Indian Boiler Regulations -

IBR

In the event of any differences due to the additional requirements mentioned in this specification, over and above those obligatory as per codes, this specification shall be binding. 3.0

BASE METAL:

3.1

In general, use of carbon steel, alloy steel and stainless steel is envisaged. The details of the material specifications are given in the Welding Specification Chart.

3.2

The Contractor shall provide the manufacturer's test certificates for every heat of the materials supplied by him.

4.0

WELDING CONSUMABLES:

4.1

The Contractor shall provide, at his own expense, all the welding consumables necessary for the execution of the job such as electrodes, filler wires, argon etc. and these should bear the approval of the Engineer-in-Charge.

4.2

The welding electrodes and filler wires supplied by the Contractor shall conform to the class specified in the Welding Specification Chart. The materials shall be of the make approved by the Engineer-in-Charge.

4.3

Electrode qualification test records should be submitted as per the Exhibit-A (attached) in respect of the electrodes tested by the Contractor, for obtaining the approval of the Engineer-in-Charge.

4.4

The Contractor shall submit batch test certificates, from the electrode manufacturers, giving details of physical and chemical tests carried out by them, for each batch of electrodes to be used.

4.5

All electrodes shall be purchased in sealed containers and stored properly to prevent deterioration. The electrodes removed from the containers shall be kept in holding ovens at temperatures recommended by the electrode manufacturer. "Out of the oven time" or electrodes, before they are consumed, shall not exceed the limits recommended by the electrode manufacturer. The electrodes shall be handled with care to avoid any damage to the flux covering.

4.6

All low hydrogen type of electrodes shall be rebaked at 350°C for 1 hour minimum and stored in ovens kept at 80-100°C before use. Recommendations of the electrode manufacturer shall I be followed if available.

4.7

The electrodes, filler wires and flux used shall be free from rust, oil, grease. earth and other foreign matter which affect the quality of welding.




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4.8

Tungsten electrodes used shall conform to ASME Sec. II C SFA 5.12 specification.

5.0

SHIELDING & PURGING GAS:

5.1

Argon gas used in GTA welding for shielding purposes shall be 99.995% pure. The purity of the gas shall be certified by the manufacturer. The rate of flow for shielding purposes shall be established through procedure qualification tests. Normally this rate may be 12-20 CFH.

5.2

Argon gas with a purity level of 99.995% shall be used for purging.

5.3

When GTAW process alone or a combination of GTAW and SMAW processes is recommended for the production of a particular joint, the purging shall be maintained during the root pass and for the first filling pass to minimize oxidation on the inner side of the pipe, unless otherwise specified in Welding Specification Chart.

5.4

Initial purging shall be maintained for sufficient period of time so that at least 4-5 times the volume between the dams is displaced, in order to completely remove the entrapped air. In no case should the initial purging period be less than 10 minutes. High gas pressure should be avoided.

5.5

After initial purging, the flow of the backing gas should be reduced to a point where only a slight positive pressure prevails. For systems, which have a small volume (up to ½ cubic foot) to be purged, a gas flow rate of 6-CFH is usually adequate. Systems of larger volume may require higher flow rates and these should be established during procedure qualification tests.

5.6

Gas backing (purging) is not required for socket type of welded joints.

5.7

Dams, used for conserving inert gas during purging, shall be removed after completion of the welding, and shall be accounted for. Wherever, removal of dams is not possible after welding, use of water-soluble dams should be made.

6.0

EQUIPMENTS & ACCESSORIES:

6.1

The Contractor should have the arrangement of sufficient number of welding and cutting equipments, auxiliaries, and accessories of sufficient capacities so as to meet the target / schedule.

6.2

All the equipments for performing the heat treatment, including transformers, thermocouples, pyro-meters, automatic temperature recorders (with suitable calibration arrangement etc.) shall be provided by the Contractor at his own expenses and these should bear the approval of the Engineer-in-Charge.

6.3

Contractor shall make necessary arrangements at his own expense, for providing the radiographic equipments, radiographic films, processing equipment all other darkroom facilities and all the equipments/materials required for cawing out the




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dye penetrant / magnetic particle test/ultrasonic testing for satisfactory and timely completion of the job. 6.4

Redoing of any work, necessitated by faulty equipments or operation used by the Contractor, will be done at his own expense.

7.0

WELDING PROCEDURE:

7.1

Welding of various materials under this specification shall be carried out using one or more of the processes with the approval of the Engineer-in-Charge. -

Shielded Metal Arc Welding Process (SMAW).

-

Gas Tungsten Arc Welding Process (GTAW)

7.2

The welding processes to be employed are given in the Welding Specification Chart. Any deviation desired by the Contractor shall be obtained through the express consent of the Engineer-in-Charge.

7.3

Automatic and semi-automatic welding processes shall be employed only with the express approval of the Engineer-in-Charge. The welding procedure adopted and consumables used shall be specifically approved.

7.4

A combination of different welding processes could be employed for a particular joint only after duly qualifying the welding procedure to be adopted and obtaining the approval of Engineer-in-Charge.

8.0

EDGE PREPARATION:

8.1

General The edges to be welded shall be prepared to meet the joint design requirements by any of the following methods recommended: (a)

Carbon Steel Gas cutting, machining or grinding methods shall be used. After gas cutting, oxides shall be removed by chipping or grinding.

(b)

Low Alloy Steels (containing up to 5% Chromium). Gas cutting, machining or grinding methods shall be used. After gas cutting, machining or grinding shall be carried out on the cut surface.

(c0

High alloy steel (> 5% Chromium) and stainless steels, nickel alloys: Plasma cutting, machining or grinding methods shall be used. After plasma cutting, cut surfaces shall be machined or ground smooth.




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8.2

Cleaning (a)

The ends to be welded shall be properly cleaned to remove paint, oil, grease, rust, oxides, sand, earth and other foreign matter. The ends shall be completely dry before the welding commences.

(b)

On completion of each run, craters, welding irregularities, slag etc., shall be removed by grinding and chiseling. Wire brushes used for cleaning stainless steel joints shall have stainless steel wires and the grinding wheels used for grinding stainless steel shall be of a suitable type. Separate grinding wheels and wire brushes should be used for carbon steels and stainless steels.

9.0

ALIGNMENT & SPACING:

9.1

Components to be welded shall be aligned and spaced as per the requirements laid down in applicable code. Special care must be taken to ensure proper fitting and alignment when the welding is performed by GTAW process. Flame heating for adjustment and correction of ends is not permitted unless specifically approved by the Engineer-in-Charge.

9.2

A wire spacer of suitable diameter may be used for maintaining the weld root opening while tacking, but it must be removed after tack welding and before laying the root bead.

9.3

For pipes of wall thickness 5 mm and above, the ends to be welded shall be secured in position with the aid of couplers, yokes and 'C' clamps, to maintain perfect alignment. Yokes shall be detached after the completion of weld, without causing any surface irregularity. Any irregularity caused on the pipe surface must be suitably repaired to the satisfaction of the Engineer-in-Charge.

9.4

Tack welds, for maintaining the alignment, of pipe joints shall be made only by qualified welders using approved W S . Since the tack welds become part of the final weldment they shall be executed carefully and shall be free from defects. Defective tack welds must be removed prior to the actual welding of the joints.

9.5

Tacks should be equally spaced. Minimum number of tacks shall be:

9.6

3 tacks

-

for 2 1/2" and smaller dia. pipes

4 tacks

-

for 3" to 12" dia. pipes

6 tacks

-

for 14" and larger dia. pipes

Welding shall commence only after approval of fit-up by the Engineer-In-Charge.

10.0 WEATHER CONDITIONS:




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10.1 10.2

The parts being welded and the welding personnel should be adequately protected from rain and strong winds. In the absence of such a protection no welding shall be carried out. During field welding using GTAW process, particular care shall be exercised to prevent any air current affecting the welding process.

11.0 WELDING TECHNIQUE: 11.1

Root Pass (a)

Root pass shall be made with electrodes/filler wires recommended in the welding specification chart. For fillet welding, root welding shall be done with consumables recommended for filler passes. The preferred size of the electrodes is 2.5 mm diameter (12 SWG) but in any case not greater than 3.25 mm (10 SWG).

(b)

Upward technique shall be adopted for welding pipe held fixed with its axis horizontal.

(c)

The root pass of butt joints should be executed so as to achieve full penetration with complete fusion of the root edges. Weld projection inside the pipe shall be as per applicable code. It shall be limited 3mm map, when the applicable code does not place any restriction.

(d)

Any deviation desired from the recommended welding technique and electrodes indicated in the welding specification chart should be adopted only after obtaining express approval of the Engineer-in-Charge.

(e)

Welding shall be uninterrupted.

(f)

While the welding is in progress care should be taken to avoid any kind of movement of the components, shocks, vibrations and stresses to prevent occurrence of weld cracks.

11.2 Joint Completion (a)

Joint shall be completed using the class of electrodes, recommended in the Welding Specification Chart. Size of the electrode shall not exceed 4 mm in diameter for stainless steels and alloy steels used for low temperature applications.

(b) (c)

Two weld beads shall not be started at the same point in different layers. Butt joints shall be completed with a cover layer that would affect good fusion at the joint edges and a gradual notch free surface.

(d)

Each weld joint shall have a workmanship like finish. Weld identification work shall be stamped clearly at each joint, just adjacent to the weld.




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Metal stamping shall not be used on thin pipe having wall thickness less than 3.5mm. Suitable paint shall be used on thin wall pipes for identification. (e)

Rust preventive / protective painting shall be done after the weld joint has been approved.

11.3 Dissimilar Welds Where welds are to be produced between carbon steels and alloy steels, preheat and post weld heat treatment requirements shall be those specified for corresponding alloy steels and filler wire / electrodes shall correspond to ER 70 S-G or AWS E-7016/7018 type. For welds between two dissimilar Cr-Mo low alloy steels, preheat and post weld heat treatments shall be those specified for higher alloy steel and electrodes used shall correspond to those specified for steel of lower alloy content. For carbon steel or alloy steel to stainless welds, use of filler wire / electrodes E / ER-309 / E-310 / E NiCr Fe-3 shall be made. The welding procedure, electrodes / filler wires to be used shall be approved by the Engineer-in-Charge. 12.0 HEAT TREATMENT: 12.1 Preheating (a)

No welding shall be performed without preheating the joint to 10°C (50°F) when the ambient temperature is below 10°C.

(b)

Preheating requirements for the various materials shall be as per the Welding Specification Chart attached.

(c)

Preheating shall be performed using resistance or induction heating methods. Preheating by gas burners, utilizing oxy-acetylene or oxy-propane gas mixtures, with neutral flame may also be carried when permitted by the Engineer-in-Charge

(d)

Preheating shall extend uniformly to at least three times the thickness of the joint, but not less than 50 mm, on both sides of the weld.

(e)

Preheating temperature shall be maintained over the whole length of the joint during welding. Temperature recorders shall be provided by the Contractor to record the temperature.

12.2 Post Heating In case of alloy steel materials such as Cr-Mo steels, if the post weld heat treatment is not performed immediately after welding, the weld joint and adjacent portion of pipe, at least 50 mm on either side of weld, shall be uniformly heated to 300°C. This temperature shall be maintained for half an hour minimum, and then GAIL (INDIA) LTD NEW DELHI



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wrapped in asbestos or insulation before allowing it to cool to room temperature. If the Post Heating temperature specified in the Welding Specification Charts exceeds 300°C, the same shall be followed. Similarly, if the welding specification chart specifies post-heat time, the same shall be applicable. Post weld heat treatment as specified in the Welding Specification Chart shall be carried out later on.

12.3 Post Weld Heat Treatment (a)

Post weld heat treatment, wherever required for joints between pipes, pipes and fittings, pipe body and supports shall be carried out as per the welding specification chart, applicable codes standards and the instructions of the Engineer-in-Charge.

(b)

The Contractor shall submit for the approval of the Engineer-in-Charge, well before carrying out actual heat treatment, the details of the post weld heat treatment procedure as per Exhibit - B attached, that he proposes to adopt for each of the materials / assembly /parts involved.

(c)

Post weld heat treatment shall be done in a furnace or by using an electronic resistance or induction-heating equipment, as decided by the Engineer-in-Charge.

(d)

While caving out local post weld heat treatment, technique of application of heat must ensure uniform temperature attainment at all points of the portion being heat treated. Care shall be taken to ensure that width of heated band over which specified post weld heat treatment temperature attained is at least that specified in relevant applicable codes /standards. Throughout the cycle of heat treatment, the portion outside the heated band shall be suitably wrapped under insulation so as to avoid any harmful temperature gradient at the exposed surface of pipe. For this purpose temperature at the exposed surface should not be allowed to exceed 50% of the peak temperature.

(e)

(f)

The temperature attained by the portion under heat treatment shall be recorded by means of thermocouple pyrometers. Adequate number of thermocouples should be attached to the pipe directly at equally spaced location along the periphery of the pipe joint. The minimum number of thermocouples attached per joint shall be 1 up to 6" dia., 2 up to 10" dia. and 3 for 12" dia. and above. However, the Engineer-in- Charge can increase the required number of thermocouples to be attached if found necessary.

(g)

Automatic temperature recorders, which have been suitably calibrated, should be employed for measuring & recording the temp. The time-temp graph shall be submitted to Engineer-in-Charge immediately on completion of S.R. The calibration chart of each recorder should be submitted to the Engineer-in-Charge prior to starting the heat treatment operations and his approval should be obtained.




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(h)

Manufacturer's test certificate shall be submitted for the thermocouple materials.

(i)

Immediately on completion of the Heat Treatment, the Post Weld Heat Treatment charts/records along with the hardness test results on the weld points, wherever required as per the Welding Specification Chart, shall be submitted to Engineer-in-Charge for his approval.

(j)

Each joint shall bear an identification number, which shall be maintained in the piping sketch to be prepared by the Contractor. The joint identification number should appear on the corresponding post weld heat treatment charts. The chart containing the identification numbers and piping sketch shall be submitted to Engineer-in-Charge in suitable folders.

13.0 CLEANING OF THE WELD JOINTS: All weld joints shall be free from adherent weld spatters slag, sward, dirt or foreign matter. This can be achieved by brushing. For stainless steels, brushes with only stainless steel bristles should be used. 14.0 INSPECTION AND TESTING: 14.1 General (a)

The Owner's inspector shall have free access to all concerned areas, where the actual work is being performed. The contractor shall also accord the Owner's Inspector all means and facilities necessary to carry out inspection.

(b)

The Owner is entitled to depute his own inspector to the shop or field where prefabrication and erection of pipe lines is in progress for (but not limited to) the following objectives:

(c)

i)

To check the conformance to relevant standards and suitability of various welding equipments and the welding performance.

ii)

To witness the welding procedure qualification.

iii)

To witness the welder performance qualification.

iv)

To check whether shop / field welding being executed is in conformity with the relevant specifications and codes of practice followed in piping construction.

Contractor shall intimate sufficiently in advance the commencement of qualification tests, welding works and acceptance tests, to enable the Owner's inspector to be present to supervise them.

14.2 Welding Procedure Qualification




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Welding procedure qualification shall be carried out in accordance with the relevant requirements of ASME Sec. IX latest edition or other applicable codes and the job requirements. The contractor shall submit the welding procedure specification in format as per Exhibit-C (attached) immediately after the receipt of the order. Owner's inspector will review, check and approve the welding procedure submitted and shall release the procedure for qualification tests. The procedure qualification test shall be carried out by the Contractor at his own expense. A complete set of test results in the format as per Exhibit-D (attached) shall be submitted to the Owner's inspector for his approval immediately after completing the procedure qualification test and at least 2 weeks before the commencement of actual work. Standard test as specified in the code shall be carried out in all cases. In addition to these tests, other tests like macro/micro examination, hardness tests. Dye penetrant examination, charpy V-notch, Corrosion tests, impact tests etc. shall be carried out on specimens depending upon the type of base material, operating conditions and requirements laid own in the detailed drawings and specifications. It shall be the responsibility of the Contractor to carry out all the tests required to the satisfaction of the Owner's inspector.

14.3 Welder's Qualification (a)

Welders shall be qualified in accordance with the ASME Section-IX or other applicable codes. The Owners inspector shall witness the test and certify the qualification of each welder separately. Only those welders who have been approved by the Owner's Inspector shall be employed for welding. Contractor shall submit the welder qualification test reports in the format as per Exhibit-E (attached) and obtain express approval before commencement of work. It shall be the responsibility of Contractor to carry out qualification tests of welders. For welding of the steam piping, falling under the purview of Indian Boiler Regulations only those welders with IBR Certification, qualified by Boiler Inspectorate, and acceptable to the local Boiler Inspector authority shall be employed.

(b)

The welders shall always have in their possession the identification card as shown in Exhibit4 and shall produce it on demand by the Owner's inspector. It shall be the responsibility of the Contractor to issue the identify cards after it has been duly certified by the Inspector.

(c)

No welder shall be permitted to work without the possession of identify card.

(d)

If a welder is found to perform a type of welding or in a position for which he is not qualified, he shall be debarred from doing any further work. All welds performed by an unqualified welder shall be cut and redone by a qualified welder at the expense of the Contractor

14.4 Visual Inspection




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Inspection of all welds shall be carried out as per the latest editions of the applicable codes and specifications. All finished welds shall be visually inspected for parallel and axial alignment of the work, excessive reinforcement, concavity of welds, shrinkage cracks, inadequate penetration, unrepaired burn-through, under cuts, dimensions of the weld, Surface porosity and other surface defects. Undercutting adjacent to the completed weld shall not exceed the limits specified in the applicable standard / code.

14.5 Radiographic Examination (a)

Contractor shall appoint agency for carrying out the radiography works at site from the list of agency (ies) enclosed in the bid document or separately supplied by owner.

(b)

The Radiographic Examination procedures to be adopted shall be submitted by the contractor as per Exhibit-F and shall be got approved from the Owner's Inspector prior to employment. A person qualified to ASNT Level-II in Radiographic testing shall prepare the procedure. The Radiography Procedure shall be established to demonstrate that the required sensitivity can be consistently achieved under the most unfavorable parameters (e.g. source to film distance, geometric unsharpness, thickness etc.). The radiographic technique and procedure adopted shall conform of the requirements mentioned in Article 2 as well as Article 22 (SE 94, 142, 747, 999 & 1025) of ASME Sec.V. The IQI sensitivity obtained shall be equal to or better than the requirements mentioned in Article 2 of ASME Sec. V. Source side penetrameter shall be used in establishing radiographic procedure/ technique. The acceptance criteria shall be as per the relevant codes of Fabrication and over riding requirements if mentioned else where in the technical specifications of the contract. The Contractor shall be responsible for carrying out Radiography; rectification of defects and reradiography of welds repaired / rectified at his cost.

(c)

The extent of Radiography shall be as per specifications to be supplied to the Contractor. For welds between dissimilar materials, the extent of Radiographic Examination shall be the more stringent of the two recommended for the materials being welded. Wherever random Radiography is called for, in a particular piping class, the dissimilar materials weld joints shall essentially be included.

(d)

Type of Radiation source and film to be used shall be as per Exhibit-H for carrying out radiographic examination. However if specifications (as given else where in the contract) for some critical material require usage of XRadiation, then Radiography shall be done using X-Rays only.

(e)

The Contractor shall fulfill all the statutory and owner's safety requirements while Handling X-ray and Gamma-ray equipments.




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(f)

The joints for Radiography shall be selected by the Owner's Inspector and the Radiography shall be performed in his presence, if he instructs the contractor to do so. The contractor shall furnish all the radiographs, to the Owner's inspector immediately after processing along with evaluation by a person qualified to ASNT Level - II in Radiographic testing, inline with clause T-292 of Article 2 of ASME Sec. V. The certificate of ASNT Level-II (RT) personnel shall be submitted to owner's inspector for his approval prior to start of job.

(g)

The Contractor shall provide the Owner's Inspector all the necessary facilities at site such as a dark room with controlled temperature, illuminator (viewer) suitable for varying densities, a duly calibrated electronic densitometer with batteries, magnifying glass, tracing papers, ruler marking pencils etc. to enable him to review the radiographs.

(h)

Where random radiography is specified, the first weld of each welder shall be completely radiographed. In the case of pipe of size 6" and below, the first two welds shall be completely radiographed.

(i)

For each weld performed by a welder found unacceptable, two additional checks shall be carried out on welds performed by the same welder. This operation is iterative and of the two additional welds for each weld deemed unsatisfactory shall be continued till such time that two consecutive welds of satisfactory quality are found for every defective weld.

(j)

The Contractor shall carry out these additional radiographic testing at his own expense. To avoid the possibility of too many defective welds by a single welder remaining undetected for a long period to time, the Contractor shall promptly arrange for Radiographic Examination so that there is no accumulation of defective joints.

(k)

Contractor shall quote rates for X-ray as well as Gamma Ray for joints indicated to be radiographed by X-ray in Table of Exhibit-H.

14.5.1

14.6

Check Shots (a)

Owner shall select 5% of the total joints radiographed on a day for check shots. Contractor shall carry out check shots as directed.

(b)

Weld profiles of check shots shall be compared with weld profile observed in the earlier Radiographs. In the event of any one variation in the check shots and earlier Radiographs, contractor shall re-shoot the entire lot of joints radiographed by particular Radiography agency on the particular date. All the re-shot films shall be compared with the originally submitted films.

Liquid Penetrant and Magnetic Particle Examination




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14.7

(a)

Whenever such tests are specified, the tests shall be carried out on joints chosen by the Owner's inspector, as per ASME Section V article 6 and 7 respectively.

(b)

For austenitic stainless steels and other nonmagnetic materials, liquid (dye) penetrant test shall be carried out. For carrying out this test, the materials shall be brought within a temperature limit of 15 - 500C.

Hardness Test Hardness requirements for welds shall be as per the Welding Specification Chart (attached). Hardness testing shall be carried out by Vickers Hardness Tester during welding procedure qualification and shall be cross sectional. In all other cases, hardness testing may be carried out by Portable Shore Seleroscope hardness tester. Contractor shall produce documentary evidence / calibration certificate to the Owner's Inspector and obtain approval of the equipment.

14.8

Proof Tests Hydrostatic and pneumatic tests shall be performed as per the requirements laid down by respective flushing and Testing specification/applicable codes to demonstrate the soundness of the welds. The tests shall be conducted after fulfilling the requirement of visual examinations, radiography etc. and after the entire work has been certified by the Owner's inspector to be fit for being subjected to such tests.

15.0

16.0

REPAIRS OF WELDS: (a)

Defects ascertained, through the inspection methods, which are beyond acceptable limits shall be removed after the joint is completely radiographed by the process of chipping and grinding.

(b)

When the entire joint is judged unacceptable, the welding shall be completely cut and edges suitably prepare as per required alignment tolerances. The re-welded joint shall again be examined following standard practices.

(c)

No repair shall be carried out without prior permission of the Owner's inspector.

(d)

Repairs and / or work of defective welds shall be done in time to avoid difficulties in meeting the construction schedules.

DOCUMENTS TO BE SUBMITTED BY CONTRACTOR (4 COPIES EACH): (a)

Electrode and Welding Consumable Qualification Records as per Exhibit-A, for the Welding Consumables tested and approved for the work.




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(b)

Batch Test Certificates, for the Electrodes used, obtained from the Electrode Manufacturers.

(c)

Proposed Heat Treatment Procedure as per Exhibit-B .

(d)

Heat Treatment Charts.

(e)

Weld joint hardness test results.

(f)

Welding Procedure Specifications as per Exhibit-C immediately after receipt of the order.

(g)

Welding Procedure Qualification records as per Exhibit-D.

(h)

Welder Performance Qualification records as per Exhibit-E immediately after conducting Welder Qualification Tests.

(i)

Radiography Procedure as per Exhibit-F and other NDT procedures.

(j)

Radiographic test Report along with Radiographs and other NDT reports.

(k)

Piping Sketch (Isometric) giving all the details regarding the pipe specifications, welded joints, joints radiographed magnetic particle, tested, ultrasonic tested, penetrant tested, joints heat treated, WPS used, welders identification number, etc.




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EXHIBIT - A Sheet 1 of 3 ELECTRODE QUALIFICATION TEST RECORD A:

B:

Tested at (Site name)

Date:

Manufacturer's Name

:

Brand Name

:

Batch Number & Size tested

:

Classification & Code

:

Intended for welding in position

:

In combination with (if any)

:

Code of Reference (used for testing)

:

Special Requirements (if any)

:

All-weld Tensile Test

:

Base Material used

:

Pre-heat temperature

:

Post weld heat treatment details

:

Visual examination

:

Radiographic examination results

:

Tensile test results

:

Identification No.


U.T.S

Yield Point

Elongation


Remarks


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EXHIBIT - A Sheet 2 of 3 C:

Impact Test Results Test Temperature:

Notch in:

Type of Specimens (Charpy): Specimen No.

Size of Specimens:

Impact Value

Average

1 2 3 D:

Chemical Analysis Results

%C E:

Electrode Size Result

:

Batch No.

:

%S

%P

% Si

% Mn

Fillet Weld Test Results

:

Welding Positions

:

Base Materials

:

Size of electrode use

:

Visual Inspection Results

:

% Cr

% Ni

% Mo

OTHER

1) 2) 3)




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EXHIBIT - A Sheet 3 of 3

F:

Macro Test Results

:

Fracture Test Results

:

Remarks

:

Other Test Results 1.

Transverse tensile test

:

In combination with

:

Base material used

:

Position of welding

:

Preheat temperature

:

Post weld heat treatment

:

Radiography

:

Identification No. 2.

Guided Bend Test

POSITION

IDENTIFICATION NO. 1 2 3

U.T.S

Fracture in :

ROOT, FACE OR SIDE BEND

G.

Any other tests

:

H.

Conclusions

:

--------------PREPARED BY (CONTRACTOR)


Remarks

----------------REVIEWED BY (CONTRACTOR)


REMARKS

---------------APPROVED BY (OWNER)


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EXHIBIT – B Sheet 1 of 2 STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION Contractor : _____________________________________________________ Name of the Heat treater : __________________________________________ Name of the Project

:_____________ Specification:_______ Reference No. _______

________________________________________________________ 1.

General Details

Other Details

Name of the equipment:________

Type of heating: Elec. Res / Induction (Tick mark applicable method) Maximum Permissible Temp at Uncovered Parent Metal_____ Width of heated Band_______ Width of Insulation_________

Material:___________________

No. of Thermo Couples (dia wise) __________________

Type of Thermo Couples___________

2.

Heat Treatment Cycle Details Charging Temp

(0C) __________________________________

Rate of heating

(0C/Hr.)_______________________________

Soaking Temperature (0C)_______________________________




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EXHIBIT – B Sheet 2 of 2 Soaking Time (Hrs.) ___________________________________ Rate of cooling

(0C/Hr.)_______________________________

Method of Cooling_____________________________________

3.

Other Details, if any ___________________________________ ___________________________________________________ ___________________________________________________




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EXHIBIT – C Sheet 1 of 3 FORMAT FOR WELDING PROCEDURE SPECIFICATION (WPS) Company Name ________________________ BY___________________ Welding Procedure Specification No.________ Date _________________ Supporting PQR No. (S)________________ Revision No. ____ Date_____ Welding Process (es)___________________ Type (s) _______________ (Automatic, Manual, Machines or Semi Auto)

JOINTS Joint Design ________________________________________________ Backing (Yes)____________________________ (No)_______________ Backing Material (Type)_______________________________________ Sketches Production Drawings. Weld Symbols Written________________ Description shod show the general arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld groove may be specified ___________________________________________________ (At the option of the Manufacturer sketches may be attached to illustrate joint design weld layers and bead sequence e.g. for notch toughness procedures, for multiple process procedures, etc.)

BASE METALS P No. _______ Group No. ________ to P. No. ______ Group No._______ OR Specification type and grade ____________________________________ to Specification type and grade__________________________________ OR Chem. Analysis and Mech. Prop. _________________________________ to Chem. Analysis and Mech. Prop._______________________________ Thickness Range: Base Metal: Groove ___________ Fillet _______________ Deposited Weld Metal: Groove Fillet______ Fillet__________ Pipe Dia Range: Groove: ____________________ Fillet _______________ Other ______________________________________________________




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EXHIBIT-C SHEET 2 OF 3

FILLER METALS

F. No.____________________________ Other __________________ A. No. ___________________________ Other __________________ Spec. No. (SFA) ___________________________________________ AWS No. (Class) ___________________________________________ Size of filler metals_________________________________________ ________________________________________________________ (Electrodes, Cold Wire, Hot Wire etc.) Electrode-Flux (Class)_______________________________________ Flux Trade Name __________________________________________ Consumable Inset _________________________________________ Each base metal/filler metal combination should be recorded individually. WPS NO. ______________

Rev. ________________

POSITIONS:

POST WELD HEAT TREATMENT

Position(s) of Groove _________ Welding Progression: Up__ Down __ Position (S) of Fillet_____________

Temperature Range_____________

PREHEAT

GAS

Preheat Temp. Min. ____________ Inter pass Temp. Max. __________ Preheat Maintenance____________

Shielding Gas (es) ______________ Percent Composition (mixtures)____ Flow Rate______________________ Gas Backing____________________ Trailing Shielding Gas Composition__

Time Range ___________________

ELECTRICAL CHARACTERISTICS Current AC or DC ____________________ Polarity _______________ Amps (Range) _______________ Volts (Range) _________________ (Amps and volts range should be recorded for each electrode size, Position, and thickness, etc. This information may be listed in a tabular form similar to that shown below) Tungsten Electrode Size and Type _____________________________ (Pure Tungsten, 2% Thoriated, etc)




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EXHIBIT-C SHEET 3 OF 3 Mode of Metal Transfer for GMAW _____________________________ (Spray arc, short circuiting arc. etc.) Electrode Wire feed speed range ______________________________

TECHNIQUE String or Weave Bead __________________________________ Orifice or Gas Cup Size_________________________________ Initial and Inter pass Cleaning (Brushing, Grinding, etc.)___________ ________________________________________________________ Method of Back Gouging ____________________________________ Oscillation _______________________________________________ Contact Tube to Work Distance _______________________________ Multiple or Single Pass (per side) ______________________________ Multiple or Single Electrodes _________________________________ Travel Speed (Range) ______________________________________ Peening _________________________________________________ Other ___________________________________________________

Weld Process Layers

Filler Metal

Current

Class Dia.

Type Amp. Polarity Rating

Travel Volt Speed Range Range

Others ex.: Remarks, Comments, Hot wire Addition, Technique Torch Angle, etc.




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EXHIBIT – D Sheet 1 of 3 FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR) RECORD ACTUAL CONDITIONS USED TO WELD TEST COUPON

Company Name ______________________________________________ Procedure Qualification record No._______________ Date ___________ WPS No. ___________________________________________________ Welding Process (es)___________________ Type (s) _______________ (Automatic, Manual, Machines or Semi Auto)

JOINTS Groove Design of Test Coupons (For combination qualification, the deposited weld metal thickness shall be recorded for each Filler Metal or Process weld)

BASE METAL

POST WELD HEAT TREATMENT

Material Spec. _______________ Temperature ___________________ Type of Grade _______________ P. No. _________ to P. No. _____ Time __________________________ Thickness of test coupon _______ Diameter of test coupon ________ Other _________________________ Other ______________________

FILLER METALS

GAS

Weld Metal Analysis A No. ______ Size of Filler metal ____________ Filler Metal E No. _____________ SFA Specification _____________ AWS Classification ____________ Other ______________________

Type of Gas or Gases _____________


Composition of Gas Mixture ________ Other _________________________



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EXHIBIT – D Sheet 2 of 3 POSITION

ELECTRICAL CHARACTERSTICS

Position of Groove ____________ Weld Progression (Uphill, Downhill) ____________________________ Other _______________________

Current _______________________ Polarity _______________________ Amps. ________________________ Tungsten Electrode Size __________ Other _________________________

PREHEAT

TECHNIQUE

Preheat Temp. ________________ Inter pass Temp. ______________

Travel Speed ___________________ String or weave bead _____________ Oscillation _____________________ Multi pass or single pass __________ Single or Multiple electrodes _______ Other _________________________

GUIDED BEND TEST Type of Figure No.

Result

TOUGHNESS TESTS Specimen Notch Notch Test Impact No. Location Type Temp. Value

Lateral Expansion % Mils Shear

Drop weight Break

No Break

FILLET WELD TEST Result – Satisfactory: Yes ____ No ____ Penetration into Parent Metal: Yes ____ No ____ Macro Results ____________________________________________




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EXHIBIT – D Sheet 3 of 3 OTHER TESTS Type of Test ______________________________________________ Deposit Analysis ___________________________________________ Other ___________________________________________________ Welder's Name _________ Check No. _________ Stamp No. _______ Test Conducted by _____________ Laboratory Test No. ___________ We certify that the statements in this record are correct and test welds were prepared, welded and tested in accordance with the requirements of Section IX of the ASME Code. Date ________

Manufacturer ____________ BY _____________________

(Details of record of tests are illustrative only and may be moulded to conform to the type and number of tests required by codes and specifications)




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EXHIBIT – E Sheet 1 of 2 FOMAT FOR MANUFACTURER'S RECORD FOR WELDER OR WELDING OPERATOR QUALIFICATION TESTS Welder Name ____________ Cheek No. ________ Stamp. No. _____ Using WPS No. _____________ Rev. _____________ The above welder is qualified for the following ranges Variable Record

Actual Values

Process Process Type Backing (metal, Weld metal, flux, etc) Material Spec.

Qualification Range

Used in Qualification

_________________ _________________

________________ ________________

_________________ _______ to ________

________________ ________ to ______

Thickness Groove Filler

__________________ __________________

_________________ _________________

Diameter Groove Filler

__________________ __________________

_________________ _________________

Filler Metal Spec. No. Class F. No.

__________________ __________________ __________________

_________________ _________________ _________________

Position

__________________

_________________

Weld Progression

__________________

_________________

Gas Type

__________________

_________________

Electrical Characteristics Current __________________ Polarity __________________

_________________ _________________




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EXHIBIT – E Sheet 2 of 2 Guided Bend Test Results Type of Figure No.

Result

Radiographic Test Results (for alternative qualification of groove welds by radiography) Radiographic test results ____________________________________

Fillet Weld Test Results Fracture Test (Describe the location, nature and size of any crack of tearing of the specimen _____________________________________ Length and Per Cent of Defects ________________ inches _______% Macro Test - Fusion ________________________________________ Appearance - Fillet Size(ing) _____ x _____ Convexity or Concavity __ Test Conducted by ______________ Laboratory - Test No. _________ We certify that the statements in this record are correct and that the test welds were prepared, Welded and tested in accordance with the requirements of Section IX of the ASME Code. Date ________

Organization_____________ BY _____________________

(Details of record tests are illustrative only and may be modified to conformation to the type & number of tests required by the Code) Note:

Any essential variables in addition to those above shall be recorded




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EXHIBIT - F RADIOGRAPHIC PROCEDURE QUALIFICATION RECORD FOR PIPE WLDING 1.

Location

2.

Date of Testing

3.

Name of the Contractor/Agency

4.

Material: Carbon steel/Alloy Steel / Stainless Steel 4 A.

Technique: DWSI/SWSI/DWDI

5.

Diameter & Thickness:

6.

Type of Weld Joint:

7.

Radiation Source:

8.

Intensifying Screens/Lead Screens:

9.

Geometric Relationship:

10.

Limit of Film Coverage:

11.

Film Type and Make:

12.

Exposure Time:

13.

Processing:

14.

Density:

15.

Sensitivity:

16.* Type of penatrameter (source side): 17.* Type of penatrameter (Film side): Signature of Contractor/Agency with Seal Approval of GAIL’s Inspector * Refer Para regarding recommended practice Penetrameters, Article 22, SE 142, ASME Sec. V

on

placement

of

* For “Random radiography” lines placement of Penetrameters as per Article 2, ASME Sec. V is permitted.




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EXHIBIT – G WELDER’S IDENTITY CARD 1.

Name:

2.

Identification:

3.

Date of Testing:

4.

Process

5.

Thickness range

6.

Diameter range

7.

F. No.

8.

Date of approval of welding

9.

Position

Approved by:


PHOTOGRAPH

Employer’s Signature with seal



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EXHIBIT – H TYPE OF SOURCE AND FILMS TO BE USED FOR RADIOGRAPHY NOMINAL WALL THICKNESS (T) IN mm 19 ≤ T 8 ≤ T <19

T<8

Notes:

SHOP WELDED JOINTS

All Materials

Gamma Ray Carbon steel Gamma Ray All other Gamma materials Ray Carbon steel Gamma other than Ray Inspection Class IV * All other X Ray material and Carbon Steel of Inspection Class IV *

“AGFA D7” or equivalent “AGFA D5” or equivalent “AGFA D4” or equivalent “AGFA D4” or equivalent

FIELD WELDS Gamma Ray Gamma Ray Gamma Ray Gamma Ray

“AGFA D7” or equivalent “AGFA D5” or equivalent “AGFA D4” or equivalent “AGFA D4 / D2” or equivalent

“AGFA D5” or X-ray with "AGFA D5" or Equivalent to be used. equivalent

Gamma Ray with "AGFA D4/D2" or Equivalent may be allowed only if in the opinion of the owner's inspector Joints are inaccessible for X-ray equipment and radiographic sensitivity is achieved

Integral to above table

1.

Joints welded in field on Ground Level shall be considered as shop welded joints.

2.

Very fine grain (High contrast) films slower than the above may have to be used, if required radiographic sensitivity is not achieved consistently.

3.

AGFA means AGFA GAEVERTS.

*

Refer Std. Spec. No. S-05-02-012




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INSTRUCTIONS TO VENDOR FOR QUALITY DATA REQUIREMENTS




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CONTENTS

1.0

INTRODUCTION

2.0

PURPOSE

3.0

SCOPE

4.0

DEFINITIONS

5.0

INSTRUCTIONS

6.0

ATTACHMENT




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1.0

INTRODUCTION

1.1

As a part of services rendered to the Client, GAIL purchases Products/ Services for Projects on behalf of client (including in house projects) from various vendors.

2.0

PURPOSE

2.1

The purpose of this standard is to describe the vendor Quality Data Requirements which shall form a part of every Material Requisition (MR)/ Purchase Requisition (PR) released by GAIL, so as to ensure that all purchased products/ services consistently conform to planned Quality and projects’ stated and implied needs are met to Client’s total satisfaction.

3.0

SCOPE The requirements of this standard are applicable to all Vendors for supply of Packages, Equipments and Materials which are: a)

Purchased on behalf of Clients for Projects handled by GAIL.

b)

Purchased for GAIL’s in house projects.

4.0

DEFINITIONS

4.1

“Vendor” means the person(s), firm, company, organization from whom GAIL procures products/ services on behalf of Client, as a part of services to the Client for Projects handled by GAIL, or for its in house projects rendered.

4.2

“Contractor”, “Sub-Contractor”, “Sub-vendor”, “Supplier”, “Seller”, “Agents” are considered synonymous to “Vendor”.

4.3

MR means Material Requisition and PR means Purchase Requisition.

5.0

INSTRUCTIONS

5.1

Quality Assurance Plan (QAP) Vendor during bidding stage, shall confirm compliance to his QUALITY ASSURANCE (QA) Plans (consisting of relevant Procedures covering various activities like design and engineering, material procurement, manufacture, inspection and testing, documentation, dispatch to site, erection and commissioning where applicable and maintenance of Quality records) which have already been approved at the time of vendor enlistment. In the post order stage, the vendor shall confirm the validity of their QA Plans and submit only revisions/ deviations if any to these plans, to the concerned




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GAIL Inspection office/ Third Party Inspection Agency for approval within 2 weeks from the date of receipt of PR.

5.2

Inspection & Test Plan Vendor shall submit Inspection and Test plan for approval within 2 weeks of PR and before commencement of manufacture to concerned GAIL Inspection Office/ Third Party Inspection Agency (TPIA). The Inspection and Test Plan shall also cover “bought out” items from sub-vendors.

5.3

Drawing Schedule Vendor shall submit a total index of drawings and documents required for review/ records based on the Vendor Data Requirement given in the PR along with the scheduled date of submission of each drawing/ document within 2 weeks from Tele-fax Letter of Intent. The Drawing schedule shall be specific with regard to drawing/ document No., the exact title and the size of the drawings/documents.

5.4

Progress Report and Schedule Vendor shall submit Monthly Progress Report and updated procurement, engineering and Manufacturing Schedule every month, beginning within 2 weeks from Tele-fax/ Letter of Intent.

5.5

Waiver & Deviation Vendor shall strictly comply with PR stipulations and no deviations shall be permitted. However, if the need for deviation arises under exceptional circumstances, on the postorder stage, such deviation shall be subject to the approval of GAIL/ OWNER and shall be submitted through GAIL Regional - Inspection Office in the prescribed “WAIVER/ DEVIATION REQUEST” format.

5.6

Procurement of Bought out Materials All critical materials such as casting, forging, fittings, pressure holding parts, electrical and instrument accessories, etc. shall be purchased by the Vendor from GAIL approved suppliers meeting Qualification Criteria stipulated if any. Vendor shall submit a list of bought out materials and sub-vendors for these bought out materials for GAIL approval within 2 weeks from Tele-fax Letter of Intent.

5.7

Calibration Records Vendor shall use only calibrated measuring and test instruments and maintain calibration records. Vendor shall furnish records of calibration of measuring and test GAIL (INDIA) LTD NEW DELHI



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instruments including recalibration records to concerned GAIL Inspection Office/ Third Party Inspection Agency. 5.8

Inspection Test Status Inspection and Test status of products shall be identified by using markings, authorised stamps, tags, route cards, inspection records etc. during the course of manufacture to clearly indicate acceptance/ rejection of tests/stages of inspection performed during its manufacturing cycle. The identification of inspection and test status shall be maintained and records thereof shall be submitted as and when demanded by GAIL Inspection Engineer or Third Party Inspection Agency.

5.9

Quality Records Vendor shall maintain quality records as per his procedures. Inspection Reports & Test Record copies- shall be furnished to GAIL Inspection Engineer or Third Party Inspection Agency.

5.10 Identification and Traceability Vendor shall establish and maintain a standard written procedure for identifying the products from applicable drawings, specification or other documents during all stages of production, delivery and installation, A copy of this Standard procedure shall be made available at concerned GAIL Inspection office. On job to job basis, vendor shall confirm its validity and only revisions/ deviations if any, shall be submitted for approval. The vendor shall ensure that each product which is going in the process of fabrication / manufacture/ construction/ erection has proper identification throughout the process including the final output. 5.11 Vendor Documents for GAIL Review/ Records General i) All Documents shall be in ENGLISH language and in M.K.S. system of units. ii) Review of the vendor Drawings by GAIL would be only to review the compatibility with basic designs and concepts and in no way absolve the vendor of his responsibility to comply with PR requirements, applicable codes, specifications and statutory rules/ regulations. iii) Unless otherwise agreed, submission of Documents for Review/ Records shall commence within 04 weeks from the date of Telefax/ Letter of Intent. iv) Unless otherwise agreed, vendor shall submit all Drawings and Documents in number of copies, as stipulated in the Vendor Data Requirement Form, along with Document Index. The Documents shall be supplied in soft copies where specified.




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5.11.1 A blank space duly marked measuring 75 mm (W) x 38 mm (H) shall be provided on the body of all Vendor Drawings for marking of Review Codes by GAIL. 5.11.2 Documents for Review and Documents for Records shall be submitted in separate folders with separate - covering letter to facilitate expeditious processing at GAIL. 5.11.3 Before forwarding the drawings and documents, vendor shall ensure that the following information is properly entered in each drawing:

PURCHASE REQUISITION

:

NAME OF EQUIPMENT

:

EQUIPMENT TAG NO.

:

NAME OF PROJECT

:

CLIENT

:

DRAWING/ DOCUMENT TITLE

:

DRAWING/ DOCUMENT NO.

:

REVISION AND DATE

:

5.11.4 The Drawing/ Documents shall be checked, approved and duly signed/ stamped by vendor before -submission. Revision Number shall be changed during submission of the revised Vendor Documents and all revisions shall be highlighted by clouds. Before submitting any sub-vendor drawings for review by GAIL, the vendor shall ensure that these sub-vendor drawings have been reviewed, commented and stamped by the vendor. Direct submission of sub-vendor’s drawings without vendor’s review shall not be entertained. 5.11.5 While resubmitting the Drawings/ Documents, the vendor shall, in a covering letter, specifically confirm whether all the comments have been incorporated, if not, shall furnish reasons with justification. 5.11.6 Multi-sheet Documents other than Drawings shall be submitted in their entirety in the event of a resubmission even if only few sheets are revised. 5.11.7 Vendor shall forward all Drawings/ Documents (transparencies and printed matter), to GAIL (India) Limited, Attention: Vendor Print Control, and the copy of forwarding letter/ transmittal to GAIL Inspection Department as well as to the Client. 5.11.8 Documents under Review Category GAIL (INDIA) LTD NEW DELHI



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Following review codes shall be used for review of Vendor Drawings/ Documents: Review Code 1 No comments. Review Code 2

-

Proceed with manufacture/ fabrication as per commented document. Revised document required.

Review Code 3

-

Document does not conform to basic requirements as marked. Resubmit for review.

R

-

Retained for Records

V

-

Void

5.11.9 Documents under Records Category Documents under this category are meant for GAIL Records. These documents would not be returned to vendor. However, comments, if any, will be communicated to vendor. 5.12

Final Documentation

5.12.1 Final Drawings/ documents consisting of Technical Data Manual/ Mechanical Catalogue is a compilation of “as built” certified, drawings and data, manufacturing and test records, installation, operating and maintenance instructions. For drawings where Purchases approval was required, the final certified drawings shall be included. Final Documents shall be legible photocopies in A4, A3 or A2 size only. The Purchase Requisition shall also form a part of the final documentation, 5.12.2 Final Documentation shall be bound in Hard board folder(s) of size 265 mm x 315 mm (10 and a half inch x 12 and a half inch) and shall not be more than 90 mm thickness, it may be of several volumes and each volume shall have a volume number, index of volumes and index of contents of that particular volume. 5.12.3 Each volume shall contain a Title Block indicating Equipment Tag No., Equipment Name, P.O./ Purchase Requisition No., Name of Project and Name of Client.

6.0

ATTACHMENT FORMAT NO. F1 Rev-0:


WAIVER & DEVIATION REQUEST



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WAIVER/ DEVIATION REQUEST Format No-F1 Rev-0 WAIVER/ DEVIATION PERMIT Project___________________________

Originator Ref. No.______________________

Job No.___________________________

Order/ Contract No._____________________

Equipment Title___________________

Item No._______________________________

Vendor/ Contractor Department_________________________ Note: Vendor/ Contractor to note that any delay in processing of concession/ deviation permit shall be to Vendor’/ Contractor account and shall not be used as a reason for extension in delivery. Requirement as per specification

Description of Waiver/ Deviation sought

Why the Waiver/ Deviation is required? Supporting evidence/ calculations enclosed/ not enclosed Contractual implications if Concession/Deviation is granted  Time Impact More/Less/No change  Cost Impact More/Less/No change Under Present constraints requested Waiver/ Deviation is not optimum for the project and does not involve any security and safety hazard, and shall meet the stipulated performance requirements. Date:


Signature Contractor/ Vendor (with seal)



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Decision on Waiver/ Deviation including decision, on time and cost implications (To be filled by the Inspection engineer at [PROJ/ HO] or Project Manager responsible for conveying the decision to the Vendor/ Contractor, after resolution)

Date:___________

Signature:_____________

Location:_____________


Name: ______________



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WAIVER/ DEVIATION REQUEST Opinion from GAIL Site Supervisor/ inspection engineer. (Specify whether post-facto approval required for regularization)

Date:__________

Signature:______________ Name: ______________ PROJ/ Site Name:______________

Original forward to: ____________________________________________ (Department/ Group) Copy to:_____________________________________________________ (Project Manager)

Date:___________

Signature:_____________ Name:______________ Disposal by Department/ Group

Date:___________

Signature:_______________ Name:_______________ Final decision of Project manager alongwith overall review (Client’s decision required/ not required)

Date:___________

Signature:_______________ Name:_______________ Client’s decision, if required

Date:___________

Signature:_______________ Name:_______________

Format No-F1 Rev-0 GAIL (INDIA) LTD NEW DELHI



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STANDARD CONDITIONS FOR ISSUE AND RECONCILLIATION OF MATRIALS


STANDARD CONDITIONS FOR ISSUE AND RECONCILLIATION OF MATERIALS


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INDEX 1. CONDITIONS FOR ISSUE OF MATERIALS 2. CEMENT 3. REINFORCEMENT BARS/STRUCTURAL STEEL/PLATES 4. PIPING MATERIAL 5. EQUIPMENTS 6. CABLES 7. LINE PIPES 8. OPTICAL FIBRE CABLE 9. OFC JOINTING KITS




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1.0

CONDITIONS FOR ISSUE OF MATERIALS Whenever any material is issued by Owner, following conditions for issue of material in addition to other conditions specified in the contract shall be applicable:

1.6

1.1

Necessary indents will have to be raised by the Contractor as per procedure laid down by the GAIL from time to time, when he requires the above material for incorporation in permanent works.

1.2

Materials will be issued only for permanent works and not for temporary works, enabling works etc. unless specifically approved by the Engineer-in-Charge and the same shall not be taken into account for the purpose of materials reconciliation.

1.3

The Contractor shall bear all other cost including lifting, carting from issue points to work site/Contractor's store, custody and handling etc. and return of Surplus/serviceable scrap materials to Owner's storage points to be designated by the Engineer-in-Charge etc. No separate payment for such expenditure will be made.

1.4

No material shall be allowed to be taken outside the plant without a gate pass.

1.5

The Contractor shall be responsible for proper storage, preservation and watch & ward of the materials.

RETURN OF UNUSED MATERIAL 1.6.1 All unused/scrap materials shall be the property of the Owner and shall be returned in good and acceptable condition size wise, category wise by the Contractor at his own cost to Owner's Store(s). 1.6.2 No credit will be given to the Contractor for return of scrap. The Contractor should quote the rates accordingly. 1.6.3 In case the Contractor fails to return unused/scrap materials, then recovery for such quantity of materials, not returned by the Contractor shall be affected at following penal rates from the Contractor's bills or from any other dues of the Contractor to the Owner. Contractor shall make his own arrangements for weighing the off cuts to be returned to Owner's stores. 1.6.4 Penal Rates for non return of materials :




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Sl.No.

NOTE :

Material

Penal Rates

(a)

Penal rate for non return of accountable scrap

Issue Rate + 25% or Landed Rate + 25% (in case issue rate are not indicated in the contract)

(b)

Penal rates for non return of Unused material/excess scrap

Twice the Issue Rates or Twice the Landed Rates (in case Issue Rates are not indicated in the Contract)

1)

Landed Rate shall be arrived from the latest Purchase Order of respective material received at site by Owner.

2)

In case different penal rates have been indicated in the Contract (based on Project requirement), the same will supersede the above rates.

2.0

CEMENT

2.1

Cement as received from cement Manufacturer/ Stockists will be issued to the contractor. The theoretical weight of cement in each bag for issue purpose will be considered as 50 Kgs. or 20 bags per MT. However, cement bags weighing upto 4% less shall be accepted by the Contractors and charged for as full bag. Any type of cement and in any package as received from Manufacturer/Stockists shall be issued to the Contractor. No claim whatsoever shall be entertained on this account.

2.2

The Contractor will have to submit their design mix for different grades of concrete, keeping in view the requirements stipulated in IS:456 and IS 10262, specifically regarding durability, slump and water cement ratio, and specific gravity of materials brought to site as analysed in the laboratories. The design shall be based upon absolute volume method and theoretical consumption of cement shall be worked out on this basis. For other than concrete items, the coefficients for consumption of cement shall be adopted as per CPWD practice.

2.3

The permissible variation between Cement actually used on the job and theoretical consumption worked out on the basis stipulated in above para 2.2 and as determined by Engineer-in-Charge shall be 3% (Three percent only).




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2.3.1 If the actual consumption is more than 103% of the theoretical consumption, then recovery at the penal rates for the quantity of cement beyond the limit of 103% of theoretical consumption shall be affected from the Contractor's bill(s) or any other dues of the Contractor to the Owner. 2.3.2 If the actual consumption is less than 97% of the theoretical consumption then recovery at the penal rates for the quantity of cement used less than the limit of 97% of the theoretical consumption shall be affected from the Contractor's bill(s) or any other dues of the Contractor to the Owner, provided that the quality of the work has been found acceptable by the Owner. 2.4

Unused quantity of cement shall be returned by the Contractor to the Owner's stores in good condition. In case the Contractor fails to do so, then recovery at penal rates shall be affected from the Contractor's bill(s) or any other dues of the Contractor to the Owner.

2.5

The Contractor shall maintain a good store for storing cement issued to him. The flooring of the storage house, the clearances of cement bags from the side walls/ floor & stack height etc. shall be as instructed by the Engineer-in-Charge.

2.6

The cement store shall be open for inspection and verification by the Engineer-inCharge or his authorised representative at any time when the Engineer-in-Charge feels the need to do so.

2.7

Periodical stock taking as decided by the Engineer-in-Charge shall be done by the Contractor in the presence of Engineer-in-Charge or his authorised representative and a statement of stocks duly verified shall be submitted to Engineer-in-Charge.

2.8

Empty cement bags shall be the property of the Contractor and shall have to be disposed off by him.

2.9

Penal rates for excess/less consumption and/or non return of unused quantity w.r.t. theoretical consumption " allowance as explained in each type of material shall be charged as given in the Contract.

3.0

REINFORCEMENT BARS /STRUCTRUL STEEL/PLATES

3.1

The scrap allowance for the reinforcement bars/structural steel including steel plate issued by the Owner, shall be total 3% (2.5% accountable and 0.5% non-accountable) of the actual consumption as incorporated in the works.

3.2

All reinforcement bars/structural steel/steel plates shall be issued in available length/shapes/sizes and no claims for extra payment on account of issue of nonstandard lengths/shapes/sizes bending etc. shall be entertained. Reinforcement bars and structural steel shall be issued on weighment basis as per normal warehousing GAIL (INDIA) LTD NEW DELHI



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practice. In exceptional circumstances, the reinforcement bars/structural steel, if issued on linear measurement, the IS coefficients for unit weight shall be considered. For the purpose of billing and accounting, only linear measurements will be taken and weight will be calculated as per IS co-efficients in three decimals. The difference in unit weight as per IS and actual as issued, if any, shall be to Contractor's account and Contractor is deemed to have considered the same at the time of bidding. 3.3

Reinforcement bars/structural steel/steel plates shall be issued only for those items where Owner's supply has been specifically mentioned in Schedule of Rates/ Scope of Supply.

3.4

All reinforcement bars/structural steel except M.S. Plates in length of 2 meters and above shall be considered as serviceable materials provided the material is in good and acceptable condition. Reinforcement bars/structural steel section except M.S. Plates in lengths less than 2M shall be treated as scrap.

3.5

For the purpose of accounting of the plates, all plates measuring not less than 1 Sq.m in area and having any dimensions not less than 200mm when returned to Owner's store, will be considered as serviceable material. All other pieces will be treated as wastage/ scrap. The Contractor will prepare a plate cutting diagram in such a way that the minimum scrap is generated. Also the cut plates should be used at a proper place to reduce scrap.

3.6

Above serviceable cut pieces as mentioned in 3.4 & 3.5 above shall be considered as unused material.

3.7

For non return of unused quantity of material shall be charged at penal rates.

3.8

The wastage generated by the Contractor in excess of the allowable percentage shall also be charged at the penal rates.

4.0

PIPING MATERIALS

4.1

All pipes shall be issued in available lengths/shapes and no claims for extra payments on account of issue of non-standard length & shape will be entertained. Pipes shall be issued on linear measurement basis. All valves, flanges, fittings etc. shall be issued on number(s) basis. Contractor shall store the materials in such a way so as to avoid mixing of different types of material and shall maintain complete identification and traceability at all times.

4.2

The scrap allowance for pipes issued by the Owner shall be 3% (2½% accountable + ½% non accountable) of the actual consumption as incorporated in the works.

4.3

All pipes in length of 2 meters and above shall be considered as serviceable material provided the material is in good and acceptable condition and has clear identification GAIL (INDIA) LTD NEW DELHI



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4.4

and traceability (Manufacturer’s name, heat number/batch number and test certificates). Pipes in lengths less than 2 M shall be treated as scrap. For the non account of pipes drawn by the Contractor over and above the actual consumption as determined by the Engineer-in-Charge, plus 3% (2½% accountable + ½% non accountable) thereof to cover the scrap allowance, recovery at penal rate shall be effected from the Contractor's bill(s) or from any other dues of the Contractor to the Owner.

4.5

All unused/scrap pipes, valves, flanges, forged fitting like elbows, reducers tees shall be returned by the Contractor category wise duly cleaned, greased and spec. marked at his own cost to Owner's stores. In case the Contractor fails to do so then recovery for such quantity of pipes not returned by the Contractor at the penal rates shall be effected from the Contractor's bill(s) or from any other dues of the Contractor to the Owner.

5.0

EQUIPMENTS Various equipment/materials intended for the installation will be received by Owner in unpacked, skid mounted, crated, packed or loose condition and will be stored in the warehouses and open yards. In general, materials will be issued to the Contractor in ‘as received’ condition. It will be the Contractor’s responsibility to draw, load and transport all materials from Owner’s designated places of issue to the point of installation and return all packing materials like steel frames, wooden boxes/scrap etc. to Owner’s stores. All materials supplied by the Owner shall be duly protected by the Contractor at his own cost with appropriate preservative like primer, lacquer coating, grease etc. as required.

6.0

CABLES

6.1

Appropriation of cables shall be done as follows:

6.1.1 All the surplus and serviceable cables out of the cables quantity(ies) issued by the Owner to the Contractor shall be returned by the Contractor to the Owner's store in good condition and as directed by the Engineer-in-Charge. 6.1.2 The Contractor shall be allowed a cutting/wastage allowance of 1.5% for power cables and 3% for the control cables. This cutting/wastage allowance shall be computed on the length of cables actually laid, measured and accepted. 6.1.3 All cables being returned to store should carry Aluminium sheet tags indicating the size & type of cable. Cables of less than 15 meters length will be termed as scrap. Cables of lengths 15 M and above shall be termed as serviceable material & shall be returned size wise and category wise to the Owner's store in wooden drums. Cables of serviceable length being returned to stores in drum(s) shall be accepted only after Megger value




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continuity test and physical measurement is carried out by the Contractor to the satisfaction of Engineer-in- Charge. Empty cable drums and major packing material (as decided by Engineer-in-charge) shall be Owner’s property and shall be returned to Owner’s Store/designated place without any additional cost. 6.1.4 While carrying out material appropriation with the Contractor, the above points will be taken into account. All serviceable materials returned by the Contractor (size wise & category wise) shall be deducted from the quantity(ies) issued to the Contractor for the respective sizes. Scrap generated for power cable and control cable shall also be returned to Owner’s store on Lot basis. 6.1.5 Material appropriation shall be done & allowable scrap quantity calculated. The wastage generated by the Contractor in excess of the allowable percentage shall be charged at the penal rates. 7.0

LINE PIPES

7.1

All coated line pipes as per Line Pipe specifications shall be issued on linear measurement basis. The line pipes shall be issued in available lengths and shapes and no claim for extra payment on account of issue of non-standard length and shape will be entertained. Contractor shall store and maintain the line pipes in proper manner to avoid mixing of different classes of pipes. Contractor shall maintain complete identification and traceability at all times. All cut pieces when returned to Owner's storage points after bevelling, shall be considered as serviceable material provided: 7.1.1 Corrosion Protection Coating is intact. 7.1.2 Pipe pieces have pipe specifications, manufacturer’s logo/name and heat number duly authenticated with hard stamp of the authorised inspector as per approved procedure. All cut pieces of pipes measuring less than 2 M will be treated as wastage/scrap.

7.2

For the purpose of accounting of coated line pipes, following allowances shall be permitted: a)

Unaccountable wastage

0.1%

b)

Scrap (All cut pieces of pipes measuring less than 2 Meter)

0.25%

c)

Serviceable materials (All cut pieces of pipe measuring 2 Meter and above)

0.5%

Scrap shall be accounted at actuals as per site assessment subject to maximum limits as stated above. GAIL (INDIA) LTD NEW DELHI



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The percentage allowance shall be accounted on the basis of pipe book chainage for main pipeline 7.2.1 Material appropriation shall be done & allowable scrap quantity calculated. The wastage generated by the Contractor in excess of the allowable percentage shall be charged at the penal rates as given in the contract. 8.0

OPTICAL FIBRE CABLE For the purpose of accounting of optical fibre cable, all cut pieces measuring in length of 40 m and above when returned to Owner's storage points shall be treated as serviceable materials. All cut pieces of cable measuring less than 40 M will be treated as scrap. For the purpose of accounting of OFC (Optical Fibre Cable) following allowances shall be permitted: (i) Unaccountable wastage

0.1%

(ii) Scrap (All cut pieces of cables measuring less than 40 M)

0.25%

(iii) Serviceable material (measuring 40M and above)

0.25%

Material appropriation shall be done & allowable scrap quantity calculated. The wastage generated by the Contractor in excess of the allowable percentage shall be charged at the penal rates as given the contract. 9.0

OFC JOINTING KITS The Contractor shall make a schedule for use of Cable jointing kits and get the same approved from Engineer-in-charge. The quantity mentioned in this schedule will be termed as ‘planned’ usage quantity which shall be issued to the Contractor. However, any jointing based on site requirements as decided by Engineer-in-charge shall be included in planned quantity. Any unplanned jointing required to be carried out by Contractor due to reasons not attributable to GAIL shall be issued from spare quantity, if available with Owner. Such unplanned OFC Jointing Kits shall be charged from the Contract at penal rates.




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SPECIFICATION FOR PIPELINE INFORMATION MANAGEMENT SYSTEM


STANDARD SPECIFICATION FOR PIPELINE INFORMATION MANAGEMENT SYSTEM


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CONTENTS SI.No.

Description

1.0

INTRODUCTION

2.0

DETAILED SCOPE OF PIPELINE INFORMATION MANAGEMENT SYSTEM

3.0

SCOPE OF CONTRACTOR’S RESPONSIBILITY

4.0

EXPERIENCE CRITERIA




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1.0

INTRODUCTION

1.1

The Pipeline Information Management System (PIMS) shall be used for the construction progress on a real time basis and shall be updated daily. The progress needs to be displayed electronically on a web based format s per the scope of work detailed below.

2.0

DETAILED SCOPE OF PIPELINE INFORMATION MANAGEMENT SYSTEM

2.1

Construction management

2.2

The scope of work includes all materials, hardware, software, manpower, services etc. required for customized pipeline data information management solution for the Pipeline Project. The work shall include the following as the minimum: a.

Progress of all construction activities (ROU grading to pre-commissioning) -Pre construction survey, ROU clearing and grading -Pipe history -Trenching -Stringing -Bending -Welding including weld repair details -NDT -Joint Coating -Concrete coating -Lowering (including OFC laying) -All crossings and HDD -TCP/PCP -Back Filling & Tie-in -OFC Jointing -Hydrotest -Pre-commissioning activities -Station works -Restoration

Details of any major repairs on pipe/coating conducted at pipe ware house or at site shall also be indicated. b.

Progress of each construction activity to be tracked separately and all procedures




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& reports shall be linked to the data. c. 2.3

Reporting formats shall be customized for the Pipeline project.

SCANNING, CATALOGUING AND DATA ENTRY Scanning, cataloguing, indexing and retrieval of all project related documents including but not limited to the following:

2.3.1 Pipe information a.

Manufacturing history (including all relevant inspection & test documents) of pipes & plates.

b.

Pipe reconciliation statement with supporting document

2.3.2 Material Acceptance a.

Joint coating material Manufacturer’s Test certificates

b.

Filler Metal/electrode Manufacturer’s Test Certificates and site qualification tests reports

2.3.3 Procedure and Reports Approved procedures, Job Procedures, welding procedures specification & qualification, QAP’s and ITP’s for all pipeline activities including Terminals, SV Stations, IP Stations etc. Scanning and digitisation of Gazette notifications available with the COMPANY. All construction activity reports including crossings. 2.3.4 Cadastral survey documents a. b. c. d. e.

Surveys nos. Ownership area of affected survey no. in ROU Permanent feature along centre of pipeline Village maps, Talukas, Districts etc. Nearest police station with details, hospital, fire station, village panchayat, district details

2.3.5 Land acquisitions details a. b. c. d.

The land owner details including the permanent and alternative address Mutation details Land usage details of the property owner including the crop details The information on the compensation paid to owner.

2.3.6 Clearance and Restoration Clearance and restoration acceptance from statutory authorities such as Forest GAIL (INDIA) LTD NEW DELHI



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Department, Railways, PWD etc. 2.3.7 Hydrotesting and Precommissioning All relevant hydro-testing and pre -commissioning documents/data including (but not limited to) a. b. c. d. e. f. g.

Water filling, Pressurization and Hydrotest reports Dewatering Inspection reports Magnetic Cleaning reports EGP reports Drying Inspection reports Swabbing Inspection reports Inertisation/ Preservation/ Inspection/ commissioning reports

2.4

Management Information System

2.4.1

Pre-construction and post-construction linkage with videography, digital photographs at terminals/stations, crossings (at least 100m on either side of railway, SH, NH and river crossings) and SV stations to route map shall be provided. The following shall be linked to schematic route map to provide information during operation of the pipeline. a. b. c. d. e. f. g. h.

2.5

Pipe book with all details As built Alignment sheets As built drawings for crossings and their photographs Station General Arrangement Drawings(IP,SV, terminals),isometrics, layout, P&ID etc Data Sheet of Equipment such as filters, metering, scraper traps etc. Test certificates – Pipe, pipe coating, equipment, contractor supplied items, etc. All SV/ IP Stations/ turning points/ crossing/ km posts/ warning signs/ scraper stations shall be geo-referenced. All required scanning, cataloguing and data entry as required for successful operation of the system.

Other requirement of pipeline information management system

2.5.1 The software system/package of data information management system shall be able to function on a LAN/ WAN, restricted to 20 users, with adequate provision of security. the software package should be a web based system providing simultaneous access to the CONTRACTOR & GAIL. 2.5.2 The system shall enable quick retrieval and printing of relevant pipeline data/ as built information through a suitable application. 2.5.3 The proposed system shall be equipped with security facilities to prevent datatampering, data theft, sabotage and virus attack. 2.5.4 The CONTRACTOR shall collect, store, classify, handle and protect all input data and GAIL (INDIA) LTD NEW DELHI



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acquired data in good shape till completion and handing over of finished work. CONTRACTOR shall not make any unauthorised alteration, modification and copies of any input data unless explicitly authorised by the COMPANY. All input and acquired data shall be returned to the COMPANY at the completion of work in its original form. 3.0

SCOPE OF CONTRACTOR’S RESPONSIBILITY

3.1

The CONTRACTOR shall be solely responsible for arranging all resources, facilities and logistic supports etc. required to complete the work under this contract. In broad, the CONTRACTOR shall be responsible for providing the following: a.

Establishment of a suitable onsite office with proper storage and security arrangement.

b.

Deployment of requisite manpower for project implementation (onsite and offsite).

c.

Deployment of all requisite hardware (servers, computers, printers, scanners, UPS, etc.) loaded with requisite software to run applications required for the project implementation

d.

All consumables for scanning, printing, storing, and creation of backup data CD’s/DVDs.

e.

Establishment of suitable communication network with a provision of Internet connection for communication, email and uploading and downloading of scanned documents.

f.

The integrity and confidentiality of the COMPANY’s information assets are to be maintained.

The scope of work shall also include any other item/Work required to complete the work in all respects as per specifications and instructions of COMPANY’s representative whether specifically mentioned here in or not, but required to fulfill the intended purpose of this tender document and this specification. 4.0

EXPERIENCE CRITERIA The bidder shall submit information about the Agency’s experience in providing such a solution. A project specific detailed methodology to carry out all the above activities shall be submitted for COMPANY’s review. The subcontractor and his software shall be approved by COMPANY.




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TECHNICAL NOTES FOR PIPES



TECHNICAL NOTES S – 05 – 02 – 001

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TECHNICAL NOTES FOR PURCHASE OF PIPES 1.0

GENERAL

1.1

All pipes and their dimensions, tolerances, chemical composition, physical properties, heat treatment, hydrotest and other testing and marking requirements shall conform to latest codes and standards specified in the material requisition (MR). Deviation(s), if any, shall be clearly highlighted in the offer.

1.2

Testing

1.2.1 Test reports shall be supplied for all mandatory tests as per the applicable material specifications. Test report shall also be furnished for any supplementary tests as specified in the MR and clauses 1.10 & 1.11. 1.2.2 Material test certificates (Physical property, chemical composition & heat treatment report) shall also be furnished for the pipe supplied. 1.2.3 PMI shall be performed as per the scope and procedures as defined in the GAIL standard spec. for PMI at vendor’s work 1.3

Manufacturing Process

1.3.1 Steel made by acid Bessemer process shall not be acceptable. 1.3.2 All longitudinally welded pipes other than IS 3589 should employ only automatic welding. 1.4

Pipe shall be supplied in single or double random length of 4 to 7 and 7 to 14 meters respectively.

1.5

a.

Seamless and ERW pipes shall not have any circumferential seam joint in a random length. However, in case of E.FS.W. pipe, in one random length one welded circumferential seam of same quality as longitudinal weld is permitted. This weld shall be at least 2.5 m from either end. The longitudinal seams of the two portions shall be staggered by 900. Single random length in such cases shall be 5 to7 m.

b.

Unless otherwise mentioned in the respective material code, E.FS.W. pipes < 36” shall not have more than one longitudinal seam joint and E.FS.W pipes ≥ 36” shall not have more than two longitudinal seam joints.

1.6

Pipe with screwed ends shall have NPT external taper pipe threads conforming to ASME/ ANSI B1,20.1 up to 1.5” NB & IS 554 for 2” to 6” NB.

1.7

Pipe with beveled end shall be in accordance with ASME B 16.25. Weld contour shall be as follows:




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Material

Wall Thickness

Weld Contour

Carbon steel (except Low Up to 22 mm Temp. Carbon Steel) > 22 mm

Figure 2 Type A

Alloy Steel, Stainless Steel Up to 10 mm & Low Temp. Carbon > 10 mm & Up to 25 mm Steel

Figure 4

> 25 mm

Figure 3 Type A

Figure 5 Type A Figure 6 Type A

1.8

Galvanised pipes shall be coated with zinc by hot dip process conforming to IS 4736 / ASTM A 153.

1.9

All austenitic stainless steel pipes shall be supplied in solution annealed condition. All types of 321 or 347 stainless steel pipes shall be in a stabilized heat treated condition. Stabilized heat treatment shall be carried out subsequent to the normal solution annealing. Soaking time & holding temp. for stabilizing heat treatment shall be 9000 C & 4 hrs respectively.

1.10

I.G.C Test for Stainless Steel

1.10.1 For all austenitic stainless steel pipes intergranular corrosion test shall have to be conducted as per following: ASTM A 262 Practice “B” with acceptance criteria of “60 mils/year (max.)”. OR ASTM A 262 Practice “E” with acceptance criteria of “No cracks as observed from 20X magnification” & ‘Microscopic structure to be observed from 250X magnification” 1.10.2 When specifically asked for in MR for high temperature application of some grades of austenitic stainless steel (eg. SS 309, 310, 316, 316 H etc.) ASTM A 262 Practice “C” with acceptance criteria of “15 mils/year (max)” shall have to conducted. 1.10.3 For the IGC test as described in 1.10.1 & 1.10.2, two sets of samples shall be drawn from each solution annealing lot; one set corresponding to highest carbon content and the other set corresponding to the highest pipe thickness. When testing is conducted as per Practice “E”, photograph of microscopic structure shall be submitted for record. 1.11

All welded pipes indicated as “CRYO” & “LT” in MR shall be impact tested per requirement and acceptance criteria of ASME B 31.3. The impact test temperature shall be (-)1960 C & (-) 450 C for stainless steel and carbon steel respectively unless specifically mentioned otherwise in the MR.

1.12

Pipes under “NACE” category shall meet the requirements given in MR-01-75




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1.13

Specified heat treatment for carbon steel and alloy steel and solution annealing for stainless steel pipes shall be carried out after weld repairs. Number of weld repairs at the same spot shall be restricted to maximum two by approved repair procedure.

1.14

For black or galvanized pipes to IS 1239, the minimum percentage of elongation shall be 20 %.

1.15

All 1 Cr – 0.5 Moly & 1.25 Cr – 0.5 Moly seamless pipes shall be normalized and tempered.

1.16

For all welded Alloy steel pipes with mandatory requirement of heat treatment and radiography, radiography shall be performed after heat treatment.

2.0

IBR PIPES

2.1

IBR Documentation :

2.1.1 Pipes under purview of IBR shall be accompanied with IBR certificate original in Form IIIA, duly approved and countersigned by IBR authority/ local authority empowered by the Central Boiler of India. Photocopy of the original certificate duly attested by the local boiler inspector where the supplier is located is the minimum requirement for acceptance. 2.1.2 For material 1 ¼ Cr – ½ Mo (ASTM A335 Gr.P11 / A691 Gr. 1 ¼ Cr) & 2 ¼ Cr – 1 Mo (ASTM A 335 Gr. P22 / A 691 Gr. 2 ¼ Cr), Form III-A approved by IBR shall include the tabulation of Et, Sc & Sr values for the entire temperature range given below. Et, Sc & Sr values shall be such that throughout the temperature range Et / 1.5 ≥ Sr / 1.5 ≥ Sc

SA

≥

Where, SA

:

Allowable stress at the working metal temperature

Et

:

Yield Point (0.2 % proof stress at the working metal temperature)

Sc

:

The average stress to produce elongation of 1% (creep) in 100000 hrs at the working metal temperature.

Sr

:

The average stress to produce rupture in 100000 hrs at working metal temperature and in no case more than 1.33 times the lowest stress to produce rupture at this temperature.




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SA (psi) Temp 500 (oF) Material

600

650

700

750

800

850

900

950

1000

1050

1100

A335 Gr. P 11

17200

16700

16200

15600

15200

15000

14500

12800

9300

6300

4200

2800

A691 Gr. 1 ¼ Cr

18900

18300

18000

17600

17300

16800

16300

15000

9900

6300

4200

2800

A 335 Gr. P22 / A691 Gr. 2 ¼ Cr

17900

17900

17900

17900

17900

17800

14500

12800

10800

7800

5100

3200

Note:

2.2

SA values given above are as per ASME B 31.3 – 1999. Values shall be as per the latest edition prevailing.

For carbon steel pipes under IBR the chemical composition shall conform to the following : Carbon (max)

:

0.25 %

Others (S, P, Mn)

:

As prescribed in IBR regulation.

The chemical composition as indicated in this cluse is not applicable for pipes other than IBR services. 3.0

HYDROSTATIC TEST Refer Annexure – I

4.0

MARKING AND DESPATCH

4.1

All pipes shall be marked in accordance with the applicable codes, standards and specifications. In addition the purchase order number, the item code & special condition like “IBR”, “CRYO”, “NACE” etc. shall also be marked.

4.2

Pipes under “IBR”, “CRYO”, “NACE”, “H2 (Hydrogen)” shall be painted in red stripes, light purple brown stripes, canary yellow stripes and sea green stripes respectively longitudinally throughout the length for easy identification. Marking of pipes circumferentially for sizes 1” and below at one meter interval along the length of pipes is also acceptable.

4.3

Paint or ink for marking shall not contain any harmful metal or metallic salts such as zinc, lead or copper which cause corrosive attack on heating.




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4.4

Pipes shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind.

4.5

Pipes shall be protected from rust, corrosion and mechanical damage during transportation, shipment and storage.

4.6

Rust preventive used on machined surfaces to be welded shall be easily removable with a petroleum solvent and the same shall not be harmful to welding.

4.7

Both ends of the pipe shall be protected with the following material: Plain end Bevel end Threaded end

: : :

Plastic Cap Wood, Metal or Plastic Cover Metal or plastic threaded cap

4.8

Pipes may be provided with plastic push fit type end caps/ steel caps without belt wire..

4.9

Plastic caps can also be used as end protector for galvanized pipe ends.




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Page 1 of 3 ANNEXURE – I 3.0

HYDROSTATIC TEST

3.1

All pipes shall be hydrostatically tested.

3.2

The mill test pressure shall be as follows :

3.2.1 Seamless, E.R.W. & Spiral welded : a)

Carbon Steel Material Std.

ASTM A 106 Gr. B API 5L Gr. B, Seamless API 5L, E.R.W. API 5L, Spiral ASTM A333 Gr.3 & 6, Seamless ASTM A333 Gr.3 & 6, E.R.W b)

ASTM A 530 API 5L API 5L API 5L ASTM A 530 ASTM A 530

Seamless Alloy Steel Material Std.

ASTM A335 Gr.. P1, P12, P11, P22, P5, P9 ASTM A268 TP 405, TP 410 c)

Test Pressure Std.

Test Pressure Std. ASTM A 530 ASTM A 530

Seamless Stainless Steel Material Std.

ASTM A312 Gr. TP 304, 304L, 304H, 316, 316L, 316H, 321, 347 d) Seamless Nickel Alloy Material Std. ASTM B161 UNS No. 2200 ASTM B165 UNS No. 4400 ASTM B167 UNS No. 6600 ASTM B407 UNS No. 8800 API 5L Gr. B, Seamless API 5L, E.R.W. API 5L, Spiral ASTM A333 Gr.3 & 6, Seamless ASTM A333 Gr.3 & 6, E.R.W GAIL (INDIA) LTD NEW DELHI

Test Pressure Std. ASTM A 530

Test Pressure Std. ASTM B161 ASTM B165 ASTM B167 ASTM B407 API 5L API 5L API 5L ASTM A 530 ASTM A 530



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Page 2 of 3 e)

Welded Nickel Alloy Material Std.

Test Pressure Std.

ASTM B725 UNS No. 2200, 4400 ASTM B517 UNS No. 6600 ASTM B514 UNS No. 8800

ASTM B725 ASTM B517 ASTM B514

3.2.2 Electric Fusion Welded a)

Carbon Steel & Alloy Steel E.FS.W (16” & above) Material Std.

Test Pressure Std.

API 5L Gr. B ASTM A671 Gr.CC65, 70 (Cl.32) ASTM A672 Gr.C60, 65, 70 (Cl.12, 22) ASTM A671 Gr.CF60, 65, 66, 70 (Cl.32) ASTM A691 Gr.1/2 Cr, 1Cr, 1 ¼ Cr, 2 ¼ Cr, 5Cr, 9Cr (Cl.42) b)

P = 2ST / D S = 90% of SMYS Except for API 5L Gr. B S = 85% of SMYS For API 5L Gr. B T = Nominal Wall Thickness D = O.D of Pipe

Stainless Steel E.FS.W (2” to 6”) :

The hydrostatic test pressure in kg/cm2 for the following materials shall be as given below : Material Gr. 1 :ASTM A 312 TP 304 / 304 H/ 316 / 316H/ 321/ 347 welded. Material Gr. 2 :ASTM A 312 TP 304 L/ 316L welded. Size 2” 3” 4” 6”

Pipe Schedule : 10S Material Material Gr.1 Gr.2 100 80 80 60 80 50 65 35






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Page 3 of 3 c)

Stainless Steel E.FS.W (8” and above) Material Std.

Test Pressure Std.

P = 2ST/D ASTM A358 TP 304L, 304, 304H, 316L, 316, 316H, 321, 347 (Classes 1, 3 S = 85% of SMYS T = Nominal Wall Thickness & 4) D = O.D. of pipe P = 2ST/D ASTM A358 TP 304L, 304, 304H, 316L, 316, 316H, 321, 347 (Classes 2 & S = 72% of SMYS T = Nominal Wall Thickness 5) D = O.D. of pipe 3.2.3 Carbon Steel Pipes to IS Standards: Material Std. IS 1239 IS 3589


Test Pressure Std. IS 1239 IS 3589



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TECHNICAL NOTES FOR PIPELINE VALVES


TECHNICAL NOTES FOR VALVES


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CONTENTS S. NO.

TITLE

1.0

GENERAL

2.0

DOCUMENTATION

3.0


4.0

OPERATION

5.0


6.0

RADIOGRAPHY OF CAST VALVES

7.0

IBR CERTIFICATION

8.0

MARKING

9.0

DESPATCH

10.0

ATTACHMENTS






TECHNICAL NOTES FOR VALVES 1.0

GENERAL

1.1

Vendor shall supply valves in accordance with the valve specification sheets along with auxiliaries, if any, such as gear operator, bypasses, drains etc. wherever specified in the specification sheets, subject notes and other enclosures to the material requisition (MR).

1.2

Vendor shall quote in strict accordance with the valve data / specification sheets, subject technical notes and all other enclosures to the MR. Deviations to the specification / data sheets, subject technical notes and other enclosures of the MR, if any, shall be asked as explained in clause 2.0.

1.3

All codes and standards for manufacture, testing, inspection etc. shall be of latest editions.

2.0

DOCUMENTATION

2.1

Vendor shall submit the following with the offer:

2.1.1

Manufacturer’s complete descriptive and illustrative catalogue / literature.

2.1.2

Detailed dimensioned cross section drawing with parts /material lists, weight etc.for the ball valves, plug valves, butterfly valves, diaphragm valves and valves to manufacturer’s standard.

2.1.3

Drawings for valves with accessories like gear operator, hydraulic / pneumatic operator, motor, extension bonnet, extended stems with stands, bypass etc. giving major salient dimensions.

2.1.4

One copy of the valve specification sheets signed as “Accepted” by the manufacturer with all deviations marked clearly.

2.1.5

If the valve is regretted or has no deviation, the manufacturer shall write clearly on valve specification sheets as “Regret” or “No Deviation”.

2.1.6

For subject notes, if there is any deviation, the same shall be listed clause-wise. Even clauses which are acceptable shall be categorically confirmed as “Accepted”.

2.1.7

On failure to submit documents as specified in clauses 2.1.1 to 2.1.6 above, the offer is likely to be rejected.

2.2

The following documents shall be submitted after placement of the order:

2.2.1

Vendor shall submit for approval drawings mentioned in clauses 2.1.2 & 2.1.3 before start of manufacture. No other drawing shall be submitted for approval.






2.2.2

Test report shall be supplied for all mandatory tests as per the applicable code. Test reports shall also be furnished for any supplementary tests as specified in clauses 3.13, 3.14 & 3.15.

2.2.3

Material test certificates (physical properties, chemical composition & heat treatment report) of the pressure containing parts shall be furnished for the valves supplied. Material test certificates for the other parts shall also be furnished for verification during inspection.

3.0


3.1

Valve shall be designed, manufactured, tested, inspected and marked as per the manufacturing standards; design codes and standards (latest editions) indicated in the respective valve specification sheets. Any conflict between the requisition, enclosures, specification sheets and referred standard codes shall be brought to the notice of the purchaser for clarifications. But generally, specification sheets and enclosures of the requisition including subject notes shall govern. After issue of the Purchase Requisition (PR) no deviation to specification / standards shall be permitted through vendor drawing approval. Approval of drawings shall be valid only for design / constructional features.

3.2

All flanged valves shall have flanges integral (except forged valves) with the valve body. Flange face finish shall be normally specified in the valve specification sheet as serrated finish, 125 AARH etc. The interpretation for range of face finish shall be as follows: Stock Finish Serrated Finish / Smooth Finish/ 125 AARH AARH Extra Smooth Finish / 63 AARH

3.3.

:

1000 µ in AARH max.

:

Serrations with 125 to 250 µ in

:

32 TO 63 µ in AARH

For all weld end valves with bevel end as per ASME B16.25 the contour of bevel shall be as follows:






3.4

For flanged valves with ring joint flanges the hardness shall be as follows Flange Material

Min. Hardness of Groove (BHN)

Carbon Steel

140

1%Cr to 5%Cr

150

Type 304, 316. 321, 347

160

Type 304L, 316L

140

3.5

Following requirements for check valves shall be met over and above the valve spec sheet requirements:

3.5.1

Unless specified otherwise in the data sheet all check valves 3” & above (except in 900#, 1500# & 2500# rating) shall have a drain boss at location “G” (Refer Fig.No.1 of ASME B16.34). A tapped drain hole with plug shall be provided as per ASME B16.34. Threads shall be as per ASME B1.20.1 (Taper) NPT.

3.5.2

Wherever check valve disc assembly is supported from the cover of the check valves the following shall be ascertained. i)

Positive location /positioning of cover must he provided to ensure correct alignment of the valve disc.

ii)

Hinge pin design must permit accurate alignment of the disc and valve seat.

3.5.3

For heavy check valves, provisions shall be available for lifting by way of lugs, eye bolts and other such standard devices.

3.6

If an overlay weld-deposit is used for the body seat ring seating surface, the corrosion resistance of the seat ring base material shall be at least equal to the corrosion resistance of the material of the shell.

3.7

Following valve bypass requirements shall be met:

3.7.1

By-pass requirement for Gate valves is indicated in the respective data sheets. As a rule, the following shall be followed: ANSI 150 Class

:

On sizes 26” and above

ANSI 300 Class

:







ANSI 600 Class

:


ANSI 900 Class

:


ANSI 1500 Class

:


ANSI 2500 Class

:


3.7.2

The by-pass piping arrangement shall be such that clearance between main valve body and by-pass assembly shall be the minimum possible for layout reasons.

3.7.3

By-pass valve shall be a globe valve. The sizes shall be as under: On main valve ≤ 4”

:

1/2” or more

On main valve > 4” but < 10” :

3/4” or more

On main valve > 10”

1” or more

:

The by-pass arrangement shall be as specified in Specification Sheet No.12 - 13. 3.7.4

Vendor shall supply the by-pass valve duly tested and fitted to the main valve. Valves with by-pass shall have the direction of flow marked on the main valve. By- pass attachment to the main valve body shall not be screwed. All fillet welds for bypass installation shall be 100% examined by DP/ MP test.

3.8

Valve body / bonnet shall be forged / cast as specified. Forgings are acceptable in place of casting but not vice-versa.

3.9

Material of construction of yoke shall be minimum equivalent to body / bonnet material.

3.10

Stem shall be forged or machined from forged / rolled bar. No casting is permitted. However, integral stern of cast stainless steel ball valve is acceptable.

3.11

Stelliting / Hardfacing by deposition, shall be minimum 1.6 mm. Renewable seat rings shall he seal welded.

3.12

For Low Temperature & Cryogenic valve requirements, refer Specification. @ Sheet no-17.

3.13

Valves under “NACE” category shall meet the requirements specified in MR unless otherwise specified.

3.14

For all austenitic stainless steel valves Inter Granular Corrosion (IGC) test shall be conducted as per the following: GAIL (INDIA) LTD NEW DELHI





3.15.1 ASTM A262 Practice “B” with acceptance criteria of “60 mils/year (max.)” for all materials forged, rolled, wrought and casting. Qr ASTM A262 Practice “E” with acceptance criteria of “No cracks as observed from 20X magnification” for all materials other than castings. Microscopic structure to be observed from 250X magnification” in addition. 3.15.2 When specifically asked for in MR for high temperature application of some grades- of austenitic stainless steel (e.g. SS 309, 310, 316, 316H etc) ASTM A262 Practice “C” with acceptance criteria of “15 mils/year (max.)” shall be conducted. 3.15.3 For the IGC test as described in Clauses 3.15.1 & 3.15.2, two sets of samples shall be drawn from each solution annealing lot. One set shall correspond to the highest Carbon content and the other to the highest pressure rating. When testing is conducted as per practice “E”, photograph of the microscopic structure shall be submitted for record. 3.16

All types of 321 or 347 stainless steel valves shall be in a stabilised heat treated condition. Stabilising heat treatment shall be carried out subsequent to the normal solution annealing. Soaking temperature and holding time for stabilising heat treatment shall be 900°C and 4 hours respectively.

3.17

Spiral wound bonnet gaskets are to be provided with inner/ outer ring except when encapsulated gaskets type body-bonnet joints are employed. Outer ring may be avoided in case of non-circular spiral wound gasket used in 150# valve provided the outermost layer of spiral touches the bolts ascertaining the centering.

3.18

Ball/ Plug/ Butterfly Valves:

3.18.1 As a prequalification, fire safe test as per API 607 / API 6FA / BS 6755 Part II shall be carried out on soft seated ball, plug & butterfly valves and also on lubricated plug valves. The test shall be witnessed and certified by a third party inspection agency like Lloyds, B.V., DNV etc. The vendor has to submit test certificate for the particular design of the valve offered. 3.18.2 Each valve shall be supplied with a lever / wrench except for gear operated / motor operated valves. 3.18.3 Soft-seated ball, plug & butterfly valves shall he supplied with antistatic devices. 3.18.4 Soft-seated BW / SW end ball valves shall have a 100mm long seamless pipe nipple welded to each end of the valve. Nipples are to be welded prior to assembling Teflon seats I seals. Specifications of the nipples shall be as indicated in the MR. GAIL (INDIA) LTD NEW DELHI





3.18.5 The face-to-face dimensions of all ball valves shall be same as those of gate valves of the corresponding ANSI class (except 10” onwards in Class 150 where the face-to-face dimensions shall be as per API 6D long pattern). 3.18.6 The ball of ball valve shall not protrude outside the end flanges of valve. 3.18.7 Ball valves shall be of floating ball/ trunnion mounted type as per following:

150#

8” & below

Floating ball

10” & above

Trunnion mounted

4” & below

Floating ball

6” & above

Trunnion mounted

300#

600# & above

1.5” & below Floating ball 2” & above

Trunnion mounted

3.18.8 Unless otherwise specified in the data sheets, bore of all reduced bore ball valves shall be limited to one size lower than the nominal bore. 3.19

The MOVs are to be installed in an open area and the actuators shall be suitable for all weather conditions. The testing of complete assemblies of MOVs along with the actuators shall be done by the supplier at his works. Torque details for MOVs shall be furnished by the bidder / supplier in the format attached with the MR.

4.0

OPERATION

4.1

Generally the valves are hand wheel or lever operated. Gear operation shall be provided as under:






For sizes lower than these ranges, hand wheel / lever / wrench shall be provided. For pressure balance plug valves manufacturer’s recommendation shall be acceptable provided the requirements specified in clause 4.6 are met. 4.2

Gear operator shall be as under, with position indicators for open / close positions and with limit stops. (Limit stops are not applicable for gate and globe valves). For Gate / Globe / Diaphragm Valves

Totally enclosed bevel gear in grease case with grease nipples / plugs.

For Ball / Plug / Butterfly Valves

Totally enclosed helical worm or combination of helical worm and spur gear in grease case with grease nipples / plugs.






4.3

Where gear operator is not called for as per Clause 4.1 but vendor recommends a gear operator, he shall highlight such case(s).

4.4

Gear operator shall be so designed as to operate effectively with the differential pressure across the closed valve equal to the cold non-shock pressure rating.

4.5

Ball, plug and butterfly valves, even with wrench or lever operators shall have “Open” position indicators with limit stops.

4.6

Hand wheel diameter shall not exceed 750mm and lever length shall not exceed 500mm on either side. Effort to operate shall not exceed 35 Kg at hand-wheel periphery. However, failing to meet the above requirements, vendor shall offer gear operated valve and quote as per clause 4. 3.

5.0


5.1

Every valve shall be subjected to all the mandatory tests and checks called in the respective codes / data sheet by GAIL inspection or any third party as approved by the owner. For IBR valves refer clause 7.0.

5.2

Every valve, its components and auxiliaries must be subjected to all the mandatory tests and checks called for in the respective codes, data sheets etc. by the manufacturer.

5.3

Though the extent of inspection shall be as under, exact extent with hold points shall he decided by GAIL inspection office and recorded in the form of inspection plan. In case of third party inspection, the inspection plan shall be approved by the purchaser. Forged Valves: 1. 2. 3. 4. 5.

Visual and dimensional inspection. Review of material test certificates. Any mandatory or supplementary test. Hydrostatic test on 10% valves selected on random basis. Strip check is required for 1 % of total ordered quantity of valves (min. 1 No.) against each specification lot.

Cast Steel Valves: 1. 2. 3. 4. 5.

Visual and dimensional inspection. Review of material test certificates. Review of radiographic reports or any other NDT tests wherever applicable as per data sheet. Any mandatory or supplementary test. Hydrostatic test 100% for body, 10% other test.



TECHNICAL NOTES

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6,

Strip check is required for 1 % of total ordered quantity of valves (mm. 1 No.) against each specification lot.

Samples for strip check shall be selected at random and shall generally be in the size in the lot.

highest

5.4

In case of motor operated or actuator operated valves, functional / operational checks as per the requirements of the specifications shall be made on each valve.

5.5

Positive Material Identification (PMI) shall be performed as per the scope and procedures as defined in the ‘Specification for Positive Material Identification (PMI) at Vendor’s Works’

6.0

RADIOGRAPHY OF CAST VALVES

6.1

Valve castings shall undergo radiographic examination as specified below. However, for sizes 24” & below in 150# and 16” & below in 300#, radiography percentage specifically mentioned in individual valve material spec sheet shall govern.

Material

All

Rating

Size Range

Radiography

150#

24” and below

NIL

26” and above*

100%

16” and above

NIL

18” and above

100%

All Sizes

100%

300#

600# & above

*No radiography is required for valves of size ≥ 26” in cooling water service. Radiography specified as random 10% or 20% etc. in the respective valve data sheet implies 10% or 20% etc. of number of valves ordered against each item number with a minimum of one valve against each item. 6.2

Radiography procedure, areas of casting to be radiographed shall be as per ASME B16.34 and acceptance criteria shall be as per ASME B16.34 Annexure-B. However for areas of



TECHNICAL NOTES

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casting to be radiographed for types of valves not covered in ASME B16.34, vendor shall enclose details of areas to be radiographed in line with ASME B16.34. 6.3

For random radiography wherever specified in individual data sheets, the sampling shall be as per size of the quantity ordered for each foundry.

6.4

Radiography wherever specified in the data sheets or as per clause 6.1 shall be done by X- ray / γ-ray to get the required sensitivity.

6.5

Over and above the stipulations laid down in clauses 6.1, 6.2, 6.3 & 6.4, all valve castings when sourced indigenously shall only be procured from foundries approved by GAIL.

7.0

IBR CERTIFICATION

7.1

For valves described “IBR”, valves shall be in accordance with the latest IBR (Indian Boiler Regulation) including the requirements specified in the specification

7.2

For SW/ BW end carbon steel valves under IBR, the chemical composition shall conform to the following: Carbon (Max)

:

0.25%

Others (S, P, Mn)

::

As per IBR regulations

The above composition is not valid for non-IBR valves. 7.3

Valves coming under the purview of “IBR” (Indian Boiler Regulations) shall each be individually accompanied by IBR certificate original in Form Ill-C duly approved by IBR authority / local authority empowered by the Central Boiler Board of India. Photocopy of original certificate duly attested by the local boiler inspector where the supplier is located is the minimum requirement for acceptance.

7.4

All “IBR” valves shall be painted red in body-bonnet/ body-cover joint.

8.0

MARKING

8.1

Valve markings, symbols, abbreviations etc. shall be in accordance with MSS-SP-25 or the standard referred in specification sheet as applicable. Vendor’s name, valve rating, material designation, nominal size, direction of flow (if any) etc. shall be integral on the body.

8.2

Each valve shall have a corrosion resistant tag giving size, valve tag / code no., securely attached to the valve body.



TECHNICAL NOTES

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8.3

Paint or ink for marking shall not contain any harmful metal or metal salts such as zinc, lead or copper which cause corrosive attack on heating.

8.4

Carbon Steel / Alloy Steel valves shall be painted with one coat of inorganic zinc silicate (minimum DFT 65 to 75 microns).

9.0

DISPATCH

9.1

Valve shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind.

9.2

Valves shall be protected from rust, corrosion and any mechanical damage during transportation, shipment and storage.

9.3

Rust preventive on machined surfaces to be welded shall be easily removable with a petroleum solvent or shall not be harmful to welding.

9.4

Each end of valve shall he protected with the following materials Flange Face Bevelled End SW & SCRD.End

: : :

Wood or Plastic Cover Wood or Plastic Cover Plastic Cap

9.5

End protectors of wood/ plastic to be used on flange faces shall be attached by at least three bolts and shall not be smaller than the outside diameter of the flange. However plastic caps for SW & SCRD end valves shall be press fit type.

9.6

End protectors to be used on bevelled end shall be securely and tightly attached.

9.7

For special service valves additional requirement of dispatch shall be prescribed in data sheet.

10.0

ATTACHMENTS (Cut out the irrelevant attachments) Bypass Piping Arrangement Special Requirement for Low temperature and Cryogenic Valves Data Sheet Format for Torque Values of MOVs



TECHNICAL NOTES

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BYPASS PIPING ARRANGEMENT

NOTES: The orientation & location of hand wheel of bevel gear operator & the bypass arrangement shall be strictly as per this sketch. 2. The bypass pipe ends shall be socket/butt welded to the body wall of the main valve. 3. The bypass arrangement shall be properly clamped to & supported by the body of the main valve. 4. Basic design of bypass shall be to MSS-SP-45 & ASME B16.34. 5. Material of bypass pipe & 90° elbows shall be same or equivalent to the body material of the Valve. 6. Vendor shall furnish dimensions L1 to L8. GAIL (INDIA) LTD NEW DELHI


TECHNICAL NOTES

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SPECIAL REQUIREMENTS FOR LOW TEMPERATURE & CRYOGENIC VALVES 1.0

Scope All valves of Low Temperature Carbon Steel (LTCS) and all grades of austenitic SS (CRYO) material are categorized as cryogenic valves. All these valves shall have extended bonnet as per BS 6364 except check valves. Valves shall be suitable for installation in any position (on vertical, horizontal or skewed pipe line). Following qualification criteria shall be met by the valve vendors to quote valves for cryogenic services.

2.0

Qualification Criteria Both cryogenic test (clause 2.1) and reference list (clause 2.2) together, as indicated herein shall be considered for vendor qualification and vendor shall furnish the same, along with his offer. Vendors whose current supply does not cover valves of all sizes, materials and ratings (cryogenic test and reference list) required by MR, should confirm/ furnish the following for consideration of their offer: i).

Evidence of having conducted successfully at least one cryogenic test as per BS 6364. Test certificate and reference list shall be furnished with the offer.

ii).

Vendor shall confirm to conduct cryogenic test per clauses 2.1 & 2.3 for the remaining valves not later than 12 weeks from the date of purchase order.

Offers of vendors who do not comply with above requirements would be rejected. Cryogenic test need not be conducted for every order. Test conducted previously, which need not be against GAIL order, is sufficient. 2.1

Cryogenic Test Vendors to furnish copies of cryogenic test certificate for tests conducted as per details given below: i).

Shall be as per BS: 6364.

ii).

Test temperature, unless specifically called for otherwise in the individual MR, shall be -45°C for LTCS and -196°C for all grades of austenitic stainless steel.

iii).

Tests carried out on a particular size of one type of valve, pressure rating and material shall qualify all sizes equal to and below the test valve size for the same type, pressure



TECHNICAL NOTES

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rating and material. In case of austenitic SS any one grade would qualify for all other grades of austenitic SS. iv). 2.2

Tests shall have to be witnessed and certified by any one of the following third party inspection agencies; M/s Lloyd, By, DNV, TUV or GAIL.

Reference List Vendor shall furnish reference list for valves supplied for cryogenic service indicating the name of client, year of supply. size, material, pressure rating, type of valve and quantity.

2.3

Post Order Testing Procedure i).

ii).

Before conducting post order testing, vendor shall submit the following for approval: a).

Test procedure (as per BS 6364).

b).

Cross-section drawing of the valve with material of construction.

c).

Schematic of test rig (as per BS 6364) with complete details.

Test has to be conducted on largest size of order for each type of valve and for each material and class rating. Vendor shall offer one, two or three valves for selection of test valve by inspector depending upon whether quantity of largest valve in the order is one, two or three and more than three respectively. In the event of failure of the test valve to meet the specification requirements, the vendor shall conduct test on two more valves. If the other two valves which pass test successfully are of lower size, then the qualification will be valid only to sizes up to which test has been conducted successfully.

iii).

In case of non-conductance of cryogenic test(s) within 12 weeks or failure in the test(s) conducted after receipt of order, the owner reserves the right to invoke any of the provisions of the purchase order including cancellation of the purchase order at the risk and cost of vendor,

3.0

Bonnet extension, wherever specified in the valve sheet to BS:6364 shall be for “non cold box application” unless otherwise specified in the MR. Even if not called for in valve sheet, valves indicated as “LT” or ‘CRYO” shall be supplied with bonnet extension.

4.0

Bonnet and Gland extension joints shall be of butt welded construction.



TECHNICAL NOTES

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5.0

Repair welding procedure for austenitic stainless steel valves in “CRYO” service shall have to be qualified for impact test as per ASME B31.3. Minimum acceptable impact energy shall he 20 J or lateral expansion of 0.38 mm at temperature of -1960C

6.0

Wherever impact test of SS studs / nuts is called for in the data sheet, the impact value shall be 27 J at the intended service temperature specified in the data sheets.



TECHNICAL NOTES

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DATASHEET FORMAT DATSHEET FOR TORQUE VALUES OF MOV

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TECHNICAL NOTES FOR BUTT WELDED, SOCKET WELDED AND SCREWED FITTINGS



TECHNICAL NOTES S-05-02-003

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1.0

GENERAL

1.1

Chemical composition, physical properties, tests, dimensions and tolerances, heat treatment and marking shall conform to the applicable latest codes / standards / specifications as specified in the material requisition (MR). Any deviation shall be highlighted on a separate sheet by the vendor in the quotation itself.

1.2

Test reports shall be supplied for all mandatory tests as per the material specifications. Test reports shall also be furnished for any supplementary tests as specified in the MR, Clauses 1.7.8, 1.9, 1.10 & 1.11. Material test certificates (physical properties, chemical composition & heat treatment report) shall also be furnished for fittings supplied.

1.3

All fittings shall be seamless in construction unless otherwise specified. If fittings are specified as welded, the same shall conform to Clause 1.7. Seamless fittings can be supplied in place of welded fitting but with maximum negative tolerance of 0.3mm (max.) on wall thickness. Welded fittings shall not be acceptable in place of seamless fittings.

1.4

Outside diameters and wall thickness (unless otherwise mentioned) of butt welded fittings shall be in accordance with ASME B36.10 and ASME B36.19 as applicable.

1.5

For reducing butt weld fittings having different wall thicknesses at each end, the greater wall thickness of the fitting shall be employed and inside bore at each end shall be matched with the specified inside diameter.

1.6

Bevelled ends for all fittings shall conform to ASME B16.25. Contour of bevel shall be as follows:

Material

Wall Thickness

Carbon Steel (Except Low Upto 22 mm Temp. Carbon Steel) > 22 mm Alloy Steel, Stainless Steel & Low Temp. Carbon Steel

1.7

Wall Contour Figure 2 Type A Figure 3 Type A

Upto 10 mm

Figure 4

> 10 mm & Upto 25 mm

Figure 5 Type A

>25 mm

Figure 6 Type A

Welded Fittings:

1.7. 1 All welded fittings shall be double welded. Inside weld projection shall not exceed 1.6 mm. Welds shall be ground smooth at least 25 mm from the ends. 1.7.2

For fittings made out of welded pipe, the welded pipe shall be double welded type & shall be manufactured with the addition of filler metal.

1.7.3

Welded tees shall not be of fabricated (stub-in) type. GAIL (INDIA) LTD NEW DELHI



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1.7.4

All welded fittings shall be normalised & 100% radiographed by X-ray on all welds made by fitting manufacturers & also on the parent materials.

1.7.5

Welded pipes employed for manufacture of fittings shall be made by automatic welding only.

1.7.6

All welded carbon steel, alloy steel & stainless steel fittings shall have maximum negative tolerance of 0.3 mm.

1.7.7

Specified heat treatment for carbon steel & alloy steel fittings shall be carried out again after weld repairs.

1.7.8

Irrespective of the material code requirement, all welded fittings indicated in the MR as “Cryo”& “LT” shall meet impact test requirements of ASME B31.3. The impact test temperature shall be -196 0C & -45 0C for stainless steel & carbon steel respectively unless specifically mentioned otherwise in the MR.

1.8

Stainless Steel Fittings:

1.8.1

All stainless steel fittings shall be supplied in solution heat treated condition.

1.8.2

Solution annealing for stainless steel fittings shall be carried out again after weld repairs.

1.8.3

For all stainless steel fittings Inter Granular Corrosion (IGC) test shall have to be conducted as per the following: ASTM A 262 Practice “B” with acceptance criteria of “60 mils/year (max.)”. Or ASTM A 262 Practice “E” with acceptance criteria of “no cracks as observed from 20X magnification” & “microscopic structure to be observed from 250X- magnification

1 .8.4 When specifically asked for in MR for high temperature application of some grades of austenitic stainless steel (e.g. SS309, 310,316,316H etc.) ASTM A 262 Practice “C” with acceptance criteria of “15 mils/year” shall have to be conducted. 1.8.5

For the IGC test as described in Clauses 1.8.3 & 1.8.4, two sets of samples shall be drawn from each solution treatment lot, one set corresponding to the highest carbon content and other set to the highest fitting thickness. When testing is conducted as per ASTM A 262 Practice “E”, photograph of microscopic structure shall be submitted for record.

1.9

Fittings under “NACE” category shall meet the requirements of MR-01-75.

1.10

Thickness I schedule lower or higher than specified shall not be accepted.

1.11

The gasket contact surfaces of stub ends shall be flat with face finish specified in the requisition. Interpretation on the specified face finish is as follows:




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Serrated Finish

:

Serrations with 250 to 500 µ in AARH

Smooth Finish/125 AARH

:

Serrations with 125 to 250 µ in AARH

1.12

Seamless stub ends shall not have any welds on the body.

1.13

Galvanized fittings shall be coated with zinc by hot dip process conforming to IS 4736 / ASTM A153.

14

Threaded ends shall have NPT taper threads in accordance with ASME/ANSI B1.20.1 upto 1.5” NB & IS 554 from 2” to 6” NB.

1.15

Unless and otherwise specified in the MR, all socket welded and screwed fittings shall be in accordance with ASME B16.11 to the extent covered in the specification except for unions which shall be in accordance with MSS-SP-83.

1.16

Special fittings like weld-o-let, sock-o-let, sweep-o-let etc. which are not covered in ASME, MSS-SP & GAIL Standards shall be as per manufacturer’s standards. Contours of these fittings shall meet the requirements of ASME B31.3. Manufacturer shall submit drawings / catalogues of these items along with the offer.

1.17

Length of all long half couplings shall be 100 mm unless otherwise specified in the MR.

1.18

All seamless pipes employed for manufacturing of fittings shall be required to have undergone hydro test to ASTM A 530. Welded pipes employed for manufacture of fittings shall be tested as given below:

1.19

Welded Pipe Employed For Manufacture of Welded Fittings.

Test Criteria

ASTM A671 Gr. C65,70 (C1.32) ASTM A672 Gr. C60,65,70 (Cl. 12, 22) ASTM A671 Gr. CF6O,65,70,66 (Cl.32) ASTM A691 Gr. ½Cr, 1Cr, 1’%Cr, 2’ACr, 5Cr, 9Cr (Cl.42)

P = 2ST/ D S = 90% of SMYS. T Nom. Wall Thickness D = O.D. of Pipe.

API5L ASTM A358 TP 304, 304L, 304H, 318, 318L, 318H, 321, 347 (Cl. 1, 3, 4)

P= 2ST/D S = 85% of SMYS. T = Nom. Wall Thickness D = O.D. of Pipe.

ASTM B725

ASTM B725

ASTM B517

ASTM B517

ASTM B514

ASTM B514

The bevel ends of all butt weld fittings shall undergo 100% MP/ DP test.




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1.20

Swage nipples (concentric/eccentric) if specified as pipe materials are acceptable in forging materials (upto 1½”) and wrought fitting materials (above 1½”) also in the corresponding material grades.

1.21

Abbreviations for ends of swages and nipples shall be as follows: PBE TBE TOE TSE TLE

: : : : :

Plain Both Ends Threaded Both Ends Threaded One End Threaded Small End Threaded Large End

2.0

IBR REQUIREMENTS

2.1

IBR Documentation Required:

2.1.1

Fittings under the purview of “IBR” (Indian Boiler Regulations) shall be accompanied with original IBR certificate in Form Ill-C duly approved and countersigned by IBR authority / local authority empowered by Central Boiler Board of India. Photocopy of the original certificate duly attested by the local boiler inspector where the supplier is located is the minimum requirement for acceptance.

2.1.2

For materials 1¼Cr - ½Mo (ASTM A234 Gr.WP11 & ASTM A234 Gr.WP11W) & 2¼Cr 1Mo (ASTM A234 Gr.WP22 & ASTM A234 Gr.WP22W), where fittings are manufactured from pipe, Form III-C approved by IBR shall include the tabulation of Et, Sc, & Sr values for the entire temperature range given below. Et, Sc, & Sr values shall be such that throughout the temperature range

SA: Allowable stress at the working metal temperature. Et: Yield point (0.2% proof stress at the working metal temperature) Sc: The average stress to produce elongation of 1% (creep) in 100000 hrs at the working metal temperature. Sr : The average stress to produce rupture in 100000 hrs at the working metal temperature and in no case more than 1.33 times the lowest stress to produce rupture at this temperature.




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Note: SA values given above are from ASME B31.3-1996. Values shall be as per the latest edition prevailing. 2.2

For carbon steel fittings described “IBR” chemical composition shall conform to the following: Carbon (max)

:

0.25 %

Others (S, P, Mn)

:

As prescribed in IBR regulations

The above composition is not valid for Non-IBR fittings. 3.0


3.1

Each fitting shall be legibly and conspicuously stamped in accordance with the requirements of applicable standards along with special condition like “IBR”, “Cryo”, “NACE” etc.

3.2

Steel die marking with round bottom punch may be permitted on body of butt weld CS & lower alloy steel fittings, but for SS & higher alloy steel fittings, the same should be marked by electro-etching only.

3.3

Paint or ink for marking shall not contain any harmful metals or metal salts such as Zinc, Lead or Copper which causes corrosive attack on heating.

3.4

Fittings shall be dry, clean and free of moisture, dirt and loose foreign materials of any kind.

3.5

Fittings shall be protected from rust, corrosion and mechanical damage during transportation, shipment and storage.

3.6

Rust preventive used on machined surfaces to be welded shall be easily removable with a petroleum solvent and the same shall not be harmful to welding.

3.7

Fittings under “IBR”, “Cryo”, “NACE” shall be painted in red, light purple and canary yellow stripes respectively for easy identification. Width of the stripe shall be 25 mm.

3.8

Each end of fitting shall be protected with a wood, metal or plastic cover.




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3.9

Each size of fitting shall be supplied in separate packaging marked with the purchase order number, item code number, material specification, size and schedule / thickness/ rating.




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TECHNICAL NOTES FOR FLANGES, SPECTACLE BLINDS AND DRIP RINGS




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1.0

GENERAL

1.1

All items, their dimensions, tolerances, chemical composition, physical properties, heat treatment and testing etc. shall conform to the latest codes and standards specified in the requisition. Deviations, if any, shall be clearly highlighted on a separate sheet by the vendor in the quotation itself.

1.2

Testing

1.2.1 Test reports shall be supplied for all mandatory tests as per the relevant material specifications. Test reports shall also be furnished for any supplementary tests as specified in the requisition & Clauses 1.11, 1.12 & 1.15. 1.2.2 Material test certificates (physical property, chemical composition & heat treatment report) shall also be furnished for the flanges supplied. 1.2.3 Positive Material Identification (PMI) shall be performed as per the scope and procedures as defined in the ‘Specification for Positive Material Identification (PMI) at Vendor’s Works. 1.3

Ends of weld neck flanges shall be bevelled to suit the schedule / thickness of matching pipe, as specified in the requisition.

1.4

Bevel end details for welding neck flanges shall be as per ASME B 16.25. Contour of bevel end shall be as follows:

1.5

Bore of socket weld flanges & reducing blind flanges shall suit the outside diameter and schedule/ thickness of matching pipe.

1.6

Bore of slip on flanges shall suit the outside diameter of matching pipe.

1.7

Flange face finish shall be normally specified in the requisition as serrated finish, 125 AARH etc. The interpretation for range of face finish shall be as follows: Stock Finish Serrated Finish/125 AARH 63 AARH


: : :

1000 μ in AARH max. Serrations with 125 to 250 μ in AARH 32 TO 63 μ in AARH



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1.8

Galvanised flanges shall be coated with zinc by hot dip process conforming to IS 4736/ ASTM A153.

1.9

Ends of screwed flanges unless otherwise specified shall have taper threads as per ASME/ ANSI B1.20.1 (upto 1.5” NB) and IS 554 (for 2” to 6” NB).

1.10 For ring joint flanges, blinds and spacers the hardness shall be as follows:

1.11 For ring joint flanges, blinds and spacers, the hardness shall be recorded in the test report.

1.12 Flanges, blinds, drip rings under “NACE” category shall meet the requirements given in MR01-75 unless otherwise specified. 1.13 All austenitic stainless steel flanges shall be supplied in solution annealed condition. 1.14

I.G.C. Test for Stainless Steels:

1.14.1 For all austenitic stainless steel flanges, blinds, drip rings & Fig.8 flanges inter-granular corrosion test shall have to be conducted as per following: ASTM A262 Practice ‘B’ with acceptance criteria of “60 mils/year (max.)”. OR ASTM A262 Practice ‘E’ with acceptance criteria of “No cracks as observed from 20X magnification” & “Microscopic structure to be observed from 250X magnification” 1.14.2 When specifically asked for in requisition for high temperature application of some grades of austenitic stainless steel (like SS309, 310, 316, 316H etc.) ASTM A262 Practice ‘C’ with acceptance criteria of “15 mils/year” shall have to be conducted. When testing is conducted as per Practice ‘E’, photograph of microscopic structure shall be submitted for record. 1.14.3 For the IGC test as described in 1.15.1 & 1.15.2 two sets of samples shall be drawn from each solution treatment lot; one set corresponding to highest carbon content and the other corresponding to the highest rating / thickness. 1.15

All types of 321 or 347 stainless steel flanges shall be in a stabilised heat treated condition. Stabilising heat treatment shall be carried out subsequent to the normal solution annealing. Soaking temperature and holding time for stabilising heat treatment shall be 900°C and 4 hours respectively. GAIL (INDIA) LTD NEW DELHI



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1.16

AWWA C207 flanges shall be hub type.

2.0

IBR REQUIREMENTS

2.1

IBR Documentation:

2.1.1 Flanges coming under the purview of IBR (Indian Boiler Regulations) shall be accompanied with 1BR Certificate original in Form III C duly approved and countersigned by IBR authority / local authority empowered by Central Boiler Board of India. Photocopy of original certificate duly attested by the local boiler inspector where the supplier is located is the minimum requirement for acceptance. 2.2

For carbon steel flanges described as “IBR”, chemical composition shall conform to the following: Carbon (max.)

:

0.25%

Others (S, P, Mn)

:

As prescribed in IBR Regulation

The chemical composition as indicated in this clause is not applicable for flanges other than IBR. 3.0

SPECIAL REQUIREMENTS FOR HYDROGEN SERVICE

3.1

Method of Manufacture

3.1.1 All carbon steel flanges having wall thickness 9.53 mm and above shall be normalised. The normalising heat treatment shall be a separate heat treatment operation and not a part of the hot forming operation. 3.1.2 All alloy steel (Cr-Mo) flanges shall be normalised and tempered. The normalising and tempering shall be a separate heat treatment operation and not a part of the hot forming operation. 3.2

Impact Test

3.2.1 For all carbon steels and alloy steels with wall thickness over 19 mm, Charpy-V Notch impact testing shall be carried out in accordance with paragraph UG-84 of ASME Section VIII, Div-I per heat of material and per heat treating batch. Impact test specimen shall be in accordance with ASTM A370. Impact energies at 0 °C shall average greater than 27J (20 ftlb) per set of 3 specimens, with a minimum of 19J (15 ft-lb). 4.0


4.1

All items shall be legibly and conspicuously stamped in accordance with the requirements of applicable ASME, API and MSS Standards. In addition, GAIL item code, purchase order number & special conditions like “IBR”, “CRYO”, “NACE” ‘H2” etc. shall also be stamped.




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4.2

All items coming under the purview of “IBR”, “CRYO” , “NACE” & “H2’(hydrogen) shall be painted in red stripes, light purple stripes, canary yellow stripes & sea green stripes (25 mm width) respectively for easy identification.

4.3

Paint or ink for marking shall not contain any harmful metal or metal salts such as zinc, lead or copper which cause corrosive attack on heating.

4.4

All items shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind.

4.5

All items shall be protected from rust, corrosion and mechanical damage during transportation, shipment and storage.

4.6

Rust preventive on machined surfaces to be welded shall be easily removable with a petroleum solvent and the same shall not be harmful to welding.

4.7

Each end of flange shall he protected with the following materials: Flange face Bevelled end Threaded end Socket welding end

: : : :

Wood, metal or plastic cover Wood, metal or plastic cover Plastic plug Plastic cover or plug

4.8

Each size of flanges, blinds, etc. shall be supplied in separate packagings marked with the purchase order number, item code number, material specification, size and rating.

5.0

ATTACHMENTS Specification for Positive Material Identification (PMI) at Vendor’s Works – S-14-02-001




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TECHNICAL NOTES FOR BOLTS AND NUTS (PIPING)


TECHNICAL NOTES FOR BOLTS AND NUTS


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1.

The process of manufacture, heat treatment, chemical and mechanical requirements and marking for all stud bolts, m/c bolts, jack screws and nuts shall be in accordance with the codes/standards and specifications given in the requisition. Deviation (s), if any, shall be clearly highlighted in the quotation. The applicable identification symbol in accordance with the material specification shall be stamped on each bolt and nut.

2.

a.

Test reports shall be supplied for all mandatory tests as per the relevant material specifications.

b.

Material test certificate shall also be furnished. (Heat Analysis, Product Analysis and Mechanical Requirement)

3.

All bolting shall be as per ANSI B 18.2.1 for studs, M/c bolts and jack screws and ANSI B 18.2.2 for nuts.

4.

Threads shall be unified (UNC for 1” dia and 8UN for > 1” dia) as per ANSI B. 1.12 with class 2A fit for studs, M/c bolts and jack screws and class 2B fit for nuts.

5.

Stud bolts shall be threaded full length with two heavy hexagonal nuts. Length tolerance shall be in accordance with the requirement of table F2 of Annexure-F of ANSI B 16.5.

6.

The nuts shall be double chamfered, semi-finished, heavy hexagonal type and shall be made by the hot forged process and stamped as per respective material specification.

7.

Heads of jack screws and m/c bolts shall be heavy hexagonal type. Jack screw end shall be rounded.

8.

Each size of studs & m/c bolts with nuts and jack screws shall be supplied in separate containers marked with size and material specifications. ‘CRYO’ shall be marked additionally in case ‘CRYO’ is specified in the requisition.

9.

All items shall be inspected and approved (stagewise) by GAIL inspector or any other agency authorised by GAIL.

10.

The heat treatment for stud bolts & nuts shall be as per code unless mentioned otherwise.

11.

All austenitic stainless steel bolts, nuts, screws shall be supplied in solution annealed condition unless specified otherwise in the material specification.

12.

Any additional requirements specified in the requisition shall be fully complied with.

13.

Stud bolts, m/c bolts, nuts & jack screws shall be impact tested wherever specified in the material specification and also where the material specification is indicated as “CRYO”. For S.S. nuts and bolts minimum impact energy absorption shall be 27 Joules and test temperature shall be -196.0C unless mentioned otherwise in code. For other materials impact energy and test shall be as per respective code. GAIL (INDIA) LTD NEW DELHI



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14.

Bolts/nuts of material of construction B7M/ 2HM shall be 100% Hardness tested as per supplementary requirement S3 of ASTM A193.

15.

When specified as galvanised, the studs, m/c bolts and nuts shall be hot dip zinc coated in accordance with requirements of class C of ASTM A153.




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TECHNICAL NOTES FOR GASKETS




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1.0

GENERAL

1.1

All gaskets shall conform to the codes/standards and specifications given in the requisition. Vendor shall strictly comply with MR/PR stipulations and no deviations shall be permitted

1.2 Process of manufacture, dimensions and tolerances not specified in requisition shall be in accordance with the requirements of the manufacturer’s standards.

1.3 Testing 1.3.1

Test reports shall be supplied for all mandatory tests for gaskets as per the standards specified in the requisition.

1.3.2

Chemical composition and hardness of RTJ gaskets shall also be furnished in the form of test reports on samples.

1.3.3

For Spiral wound material following shall be furnished: a.

Manufaturer’s test certificate for filler material and spiral material as per the relevant material specifications.

b.

Manufacturer’s test certificate for raw materials and tests for compressibility/ seal-ability & recovery as per the relevant material specifications.

1.3.4

PMI shall be performed as per the scope and procedures defined in the Specification for PMI at Vendor’s works for ring type joint gaskets.

1.3.5

Refer ‘Inspection and Test Plan for Gaskets.

1.4

Full face gaskets shall have bolt holes punched out.

1.5

Filler material for spiral wound gaskets shall not have any color or dye.

1.6

All spiral wound gaskets shall be supplied with outer ring. Material of outer ring shall be CS unless otherwise specified in the MR.

1.7

For spiral wound gaskets, material of Inner Compression ring shall be same as spiral strip material. In addition to the requirements as per code and as specified in the MR, inner ring shall be provided for the following:




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1.8

a.

Sizes 26” and above

b.

Class 900 and above

Hardness of metallic RTJ gaskets shall not exceed the values specified below unless otherwise specified in MR: Ring Gasket Material

Maximum Hardness (BHN)

Soft Iron

90

Carbon Steel

120

5 Cr., ½ Mo

130

Type 304, 316, 321, 347

140

Type 304L, 316L

120

1.9

Face finish of metallic RTJ gaskets shall be 32 to 63 AARH.

1.10

Gaskets of different types and sizes shall be placed in separate shipping containers and each container clearly marked with the size, rating, material specification and item code.

1.11 All items shall be inspected and approved by GAIL Inspector or any other agency authorized by GAIL. 1.12 Any additional requirements specified with.

in the requisition, shall be fully complied

1.13 Non-metallic ring gaskets as per ASME B16.21 shall match flanges to ASME B 16.5 up to 24” (except 22” size) and to ASME B 16.47 B above 24” unless specified otherwise. For 22” size, the matching flange standard shall be MSS-SP44 unless specified otherwise. 1.14 Spiral wound gasket as per ASME B 16.20 shall match flanges to ASME B 16.5 up to 24” (except 22” size) and to ASME B 16.47 B above 24” unless specifically mentioned otherwise. For 22” size, the matching flange standard shall be MSS-SP44 unless specified otherwise. 1.15 Abbreviation (I) (O) CAF GRAFIL

: : : :


Inner Ring Outer Ring Compressed Asbestos Fibre Grafoil Filler



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STANDARD SPECIFICATION FOR FABRICATION AND ERECTION OF PIPING



SPECIFICATION

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Abbreviations:

PMI

:

Positive Material Identification

NDT

:


P&ID :

Process and Instrumentation Diagram

A.S.

:

Alloy Steel

C.S.

:

Carbon Steel

C.I.

:

Cast Iron

S.S.

:

Stainless Steel

LTCS :

Low Temperature Carbon Steel

NACE :

National Association of Corrosion Engineers



SPECIFICATION

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CONTENTS Sl. No.

Description

1.

SCOPE

2.

SCOPE OF WORK OF CONTRACTOR

3.

BASIS OF WORK

4.

FABRICATION

5.

ERECTION



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1.0

SCOPE This specification covers general requirements of fabrication and erection of above ground and trench piping systems at site. The specification covers the scope of work of contractor, basis of work to be carried out by contractor and standards, specifications and normal practice to be followed during fabrication and erection by the contractor.

2.0

SCOPE OF WORK OF CONTRACTOR Generally the scope of work of contractor shall include the following:

2.1

Transportation of required piping materials (as described in Cl.2.l.1), pipe support (material as described in Cl. 2.3) and all other necessary piping materials from Owner’s storage point or contractor’s storage point (in case of contractor’s scope of supply) to work site/ shop including raising store requisitions for issue of materials in the prescribed format & maintaining an account of the materials received from Owner’s stores.

2.1.1 Piping materials include the following but not limited to the same.

2.2

a.

Pipes (All sizes and schedule)

b.

Flanges (All sizes, types & Pressure ratings).

c.

Fittings (All sizes, types and schedule)

d.

Valves (All sizes, types and Ratings)

e.

Gaskets (All sizes, types & Ratings)

f.

Bolts, Nuts or M/C Bolts (All types)

g.

Expansion Joint/Bellows (All types)

h.

Specialty items like online filters, ejectors, sample coolers, steam traps, strainers, air traps etc.

i.

Online instruments like control valve, orifice flange, rotameter, safety valves etc.

Shop & field fabrication and erection of piping in accordance with documents listed under C1.3.0 i.e. ‘BASIS OF WORK’ including erection of all piping materials enumerated above.



SPECIFICATION

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2.3

Fabrication and erection of pipe supports like shoe, saddle, guide, stops, anchors, clips, cradles, hangers, turn buckles, supporting fixtures, bracket cantilevers, struts, teeposts including erection of spring supports and sway braces.

2.4 2.4.1 Fabrication of piping specials like special radius bends, reducers, miters etc. 2.4.2 Fabrication of plain and threaded nipples from pipes as required during erection. 2.4.3 Fabrication of swage nipples as and when required. 2.4.4 Fabrication of odd angle elbow like 60°, 30° or any other angle from 90/45° elbows as and when required. 2.4.5 Fabrication of flange, reducing flange, blind flange, spectacle blinds as and when required. 2.4.6 Fabrication of stub-in connection with or without reinforcement. 2.4.7 Grinding of edges of pipes, fittings, flanges etc. to match mating edges of uneven/ different thickness wherever required. 2.5

Modifications like providing additional cleats, extension of stem of valve, locking arrangement of valves etc. as and when required.

2.6

Preparation of Isometrics, bill of materials, supporting details of all NON-IBR lines upto 2- ½” within the unit battery limit and get subsequent approval from Engineer-inCharge as and when called for.

2.7

Obtaining approval for drawings prepared by contractor from statutory authority, if required.

2.8

Spun concrete lining of the inside of pipes 3” NB & above including fittings and flanges as required in accordance with specification.

2.9

Rubber lining inside pipes, fittings, flanges as and when required, in accordance with specification.

2.10 Radiography, stress relieving, dye penetration, magnetic particle test etc. as required in specification. 2.11 Performing PMI using alloy analysers as per ‘Standard Specification for Positive Material Identification at Construction Sites. 2.12 Casting of concrete pedestals and fabrication & erection of small structures for pipe supports including supply of necessary materials. GAIL (INDIA) LTD NEW DELHI


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2.13 Providing insert plates from concrete structures and repair of platform gratings around pipe openings. 2.14 Making material reconciliation statement and return of Owner’s supply left over materials to Owner’s storage. 2.15 Flushing and testing of all piping systems as per standard specification for inspection, flushing and testing of piping systems. 2.16 Pickling (as and when applicable) as per standard specification for chemical cleaning of C.S. suction piping of compressors. 2.17 Submission of job execution procedure as per standard specification for review and approval of Engineer-in-charge covering all above activities. 3.0

BASIS FOR WORK

3.1

The complete piping work shall be carried out in accordance with the following

3.1.1 “Approved for Construction” drawings and sketches issued by GAIL to the Contractor Plans and/ or Isometrics. 3.1.2 “Approved for Construction” drawings and sketches issued by Turn-key bidders to the Contractor - Plans and/or Isometrics. 3.1.3 Approved Process licensors standards and specifications. 3.1.4 Drawings, sketches and documents prepared by contractor duly approved by Engineer-in- Charge (such as isometrics of small bore piping and offsite piping etc.) 3.1.5 Approved construction job procedures prepared by Contractor as stipulated in 2.16 3.1.6 GAIL specifications/documents as below: a.

Process and Instrument Diagram.

b.

Piping Materials Specification

c.

Piping support standards.

d.

Line list

e.

Piping support indices (only in offsite), if supports are not shown in plan.

f.

Standard specification of Non-destructive Requirement of Piping

g.

Welding specification charts for piping classes



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h.

Standard Specification for Pressure Testing of Erected Piping System

i.

Welding specification for fabrication of piping

j.

Any other GAIL or OTHER specifications attached with Piping Material Specification or special condition of contract (such as standard for cement lining of pipe, standard of jacketed piping, standard for steam tracing, Dimensional Tolerances etc.)

k.

Procedure for storage, preservation and positive identification of materials at Contractors works / stores.

3.1.7 Following codes, standards and regulations a.

ASME B 31.3

:

Process Piping

b.

ASME Sec. VIII

:

Code for unfired pressure vessel.

c.

IBR Regulations

d.

IS: 823

:

Code for procedure for Manual Metal Arc welding of Mild Steel (for structural steel).

e.

NACE Std.

:

Code for Sour Services material requirements MR-0 1-75

Note: All codes referred shall be latest edition, at the time of award of contract. 3.2

Deviations Where a deviation from the “Basis of Work and approved job procedure described above is required or where the basis of work does not cover a particular situation, the matter shall be brought to the notice of Engineer - in - Charge and the work carried out only after obtaining

4.0

FABRICATION

4.1

Piping Material Pipe, pipe fittings, flanges, valves, gaskets, studs bolts etc. used in a given piping system shall be strictly as per the “Piping Material Specification” for the “Pipe Class” specified for that system. To ensure the above requirement, all piping material supplied by the Owner / Contractor shall have proper identification marks as per relevant standards / GAIL specifications/ Licensors specification. Contractor shall provide identification marks on left over pipe lengths wherever marked up pipe lengths GAIL (INDIA) LTD NEW DELHI


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have been fabricated I erected. Material traceability is to be maintained for AS., SS., NACE, LTCS, material for Hydrogen service and other exotic materials by way of transferring heat number, etc. (hard punching) as per approved procedure. This shall be in addition to colour coding for all piping materials to avoid mix-up. For the purpose of common understanding the construction job procedure, to be submitted by the contractor, shall include proposal for - Maximizing prefabrication, inspection and testing at fabrication shop with minimum field joints. - Positive material identification, handling, storage & preservation. 4.2

Dimensional Tolerances Dimensional tolerances for piping fabrication shall be as per GAIL Standard. The Contractor shall be responsible for working to the dimensions shown on the drawings. However, the Contractor shall bear in mind that there may be variations between the dimensions shown in the drawing and those actually existing at site due to minor variations in the location of equipments, inserts, structures etc. To take care of these variations “Field Welds” shall be provided during piping fabrication. An extra pipe length of 100 mm over and above the dimensions indicated in the drawing may be left on one side of the pipe at each of the field welds. During erection, the pipe end with extra length at each field weld shall be cut to obtain the actual dimension occurring at site. Isometrics, if supplied may have the field welds marked on them. However, it is the responsibility of the Contractor to provide adequate number of field welds. In any case no extra claims will be entertained from the Contractor on this account. Wherever errors I omissions occur in drawings and Bills of Materials it shall be the Contractor’s responsibility to notify the Engineer-in-Charge prior to fabrication or erection.

4.3

IBR Piping

4.3.1 Contractor shall be supplied generally with all drawings for steam piping falling under the purview of Indian Boiler Regulations duly approved by Boiler Inspectorate. The Contractor shall carry out the fabrications, erection and testing of this piping as per requirements of Indian Boiler Regulations and to the entire satisfaction of the local Boiler Inspector. The Contractor shall also get the approval of IBR inspector for all fabrication and testing done by him at his own cost. All certificates of approval shall be in proper JBR forms. 4.3.2 Approval of boiler inspector on the drawings prepared by the contractor shall be obtained by the contractor at his own cost. 4.4

Pipe Joints The piping class of each line specifies the type of pipe joints to be adopted. In general, joining of lines 2” and above in process and utility piping shall be accomplished by butt-welds. Joining of lines 1-1/2” and below shall be by socket GAIL (INDIA) LTD NEW DELHI


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welding/butt welding/threaded joints as specified in “Piping Material Specifications”. However, in piping 1-1/2” and below where socket welding/ threaded joints are specified butt - welds may be used with the approval of Engineer-in-Charge for pipe to pipe joining in long runs of piping. This is only applicable for non-galvanized piping without lining. Flange joints shall be used at connections to Vessels, Equipment’s, Valves and where required for ease of erection and maintenance as indicated in drawings. 4.5

Butt Welded and Socket Welded Piping End preparation, alignment and fit-up of pipe pieces to be welded, welding, preheating, post-heating and heat treatment shall be as described in the welding specification and NDT specification.

4.6

Screwed Piping In general, Galvanized piping shall have threads as per IS:554 or ANSI B2.l NPT as required to match threads on fittings, valves etc. All other piping shall have threads as per ANSI B2.l, tapered unless specified otherwise. Threads shall be clean cut, without any burrs or stripping and the ends shall be reamed. Threading of pipes shall be done preferably after bending, forging or heat treating operations. If this is not possible, threads shall be gauge checked and chased after welding heat treatment etc. During assembly of threaded joints, all threads of pipes and fittings shall be thoroughly cleaned of cuttings, dirt, oil or any other foreign matter. The male threads shall be coated with thread sealant and the joint tightened sufficiently for the threads to seize and give a leak proof joint. Threaded joints to be seal-welded shall be cleaned of all foreign matter, including sealant and made up to full thread engagement before seal welding.

4.7

Flange Connections All flange facings shall be true and perpendicular to the axis of pipe to which they are attached. Flanged bolt holes shall straddle the normal centerlines unless different orientation is shown in the drawing. Wherever a spectacle blind is to be provided, drilling and tapping for the jack screws in the flange, shall be done before welding it to the pipe.

4.8

Branch Connections Branch connections shall be as indicated in the piping material specifications. For end preparation, alignment, spacing, fit-up and welding of branch connections refer welding specifications. Templates shall be used wherever required to ensure accurate cutting and proper fit-up. For all branch connections accomplished either by pipe to pipe connections or by using forged tees the rates quoted for piping shall be inclusive of this work. GAIL (INDIA) LTD NEW DELHI


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Reinforcement pads shall be provided wherever indicated in drawings/ specifications etc. 4.9

Bending Bending shall be as per ASME B31.3 except that corrugated or creased bends shall not be used. Cold bends for lines 1-1/2” and below, with a bend radius of 5 times the nominal diameter shall be used as required in place of elbows wherever allowed by piping specifications. Bending of pipes 2” and above may be required in some cases like that for headers around heaters, reactors etc. The completed bend shall have a smooth surface, free from cracks, buckles, wrinkles, bulges, flat spots and other serious defects. They shall be true to dimensions. The flattening of a bend, as measured by the difference between the maximum and minimum diameters at any cross-section, shall not exceed 8% and 3% of the nominal outside diameter, for internal and external pressure respectively.

4.10 Forging and forming Forging and forming of small bore fittings, like reducing nipples for piping 1-1/2” and below, shall be as per ASME B 31.3. 4.11 Mitre Bends and Fabricated Reducers The specific application of welded mitre bends and fabricated reducers shall be governed by the Piping Material Specifications. Generally all 90 deg. mitres shall be 4piece 3-weld type and 45 deg. mitres shall be 3-piece 2-weld type as per GAIL Standard unless otherwise specified. Reducers shall be fabricated as per directions of Engineer-in-Charge. The radiographic requirements shall be as per Material Specifications for process and utility systems and NDT Specification for steam piping under IBR, radiographic requirements of IBR shall be complied with. 4.12 Cutting and Trimming of Standard Fittings & Pipes Components like pipes, elbows, couplings, half-couplings etc. shall be cut / trimmed / edge prepared wherever required to meet fabrication and erection requirements, as per drawings and instructions of Engineer-in-Charge. Nipples as required shall be prepared from straight length piping. 4.13 Galvanized Piping Galvanized carbon steel piping shall be completely cold worked, so as not to damage galvanized surfaces. This piping involves only threaded joints and additional external threading on pipes may be required to be done as per requirement.



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4.14 Jacketed Piping The Jacketing shall be done in accordance with GAIL Specification or Licensors specification as suggested in material specification or special condition of contract. Pre-assembly of jacketed elements to the maximum extent possible shall be accomplished at shop by Contractor. Position of jump over and nozzles on the jacket pipes, fittings etc. shall be marked according to pipe disposition and those shall be prefabricated to avoid damaging of inner pipe and obstruction of jacket space. However, valves, flow glasses, in line instruments or even fittings shall be supplied as jacketed. 4.15 Shop Fabrication / Pre-Fabrication The purpose of shop fabrication or pre-fabricationm is to minimise work during erection to the extent possible. Piping spool, after fabrication, shall be stacked with proper identification marks, so as facilitate their withdrawal at any time during erection. During this period all flange (gasket contact faces) and threads shall be adequately fabricated by coating with a removable rust preventive. Care shall also be taken to avoid any physical damage to flange faces and threads. 4.16 Miscellaneous 4.16.1 Contractor shall fabricate miscellaneous elements like flash pot, seal pot, sample cooler, supporting elements like turn buckles, extension of spindles and interlocking arrangement of valves, operating platforms as required by Engineer-in-Charge. 4.16.2 Spun Concrete Lining The work of inside spun concrete lining of pipes and specials of diameter 3 and above shall be done as per material specifications and special condition contract. 4.16.3 Fabrication of pipes from plate Pipes shall be fabricated at site as and when required as per the specifications attached and the actual Piping Material Specification. 5.0

ERECTION

5.1

Cleaning of Piping before Erection Before erection all pre-fabricated spool pieces, pipes, fittings etc. shall be cleaned inside and outside by suitable means. The cleaning process shall include removal of all foreign matter such as scale, sand, weld spatter chips etc. by wire brushes, cleaning tools etc. and blowing with compressed air/or flushing out with water. Special cleaning requirements for some services, if any shall be as specified in the piping material GAIL (INDIA) LTD NEW DELHI


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specification or isometric or line list. SS jacketed piping requiring pickling shall be pickled to remove oxidation and discolouring due to welding. 5.2

Piping Routing No deviations from the piping route indicated in drawings shall be permitted without the consent of Engineer-in-Charge. Pipe to pipe, pipe to structure / equipments distances / clearances as shown in the drawings shall be strictly followed as these clearances may be required for the free expansion of piping / equipment. No deviations from these clearances shall be permissible without the approval of Engineer-in-Charge. In case of fouling of a line with other piping, structure, equipment etc. the matter shall be brought to the notice of Engineer-in-Charge and corrective action shall be taken as per his instructions.

5.3

Cold Pull Wherever cold pull is specified, the Contractor shall maintain the necessary gap, as indicated in the drawing. Confirmation in writing shall be obtained by the Contractor from the Engineer-in-Charge, certifying that the gap between the pipes is as indicated in the drawing, before drawing the cold pull. Stress relieving shall be performed before removing the gadgets for cold pulling.

5.4

Slopes Slopes specified for various lines in the drawings / P&ID shall be maintained by the Contractor. Corrective action shall be taken by the Contractor in consultation with Engineer- in-Charge wherever the Contractor is not able to maintain the specified slope.

5.5

Expansion Joints/ Bellows Installation of Expansion Joints/Bellows shall be as follows:

5.5.1 All Expansion joints / Bellows shall be installed in accordance with the specification and Installation drawings, supplied to the Contractor. 5.5.2 a.

Upon receipt, the Contractor shall remove the Expansion Joints/ Bellows from the Case (s) and check for any damage occured during transit.

b.

The Contractor shall bring to the notice of the Engineer-in- Charge any damage done to the bellows / corrugations, hinges, tie-rods, flanges / weld ends etc.

c.

Each Expansion Joint / Bellow shall be blown free of dust! foreign matter with compressed air or cleaned with a piece of cloth.



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5.5.3

5.5.4

a.

For handling and installation of Expansion Joints, great care shall be taken while aligning. An Expansion Joints shall never be slinged from bellows corrugations / external shrouds, tie / rods, angles.

b.

An Expansion Joints / Bellow shall preferably be slinged from the end pipes/ flanges or on the middle pipe.

a.

All Expansion Joints shall be delivered to the Contractor at “Installation length”, maintained by means of shipping rods, angles welded to the flanges or weld ends or by wooden or metallic stops.

b.

Expansion Joints stop blocks shall be carefully removed after hydrostatic testing. Angles welded to the flanges or weld ends shall be trimmed by saw as per manufacturer’s instructions and the flanges or weld ends shall be ground smooth.

5.5.5 a.

b.

The pipe ends in which the Expansion Joint is to be installed shall be perfectly aligned or shall have specified lateral deflection as noted on the relevant drawings. The pipe ends/ Flanges shall be spaced at a distance specified in the drawings.

5.5.6 The Expansion Joint shall be placed between the mating pipe ends / flanges and shall be tack welded/ bolted. The mating pipes shall again be checked for correct alignment. 5.5.7 Butt-welding shall be carried out at each end of the expansion joint. For flanged Expansion Joint, the mating flanges shall be bolted. 5.5.8 After the Expansion Joint is installed the Contractor shall ensure that the mating pipes and Expansion Joints are in correct alignment and that the pipes are well supported and guided. 5.5.9 The Expansion Joint shall not have any lateral deflection. The Contractor shall maintain parallelism of restraining rings or bellows convolutions. 5.5.10 Precautions a.

For carrying out welding, earthing lead shall not be attached with the Expansion Joint.

b.

The Expansion bellow shall be protected from arc weld spot and welding spatter.



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c.

5.6

Hydrostatic Testing of the system having Expansion Joint shall be performed with shipping lugs in position. These lugs shall be removed after testing and certification is over.

Flange Connections While fitting up mating flanges, care shall be exercised to properly align the pipes and to check the flanges for trueness, so that faces of the flanges can be pulled together, without inducing any stresses in the pipes and the equipment nozzles. Extra care shall be taken for flange connections to pumps, turbines, compressors, cold boxes, air coolers etc. The flange connections to these equipments shall be checked for misalignment, excessive gap etc. after the final alignment of the equipment is over. The joint shall be made up after obtaining approval of Engineer-in-Charge. Temporary protective covers shall be retained on all flange connections of pumps, turbines, compressors and other similar equipments, until the piping is finally connected, so as to avoid any foreign material from entering these equipments. The assembly of a flange joint shall be done in such a way that the gasket between these flange faces is uniformly compressed. To achieve this, the bolts shall be tightened in a proper sequence. All bolts shall extend completely through their nuts but not more than 1/4”. Steel to C.I. flange joints shall be made up with extreme care, tightening the bolts uniformly after bringing flange flush with gaskets with accurate pattern and lateral alignment.

5.7

Vents and Drains High point vents and low point drains shall be provided as per the instructions of Engineer- in-Charge, even if these are not shown in the drawings. The details of vents and drains shall be as per piping material specifications / job standards.

5.8

Valves Valves shall be installed with spindle / actuator orientation / position as shown in the layout drawings. In case of any difficulty in doing this or if the spindle orientation / position is not shown in the drawings, the Engineer-in-Charge shall be consulted and work done as per his instructions. Care shall be exercised to ensure that globe valves, check valves, and other uni-directional valves are installed with the “Flow direction arrow “on the valve body pointing in the correct direction. If the direction of the arrow is not marked on such valves, this shall be done in the presence of Engineer-in-Charge before installation.



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Fabrication of stem extensions, locking arrangements and interlocking arrangements of valves (if called for), shall be carried out as per drawings/ instructions of Engineerin- Charge. 5.9

Instruments Installation of in-line instruments such as restriction orifices, control valves, safety valves, relief valves, rotameters, orifice flange assembly, venturimeters, flowmeters etc. shall form a part of piping erection work. Fabrication and erection of piping upto first block valve / nozzle / flange for installation of offline Instruments for measurement of level, pressure, temperature, flow etc. shall also form part of piping construction work. The limits of piping and instrumentation work will be shown in drawings / standards / specifications. Orientations / locations of take-offs for temperature, pressure, flow, level connections etc. shown in drawings shall be maintained. Flushing and testing of piping systems which include instruments mentioned above and the precautions to be taken are covered in flushing, testing and inspection of piping (GAIL Stds). Care shall be exercised and adequate precautions taken to avoid damage and entry foreign matter into instruments during transportation, installation, testing etc.

5.10 Line Mounted Equipments / Items Installation of line mounted items like filters, strainers,, steam traps, air traps, desuperheaters, ejectors, samples coolers, mixers, flame arrestors, sight glasses etc. including their supporting arrangements shall form part of piping erection work. 5.11 Bolts and Nuts The Contractor shall apply molycoat grease mixed with graphite powder (unless otherwise specified in piping classes) all bolts and nuts during storage, after erection and wherever flange connections are broken and made-up for any purpose whatsoever. The grease and graphite powder shall be supplied by the Contractor within the rates for piping work. 5.12 Pipe Supports Pipe supports are designed and located to effectively sustain the weight and thermal effects of the piping system and to prevent its vibrations. Location and design of pipe supports will be shown in drawings for lines 3” NB & above for line below 3” NB Contractor shall locate and design pipe supports in line with GAIL Stds. and obtain approval of Engineer - in - Charge on drawings prepared by Contractor, before erection. However, any extra supports desired by Engineer-in-Charge shall also be installed. GAIL (INDIA) LTD NEW DELHI


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No pipe shoe I cradle shall be offset unless specifically shown in the drawings. Hanger rods shall be installed inclined in a direction opposite to the direction in which the pipe moves during expansion. Preset pins of all spring supports shall be removed only after hydrostatic testing and insulation is over. Springs shall be checked for the range of movement and adjusted if necessary to obtain the correct positioning in cold condition. These shall be subsequently adjusted to hot setting in operating condition. The following points shall be checked after installation, with the Engineer-in-Charge and necessary confirmation in writing obtained certifying that: - All restraints have been installed correctly. - Clearances have been maintained as per support drawings. - Insulation does not restrict thermal expansion. - All temporary tack welds provided during erection have been fully removed. - All welded supports have been fully welded.



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STANDARD SPECIFICATION FOR NON DESTRUCTIVE EXAMINATION OF PIPING


STANDARD SPECIFICATION OF “NON-DESTRUCTIVE EXAMINATION OF PIPING”


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Abbreviation :DP/LP :

Dye Liquid Panetrant

MP

:

Magnetic Particle

CS

:

Carbon Steel

AS

:

Alloy Steel

SS

:

Stainless Steel

ASTM :

American Society for Testing & Materials

ASME :


IBR

:

Indian Boiler Regulations

PM

:

Piping Material Specification

ASNT :

American Society of Non-Destructive Testing

PCN :

Personal Certification in Non-Destructive Testing

PWHT:

Post Weld Heat Treatment

UST

Ultrasonic Testing

:

HS&E :

Safety, Health & Environment




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CONTENTS

SL. No.

TITLE

1.

GENERAL

2.

VISUAL EXAMINATION

3.

NON DESTRUCTIVE EXAMINATIONS

4.

TABLE –I

5.

ULTASONIC WELD EXAMINATION

6.

INSPECTION




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1.

GENERAL

1.1

SCOPE The specification covers the General Requirements for Non- Destructive Examinations of shop and field fabricated piping.

1.2

RELATED CODES AND ENGINEERING STANDARDS Referred codes/ standards are as follows. Latest edition of following codes/standard shall be followed :

a. b. c. d. e. f. g. h. 1.3

ASME Boiler and Pressure Vessels codes, Section V & VIII (Div.-1) including Addenda ASME B 31.3 ANSI B 31.8 ASME B16.5 ASME B 16.34 PCN/ ASNT PMS In addition to that all general specification dealing with welding and fabrication of various equipment shall apply. CONFLICT Where a conflict occurs between this Specification and any of the above Codes or standards the more stringent shall apply. The CONTRACTOR shall inform the OWNER in writing and receive written certification form the OWNER/ CONSULTANT. The CONTRACTOR shall have readily available for use at the request of the OWNER, latest editions of all codes, specification and standards necessary for execution of the work at work site.

1.4

NDE COMPANY CERTIFICATION All Non Destructive Examination (NDE) Contractor’s contracted by the OWNER or working for fabricators or Contractor’s carrying out work on the OWNER behalf shall have in place an up-to-date Quality Control Manual and Code of Practice which shall cover the following: i)

All aspects of NDE of which the CONTRACTOR, SUB-CON TRACTOR is qualified.

ii)

Current resumes of all presently employed personnel including their certifications (PCN, ASNT, CGSB or equivalent).

iii)

All proposed specific NDE procedure,

A registered copy of QC manual shall be made available to OWNER and shall be GAIL (INDIA) LTD NEW DELHI



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reviewed and approved by the OWNER quality assurance personnel prior to services being used. Updates to the Manual shall be forwarded to the registered holder as they become available. The OWNER will review and approve element's i), ii) & iii) above: prior to start on any said company work. Any approval given by the OWNER does not relieve the CONTRACTOR of his obligations under governing, codes, rules and specifications. All equipment shall be certified and current, to recognized calibration standard and in first class working condition. Full compliance with all governmental and local regulatory requirements of HS&E which shall be fully complied with. 2.0

VISUAL INSPECTION Visual examination shall be carried out before, during and after fabrication in accordance with ASME Sec. V article 9 and ASME B31.3. Cracks, (regardless of size and location) and under cutting or any evidence of poor workmanship, materials, etc., if not repairable shall be cause for rejection. Welds shall be visually inspected wherever accessible in accordance with the following requirements: 1 2 3

4 5

Internal misalignment Cracks or lack of fusion Incomplete penetration (for Incomplete penetration (for other than 100% Radiography butt-weld)

Surface porosity and exposed slag inclusions (4.7mm. Nom Wall thickness and less) Concave root surface (SLICK UP)

6 7 8 9 10

Weld ripples irregularities Lack of uniformity in bead width Lack of uniformity of leg length Unevenness of Bead

11

Overlap

Weld Undercutting


1.5 MM or Less None permitted. Depth shall not exceed the lesser of 0.8 MM or 0.2 times thickness of thinner component joined by butt-weld. The total length of such imperfections shall not exceed 38 MM in any 150 MM of weld length. Not permitted For single sided welded joints concavity of the root surface shall not reduce the total thickness of joint including reinforcement to less than the thickness of the thinner of the components being joined. 2.5 MM or Less 2.5 MM or Less 2.5 MM or Less 2.0 MM or Less 0.8 MM or 1/4 thickness of thinner components joined by butt weld, whichever is less. (shall be smooth finished)

1.5 mm or less STANDARD SPECIFICATION OF “NON-DESTRUCTIVE EXAMINATION OF PIPING”


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12 13

Bead Deflection

2.5 mm or less

External weld reinforcement and internal weld protrusion (when backing rings are not used) shall be fused with and shall merge smoothly into the component surfaces. The height of the lesser projection of external weld reinforcement or internal weld protrusion from the adjacent base material surface shall not exceed the following limits : Wall thickness of thinner component Weld reinforcement or internal weld joined by butt weld (MM) protrusion (MM) Max

6.4 and under Over 6.4 – 12.7 Over 12.7 – 25.4 Over 25.4 14 15

1.6 3.2 4.0 4.8

Throat thickness of fillet welds: Nominal thickness of the thinner component x 0.7 or more.

Flattening: Flattening of a bend, as measured by difference between the nominal outside diameter and minimum or maximum diameter at any cross section shall not exceed 5% of the nominal outside diameter of pipe.

16

Reduction of Wall Thickness: Reduction of wall thickness of a bend, as measured by difference between the nominal thickness and minimum thickness shall not exceed 10% of the nominal wall thickness of pipe. Welds having any imperfections which exceed the limitations specified in various clauses shall be repaired by welding, grinding or overlaying etc.

Welds having any of imperfections which exceed the limitations specified in various clauses of 2.1 shall be repaired by welding, grinding, overlaying etc. However number of times of repair welding for the same weld shall be as follows: MATERIAL

NO. OF TIMES OF REPAIR WELDING

1.0 2.0

CS UP TO 300# CS ABOVE 300#

3.

NON DESTRUCTIVE EXAMINATION

3.1

The type and extent of Weld Examination shall be in accordance with Table-1. All visual and supplementary methods of girth weld examination shall be in accordance with ASME B31.3 & the requirements of this standard specification.

3.2

Welds between dissimilar material shall be examined by method & to the extent required for the material having the more stringent examination.

3.3

Following categories of critical piping are classified under inspection Class IV (100 % radiography): a) b) c)

3 OR LESS 2 OR LESS

High Pressure Severe Cyclic Low Temperature


: : :

Classes 900# & above As defined by ASME B 31.3 Below temperature of -45 Deg C.



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3.4

3.5 3.5

d)

Critical Service

:

e) f)

High alloys High Temperature

: :

Hydrogen, Oxygen, NACE, Caustic, Chlorine & such other critical services. 5 Cr. & above for all pressure classes Above 500 Deg.C

EXTENT OF INSPECTION AND TESTING a) Piping systems which are designed and constructed in accordance with ASME Standard B 31.3, Chemical Plant and Petroleum Refinery Piping, shall be radiographed as per Table - I. b)

Piping systems which are designed and constructed in accordance with ASME B31.8 standard for gas pipeline systems shall have all welds radiographically inspected for 100%,

c)

Hardness testing shall be carried out of welds on vessels and piping in sour or corrosive service and 10% of local PWHT weld as per ASTM Specification E 10, ANSI 1331.3.

The CONTRACTOR shall prepare and maintain documentation to track percentage of welds tested and the weld repair rate. The proposed documentation shall be made available for review and approval. CONTRACTOR shall not deviate from any requirement of this specification without written approval to do so from OWNER

3.6

No exemption permitted in regards to full HS&E compliance.

3.7

Open drains vents or other open ended line shall be leak tested only.




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4.

TABLE-I (with applicable Notes)

TABLE 1 : CLASS, TYPE & EXTENT OF WELD EXAMINATION INSPECTION CLASS: I IN SP N. CL AS S

1

SERVICE

CATEGO RY ‘D’ FLUID SERVICE

MATERIA L (NOTE3)

CARBON STEEL

AUSTENE TIC SS HDPE CUPRO NICKEL

TEMP DEG C

PRESS CL. B16.5/ B16.34

0-186

(-) 29 TO 86 (-) 20 TO 50 (-) 29 TO 60

150 # UP TO 10.55 KG/ 2 CM

PIPING CLASS

A3A, A3Y, J2A, J3A, J5A, A4Y, A5Y A3K A1Z, A4Z, A5Z

TYPE OF EXAM.

TYPE OF WELD EXAMINATION

GIR TH BUT T WEL D

SCK T WEL D (NO TE2)

ATTA CHME NT WELD

FAB. BRNC H WELD (NOTE 1)

FAB MITR / RED

a) VISUAL

100 %

100 %

100%

100%

100%

b) LP (NOTE 4, 6, 9)

---

---

---

10%

10%

REMARKS FOR ABOVE TABLE: 1.

LP TEST NOT APPLICABLE TO NON-METALLIC CLASSES

2.

MITRES & FABRICATED REDUCERS ARE PERMITTED ONLY IF SPECIFIED IN PMS.




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TABLE 1 : CLASS, TYPE & EXTENT OF WELD EXAMINATION (CONTD.) INSPECTION CLASS: II IN SP N. CL AS S

II

SERVICE

a) ALL SERVICES COVERED UNDER INSPECTION CLASS-I BUT EXCEEDING CATEGORYD PR./TEMP. LIMITATION.

b) ALL SERVICES EXCEPT COVERED UNDER CLASS – I BUT NONTOXIC, NOT SUBJECTED TO SEVERE CYCLIC CONDITIONS

MATE RIAL (NOTE -3)

TEM P DEG C

PRESS CL. B16.5/ B16.34

-29 TO 400 CS

150 # UP TO 10.55 KG/ 2 CM

CS (IBR)

PIPING CLASS

A1A, A6A, A7A, A8A, A9A, A11A, A13A, A15A, A20A, A32A, A33A, A33Y

A2A

TYPE OF EXAM.

a) VISUAL

b) RADIOGRAP HY (NOTE 5, 6)

c) MP/LP/ (NOTE 4,6, 10,11)

d) HARDNESS


GIR TH BUT T WEL D

SOC KT WEL D (NO TE2)

ATTA CHME NT WELD

FAB. BRNC H WELD (NOTE I)

FAB .MIT R/ RED

100 %

100 %

100%

100%

100%

10%

---

---

---

50%

---

10%

---

10%

50%

NO TE7

NO TE7

NOTE7

NOTE7

NOTE -7


FOR A2A IBR SERVICE NOTE-8 IS ALSO APPLICABLE

2.

FOR A33A & A33Y FIRE WATER SERVICE, NOTE-12 IS ALSO APPLICABLE.

3.

EXTENT OF HARDNESS TEST FOR A11A IS 100%.

4.





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TABLE 1 : CLASS, TYPE & EXTENT OF WELD EXAMINATION (CONTD.) INSPECTION CLASS: III IN SP N. CL AS S

III

SERVICE

a) TOXIC, NONLETHAL & FLAMMAB LE b) FLAMMAB LE / NON FLAMMAB L & TOXIC / NONTOXIC; NOT SUBJECT TO SEVERE CYCLIC CONDITIO NS

ALL GENERAL SERVICES EXCEPT THOSE SUBJECT TO SEVERE CYCLIC CONDITIO NS.

MATE RIAL (NOTE -3)

CS

TEM P DEG C

ABO VE (-)29

PRES S CL. B16.5/ B16.3 4

PIPING CLASS

TYPE OF EXAM.

GIRTH BUTT WELD

SCK T WEL D (NO TE 2)

ATTA CHME NT WELD

FAB. BRNC H WELD (NOTE 1)

FAB MITR / RED

100%

100 %

100%

100%

100%

20%

---

---

---

100%

c) MP/LP/ (NOTE 4,6, 11)

---

20%

---

20%

---

d) HARDNES S

NOTE7

NOTE

NOTE7

NOTE7

NOTE -7

150 # --a) VISUAL

KILLED CARBO N STEEL

CARBO N

(-) 45 TO 204

150# TO 600#

A4A, B4A, D4A b) RADIOGR APHY (NOTE 5, 6)

(-) 29 TO 427


300# TO 600#

STEEL

CS (IBR)

B1A, B6A, B9A, B13A, B32A, D1A

-7

B2A, D2A


FOR IBR SERVICE B2A & D2A NOTE-8 IS ALSO APPLICABLE

2.







5.

ULTRASONIC WELD EXAMINATION Ultrasonic Operators Ultrasonic operators supplied by the NDE CONTRACTOR shall be certified to a General Standards Board (ASNT/PCN) approved by the OWNER. UT testing shall be carried out : (i) As per ASME B31.3 and ASME Sec. V article 5. (ii) All category 'D' welds which are not being radio graphed and all other welds configuration, which does not permit to be radio graphed, shall be ultrasonic tested. (iii) All tie-in welds where pressure testing are not possible. (iv) Ultrasonic testing, in lieu of radiography, is acceptable only where radiography is not practicable e.g. branch connections

6.

INSPECTION The CONTRACTOR shall extend all facilities, assistance and co-operate fully with the OWNER in all aspects of inspection and NDE and shall give adequate notice of any required fabrication inspection stages, together with sufficient time for thorough inspection by the OWNER. OWNER shall have the right to establish hold points at any point in the fabrication sequence. Records and evidence of all weld examinations shall be available at all times for OWNER to review and approve. OWNER may use any method of inspection necessary to establish quality control and ensure adherence to welding procedures. OWNER shall have the right to accept or reject any weld not meeting the requirements of this specification. . CONTRACTOR shall intimate sufficiently in advance the commencement of qualification test, welding works and acceptance tests to enable the owner/ owner’s representative to be present to supervise them. Any discrepancies between the approved WPS and the production welds noted by OWNER, any or all of the work made under these conditions is subject to rejection.

Applicable Notes to Table-I 1.

Branch weld shall consist of the Welds between the pipe & reinforcing element (if any), nozzles & reinforcing element and the pipe & nozzle under the reinforcing element. Reinforcing element to be interpreted as pads, saddles, weldolets, sockolets etc.

2.

Seal welds of threaded joints shall be given the same examination as socket welds.

3.

Unless specifically stated, all materials shall be for Non-IBR service. GAIL (INDIA) LTD NEW DELHI





4.

5.

Magnetic particle & the Liquid penetrant method of examination shall be in accordance with section-V of the ASME Boiler and Pressure Vessels Code, Article VII and VI respectively. The entire area of the accessible finished weld surface shall be examined. Selected root runs, subject to a maximum of 10%, before finished weld, may also be examined, at the discretion of the engineer-in-charge. a)

Wherever MP/LP testing is specified, either MP or LP test may be used. But wherever only MP test is specified, LP method of examination may be used only if MP examination is impractible in the field as concurred by GAIL sitein-charge.

b)

“Random 10%” of LP/MP test shall mean testing, by applicable test, one weld for each ten welds or less made by the same welding procedure or operator or both. Similarly “Random 20%” shall mean testing, by applicable test, one weld for each five welds or less made by the same welding procedure or operator or both.

c)

When Liquid Penetrant examination is specified, the surface shall be free of peened discontinuities. Abrasive blast cleaning shall be followed by light surface grinding prior to liquid penetrant examination.

d)

Inspection shall be performed in the welds excluding those for which radiography has been done.

e)

Girth weld, branch weld, attachment weld & socket weld of 3-1/2% Ni stell shall be Liquid Penetrant tested only when welded with austenitic material where MP test has been specified.

Radiography General – o X - Ray is the preferred radiographic method. Use of Gamma ray for examination is not permitted. Particular attention shall be paid to using radiographic ultra fine grain film suitable for the application, maintaining correct radiographic geometry during exposure, obtaining correct density also required by the appropriate standard and the correct placement and exposure of image quality indicators (IQI's or penetrameters). o ASTM wire type IQI's are preferred. GAIL may permit the use of ASTM hole type IQI's on a pre-approved basis, provided the NDT CONTRACTOR can demonstrate satisfactory results. o Radiographic technique shall produce maximum contrast and good definition of IQI wires. The inability to view the appropriate wire or hole on any radiograph shall be cause for automatic rejection of that radiograph which shall be re- radiographed at no expense to GAIL o Operator Certification GAIL (INDIA) LTD NEW DELHI





a)

6.

Radiographers supplied by the CONTRACTOR shall be certified to ASNT Level II, AWS QC] and as per AWS B1.10 (guide for nondestructive inspection of welds). An operator qualified to ASNT Level I may assist the Level II operator but all film and sentencing interpretation shall be carried out by a Level ll or higher operator who shall sign off all report sheets. Visual welding inspection shall be conducted only by a qualified welding inspector, who shall have a minimum AWS (QC. I) CWI or CSWIP 3.1 certification. GAIL shall review and approve all QA/QC personnel prior to deployment on the project. “Random 10% or 20% radiography” shall mean examination not less than one from each 10 welds or less in case of “Random 10% radiography” or one from each five welds or less in case of “Random 20% radiography” made by the same welding procedure or Welder or both. Irrespective of percentage, no. of welds to be radiographed shall be minimum 1. However first two welds made by each welder shall also be radiographed in case of “Random radiography”. Welds selected for examination shall not include flange welds and shall be radiographed for their entire length. However, where it is impossible or impracticable to examine the entire weld length of field welds for either random or 100% radiography, and if the same impossibility is agreeable to GAIL site-in-charge, then a single 120 Deg. Exposure of the weld length may be given a Magnetic Particle test or Liquid Penetrant test. However in such case for ferro-magnetic materials, only MP test shall be acceptable for classes higher than 600#.

b)

In-process examination shall not be substituted for any required radiographic examination.

c)

Number of radiographs per one circumferential weld shall be as per ASME Sec. V Article 2 and 22.

When radiography or other non-destructive inspection is specified, acceptance criteria for repairs or defects shall be as follows: a)

In case of 100% examination, any unacceptable weld shall be repaired and reinspected.

b)

If required random examination reveals a defect requiring repair, then: b.1

Two additional examination of the same type shall be made of the same kind of item (if welded joint, then by the same welding procedure or operator or both).

b.2

If the group of items examined as required by b.1 above is acceptable, the item requiring repair shall be repaired or replaced and






reexamined as required and all items represented by this additional examination shall be accepted. b.3

If any of the items examined as required by b.1 above reveals a defect requiring repair, two further comparable items shall be examined for each defective item found by examination.

b.4

If all the items examined as required by b.3 are acceptable, the items requiring repair shall be repaired or replaced and reexamined as required, and all items represented by this further examination shall be acceptable.

b.5

Number of times repair welding could b done for the same weld before acceptance shall be as follows: Material

No. of times repair welding is allowed

C.S. upto 300# C.S. above 300# Killed Steel Low alloy steel Austenitic S.S. 3.5 Ni Steel Al & Al base alloy Cu & Cu base Alloy Others

3 2 2 2 2 2 2 2 2

less less less less less less less less less

b.6

Welds not found acceptable for allowed number of times of repair as per b.5 above shall be replaced and reexamined.

b.7

If any of the items examined as required by b.4 above reveals a defect requiring repair, all items represented by these examination shall be either:  

7.

or or or or or or or or or

repaired or replaced and reexamined as required. Fully examined and repaired or replaced as necessary, and reexamined as necessary.

Hardness Test: a)

Hardness test shall be in accordance with ASTM specification E10. Hardness tests of the heat affected zone shall be made at a point as near as practicable to the edge of the weld. One test per weld shall be performed.






b)

Hardness test where specifically called out in Table-I of this specification or in PMS, shall be carried out irrespective of thickness and to the extent (%age) as mentioned therein.

c)

All welds which are given heat treatment shall be hardness tested. Hardness test shall be performed after final heat treatment.

d)

A minimum of 10% of Welds of hot formed and hot bent materials in each heat treatment batch which are furnace heat treated and 100% of those which are locally heat treated, shall be hardness tested.

e)

For C-0.5 Mo steels, a minimum of 10% of welds shall be hardness tested.

f)

Hardness test requirement not covered in b) & e) above shall be as per ASME B 31.3.

g)

The hardness limit applies to the weld and heat affected zone. Following hardness values shall be maintained:

BASE METAL GROUP CS CS (NACE) Cr 0.5% or less Cr 0.5% & up to 2% Cr 2.25% & up to 10% 18/8 SS (NACE) 8.

MAXIMUM HARDNESS (BHN/ RC) 238BHN/ RC22 200 BHN 225 BHN 225 BHN 241 BHN RC 22

For IBR service lines, following IBR requirements shall apply in addition to the notes 4, 5, 6, 7, 12 and Table-I. In case of conflict between above notes and these requirements , the more stringent ones shall apply. IBR Piping shall be erected of IBR inspector approved material and construction procedure. Erected piping shall be hydrotested, inspected and approved by IBR inspector. a)

Piping over 102 mm (4”) bore: 10% of welds made by each welder on a pipeline with a minimum of two welds per welder, selected at random, shall be subjected to radiography.

b)

Piping 102 mm (4”0 bore and under, but not less than 38 mm (1-1/2”) bore: 2% of welds made by each welder on a pipeline with a minimum of one weld per welder, selected at random, shall be subjected to radiography or may be cut for visual examination and tests.






c)

Piping less than 38 mm (1.5”) bore: Special tests are not normally required but 2% of weldfs by each welder on a pipe line may be cut out from the pipeline for the visual examination and bend tests.

d)

Retests: If any test specification is unsatisfactory, two further weld specimens for retests shall be selected from the production welds and subjected to tests. In the event of failure of any retest specimens, the production welds carried out by this welder subsequent to the previous test shall be given special consideration.

9.

For fabricated fittings LP test shall be done on the final pass of welding only, in addition to visual examination.

10.

For mitres and fabricated reducers, LP/ MP test shall be done on root pass in addition to radiography applicable to circumferential joint of respective piping class.

11.

For branch connections, LP/ MP test shall be done on root pass and final pass.

12.

10% of the butt weld joints shall be radiographed, however 50% of these butt weld joints shall be field weld joints.

13.

For lined specs, testing (MP/LP/Radiography etc.) shall be performed before lining.

14.

DOCUMENTS TO BE SUBMITTED BY THE CONTRACTOR a) Electrode and welding consumables qualification records for the welding consumables tested and approved for the work. b) Batch test certificate, for the electrodes used, obtained from the Electrode Manufacturers. c) Proposed heat treatment chart procedure. d) Heat treatment chart. e) Weld joint tensile, hardness test, Impact test result. f) Welding procedure specification immediately after receipt of order. g) Welding procedure qualification records. h) Welder performance qualification records immediately after conducting welder qualification tests. i) Radiography procedure.






STANDARD SPECIFICATION FOR INSPECTION, FLUSHING AND TESTING OF PIPING SYSTEMS

GAIL (INDIA) LTD. NEW DELHI

S TANDARD SPECIFICATION FOR INSPECTION, FLUSHING & TESTING OF PIPING SYSTEMS


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CONTENTS Sl. No.

Description

1.

SCOPE

2.

INSPECTION

3.

FLUSHING

4.

TESTING




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Abbreviations PMI

:

Positive Material Identification

ppm

:

parts per million

S.S.

:

Stainless Steel




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1.0

SCOPE This specification covers the general requirements for inspection, flushing and testing of piping systems. However testing of steam lines falling under IBR shall also be governed by Indian Boiler Regulations. Flushing and testing of all piping systems shall be witnessed by the Engineer-InCharge.

2.0

INSPECTION During various stages and after completion of fabrication and erection, the piping system shall be inspected by the Engineer-In-Charge to ensure that: -

Proper piping material has been used.

-

PMI has been performed as per ‘Standard Specification for Positive Material Identification at Construction Sites, S-14-02-001.

-

Piping has been erected as per drawings and instructions of Engineer-InCharge.

-

All supports have been installed correctly.

3.0

Test preparations mentioned in this specification have been carried out.

FLUSHING Flushing of all lines shall be done before pressure testing. Flushing shall be done by fresh potable water or dry compressed air, wherever water flushing is not desirable, to clean the pipe of all dirt, debris or loose foreign material. Required pressure for water flushing shall meet the fire hydrant pressure or utility water pressure. For air flushing, the line / system will be pressurised by compressed air at the required pressure which shall be 50 psi maximum. The pressure shall then be released by quick opening of a valve, already in line or installed temporarily for this purpose. This procedure shall be repeated as many times as required till the inside of the pipe is fully cleaned. In line instruments like control valves, orifice plates, rotameters, safety valves and other instruments like thermowells which may interfere with flushing shall not be included in flushing circuit. The screens / meshes shall be removed from all permanent strainers before flushing. Screens I meshes shall be reinstalled after flushing but before testing.




REV- 0 Page 4 of 10


During flushing temporary strainers shall be retained. These shall be removed, cleaned and reinstalled after flushing but before testing. In case an equipment such as column, vessel, exchanger etc. form part of a piping circuit during flushing. This shall be done with the approval of Engineer-In-Charge. However, equipments thus included in the circuit shall be completely drained and dried with compressed air after flushing is completed. During flushing discharged water/air shall be drained to the place directed by the Engineer-In-Charge. If necessary, proper temporary drainage shall be provided by the contractor. Care shall be taken during flushing so as not to damage/spoil work of other agencies. Precautions shall also be taken to prevent entry of water/foreign matter into equipments, electric motors, instruments, electrical installations etc. in the vicinity of lines being flushed. The contractor shall carry out all the activities required before, during and after the flushing operation, arising because of flushing requirements, such as but not limited to the following: Dropping of valves, specials, distance pieces, inline instruments and any other piping part before flushing. The flanges to be disengaged for this purpose shall be envisaged by the contractor and approved by the Engineer-In-Charge. These flanges shall be provided with temporary gaskets at the time of flushing. After flushing is completed and approved, the valve distance pieces, piping specials etc. shall be reinstalled by the contractor with permanent gaskets. However, flanges at equipment nozzles and other places where isolation is required during testing, only temporary gaskets shall be provided. Records in triplicate shall be prepared and submitted by the contractor for each piping system for the flushing done in the proforma provided/approved by the Engineer-in-Charge. 4.0

TESTING

4.1

Extent of Testing With the exclusion of instrumentation, piping systems fabricated or assembled in the field shall be tested irrespective of whether or not they have been pressure tested prior to site welding of fabrication. To facilitate the testing of piping systems, vessels and other equipments may be included in the system with the prior approval of Engineer-In-Charge if the test pressure specified is equal to or less than that for the vessels and other equipments. GAIL (INDIA) LTD. NEW DELHI



REV- 0 Page 5 of 10


Pumps, compressors and other rotary equipments shall not be subjected to field test pressure. Lines which are directly open to atmosphere such as vents, drains, safety valves discharge need not be tested, but all joints shall be visually inspected. Wherever necessary, such lines shall be tested by continuous flow of fluid to eliminate the possibility of blockade. However, such lines if provided with block valve shall be pressure tested up to the first block valve. Seats of all valves shall not be subjected to a pressure in excess of the maximum cold working pressure of the valve. Test pressure applied to valves shall not be greater than the manufacturer’s recommendation nor less than that required by the applicable code. Where allowable seat pressure is less than test pressure, test shall be made through an open valve. Instruments in the system to be tested, shall be excluded from the test by isolation or removals, unless approved otherwise by the Engineer-In-Charge. Restrictions which interfere with filling, venting and draining such as orifice plates etc. shall not be installed unless testing is complete. Control valves shall not be included in the test system. Where bypasses are provided test shall be performed through the bypass and br necessary spool shall be used in place of the control valve. Pressure gauges which are part of the finished system, but cannot withstand test pressure shall not be installed until the system has been tested. Where piping systems to be tested are directly connected at the battery limits to piping for which the responsibility rests with other agencies, the piping to be tested shall be isolated from such piping by physical disconnection such as valve or blinds. 4.2

General Requirements / Test Preparation for Testing Testing shall be carried out with permanent gaskets installed unless specified otherwise or instructed by the Engineer-in-Charge. No pressure test shall be carried out against closed valve unless approved by the Engineer-in-Charge. The Engineer-in-Charge shall be notified in advance by the Contractor, of the testing sequence and programme, to enable him to be present for witnessing the test. The Contractor shall be fully responsible for making arrangements with the local boiler inspector to witness the tests for steam lines falling under IBR. IBR certificates for these tests shall be obtained in the relevant IBR forms and furnished to the Engineer-in-Charge.




REV- 0 Page 6 of 10


Before testing, all piping shall be cleaned by flushing to make it free from dirt, loose scale, debris and other loose foreign materials. All piping systems to be hydrostatically tested shall be vented at the high points and the systems purged of air before the test pressure is applied. Wherever in the line any void exists due to any reasons, like absence of control valves, safety valves, check valves etc. it shall be filled with temporary spools. All joints welded, screwed or flanged shall be left exposed for examination during the test. Before pressuring the lines, each weld joint shall be cleaned by wire brush to free it from rust and any other foreign matter. Where a system is to be isolated at a pair of companion flanges, a blank shall be inserted between the companion flanges. Minimum thickness of the blank shall be designed in accordance with applicable design code. Open ends of piping system where blanks cannot be used, such as pumps, compressors, turbines or wherever equipment or pipe spools have been recovered or disconnected prior to hydrostatic testing, shall be blinded off by using standard blind flanges of same rating as the piping system being tested. Pressure gauges used in testing shall be installed as close as possible to the lowest point in the piping system to be tested, to avoid overstressing of any of the lower portions of the system. For longer lines and vertical lines , two or more pressure gauges shall be installed at locations decided by the Engineer-in-Charge. For lines containing check valves any of the following alternatives shall be adopted for pressure testing: Whenever possible pressurize up-stream side of valve. Replace the valve by a temporary spool and reinstall the valve after testing. Provide blind on valve flanges and test the upstream and downstream of the line separately and remove the blind after testing. At these flanges, temporary gaskets shall be provided during testing and shall be replaced by permanent gaskets subsequently. For check valves in lines 1 ½” and below flapper or seat shall be removed during testing (if possible). After completion of testing the flapper! seat shall be refitted. Gas lines when hydrostatically tested shall be provided with additional temporary supports during testing as directed by the Engineer-in-Charge. Piping which is spring or counter-weight supported shall be temporarily supported, where the weight of the fluid would overload the support. Retaining pins for spring GAIL (INDIA) LTD. NEW DELHI



REV- 0 Page 7 of 10


supports shall be removed only after testing is completed and test fluid is completely drained. When testing any piping system, air or steam of approximately 2 kg/cm2g may be used as preliminary test to detect missing gaskets etc. as this avoids the necessity of draining the line to make repairs. However, steam shall not be used for this purpose, if the steam temperature is more than the design temperature of the line. For jacketed pipes testing of core pipes shall be done on individual pieces where the pipe is continuously jacketed, before it is jacketed. The outer jacket shall be tested separately as a system. For piping with discontinuous jacketing the core pipe and the jacket shall be tested as separate continuous systems. 4.3

Testing Media, Test Pressure and Test Pressure Gauges

4.3.1 Testing Media In general all pressure test shall be hydrostatic using iron free water, which is clean and free of silt. Maximum chlorine content in water for hydrostatic testing for S.S. piping shall be 15-20 ppm. Air shall be used for testing only if water would cause corrosion of the system or overloading of supports etc. in special cases as directed by Engineer-in-Charge. Where air/water tests are undesirable, substitute fluids such as gas oil, kerosene, methanol etc. shall be used as the testing medium, with due consideration to the hazards involved. These test fluids shall be specified in the line list given to the contractor. 4.3.2 Test Pressure The hydrostatic! Pneumatic test pressure shall be as indicated in the line list or as per the instruction of Engineer-in-Charge. The selection of the piping system for one individual test shall be based on the following: Test pressure required as per line list. Maximum allowable pressure for the material of construction of piping. Depending upon the above requirements and based on construction progress, maximum length of piping shall be included in each test. 4.3.3 Test Pressure Gauge




REV- 0 Page 8 of 10


All gauges used for field testing shall have suitable range so that the test pressure of the various systems falls in 40% to 80% of gauge scale range. Gauge shall be of a good quality and in first class working condition. Prior to the start of any test or periodically during the field test programme, all test gauges shall be calibrated using a standard dead weight gauge tester or other suitable approved testing apparatus. Any gauge showing an incorrect zero reading or error of more than ± 2% of full scale range shall be discarded .The Engineer-inCharge shall check the accuracy of master pressure gauge used for calibration. 4.4

Testing Procedure

4.4.1 Hydrostatic Test All vents and other connections used as vents shall be left open while filling the line with test fluid for complete removal of air. In all lines for pressurising and depressurising the system, temporary isolating valves shall be provided if valve vents, drains do not exist in the system. Pressure shall be applied only after the system / line is ready and approved by the Engineer-incharge. Pressure shall be applied by means of a suitable test pump or other pressure source which shall be isolated from the system as soon as test pressure is reached and stabilised in the system. A pressure gauge shall be provided at the pump discharge for guidance in bringing the system to the required pressure. The pump shall be attended constantly during the test by an authorized person. The pump shall be isolated from the system whenever the pump is to be left unattended. Test pressure shall be maintained for a sufficient length of time to permit thorough inspection of all joints for leakage or signs of failure. Any joint found leaking during a pressure test shall be retested to the specified pressure after repair. Test period shall be maintained for a minimum of three hours. The pump and the piping system to be tested are to be provided with separate pressure indicating test gauges. These gauges are to be checked by the standard test gauge before each pressure test. Care shall be taken to avoid increase in the pressure due to temperature variation during the test. 4.4.2 Air Test




REV- 0 Page 9 of 10


When testing with air, pressure shall be supplied by means of a compressor. The compressor shall be portable type with a receiver, after cooler and oil separator. Piping to be tested by air shall have joints covered with a soap and water solution so that the joints can be examined for leaks. All other details shall be same as per hydrotesting procedure (specified above). 4.5

Completion of Testing After the hydrostatic test has been completed, pressure shall be released in a manner and at a rate so as not to endanger personnel or damage equipments. All vents and drains shall be opened before the system is to be drained and shall remain open till all draining is complete, so as to prevent formation of vacuum in the system. After draining, lines / systems shall be dried by air. After testing is completed the test blinds shall be removed and equipment / piping isolated during testing shall be connected using the specified gaskets, bolts and nuts. These connections shall be checked for tightness in subsequent pneumatic tests to be carried out by the contractor for complete loop / circuit including equipments (except rotary equipments). Pressure test shall be considered complete only after approved by the Engineer-inCharge. Defects, if any, noticed during testing shall be rectified immediately and retesting of the system / line shall be done by the contractor at his cost.

4.6

Test Records Records in triplicate shall be prepared and submitted by the contractor for each piping system, for the pressure test done in the proforma provided/approved by the Engineer-in-Charge. Records shall also be submitted for the PMI undertaken as per GAIL Std. Specification No. S-14-02-001






STANDARD SPECIFICATION FOR SHOP & FIELD PAINTING


STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING


REV-0 Page 1 of 49


CONTENTS 1.0

GENERAL

2.0

SCOPE

3.0

CODES & STANDRADS

4.0

EQUIPMENT

5.0

SURFACE PREPARATION

6.0

PAINT MATERIALS

7.0

PAINT SYSTEMS 7.1

PRE-ERECTION / PRE-FABRICATION AND SHOP PRIMING FOR CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL, STEEL STRUCTURES, PIPING AND EQUIPMENT ETC.

7.2

REPAIR OF PRE-ERECTION / FABRICATION AND SHOP PRIMING AFTER ERECTION / WELDING FOR CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEELS, ITEMS IN ALL ENVIRONMENTS

8.0

FILED PAINT SYSTEM FOR NORMAL CORROSIVE ENVIRONMENT (FOR CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL)

9.0

FILED PAINT SYSTEM FOR CORROSIVE ENVIRONMENT (FOR CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL)

10.0

FILED PAINT SYSTEM FOR HIGHLY CORROSIVE ENVIRONMENT (FOR CARBON STEEL & LOW ALLOY STEEL), EXTERNAL SURFACES OF UNINSULATED COLUMNS, VESSELS,

HEAT

EXCHANGERS,

BLOWERS,

PIPING,

PUMPS,

TOWERS,

COMPRESSORS, FLARE LINES, STRUCTURAL STEEL ETC. 11.0

FIELD PAINT SYSTEM FOR CARBON STEEL STORAGE TANKS (EXTERNAL) FOR ALL ENVIRONMENTS

12.0

FIELD PAINT SYSTEM FOR CARBON STEEL & LOW ALLOY STEEL STORAGE TANKS (INTERNAL)

13.0

COATING SYSTEM FOR EXTERNAL SIDE OF UNDER GROUND CARBON STEEL PLANT PIPING AND TANKS

14.0

PAINTING UNDER INSULATION (HOT, COLD & SAFETY) FOR CARBON STEEL, LOW TEMPERATURE CARBON STEEL, STAINLESS STEEL PIPING AND EQUIPMENT IN ALL ENVIRONMENT

15.0

INTERNAL PROTECTION OF CARBON STEEL WATER BOXES AND TUBE SHEETS OF COOLERS / CONDENSERS

16.0

FIELD PAINTING SYSTEM FOR GI TOWERS / NON-FERROUS TUBE SHEETS GAIL (INDIA) LTD NEW DELHI



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17.0

STORAGE

18.0

COLOUR CODE FOR PIPING

19.0

IDENTIFICATION OF VESSELS, PIPING ETC.

20.0

PAINTING FOR CIVIL DEFENCE EQUIPMENT

21.0


22.0

GUARANTEE

23.0

QUALIFICATION CRITERIA OF PAINTING CONTRACTOR

24.0

PROCEDURE FOR APPROVAL OF NEW PAINT MANUFACTURERS ANNEXURE – I

LIST OF RECOMMENDED MANUFACTURERS

ANNEXURE – II

LIST OF RECOMMENDED MANUFACTURER’S PRODUCTS




REV-0 Page 3 of 49


1.0

GENERAL

1.1

These technical specifications shall be applicable for the work covered by the contract, and without prejudice to the various codes of practice, standard specifications etc. It is understood that contractor shall complete the work in all respects with the best quality of materials and workmanship and in accordance with the best engineering practice and instructions of Engineer-in-charge.

1.2

Wherever it is stated in the specification that a specific Material is to be supplied or a specific work is to be done, it shall be deemed that the same shall be supplied or carried out by the contractor. Any deviation from this standard without written appropriate authority will result in rejection of job.

2.0

deviation

permit

from

SCOPE Scope of work covered in the specification shall include, but not limited to the following.

2.1

This specification defines the requirements for surface preparation, selection and application of paints on external surfaces of equipment, vessels, machinery, piping, ducts, and steel structures, external & internal protection of storage tanks for all services, RCC Chimney & MS Chimney with or without Refractory lining and Flare lines etc.

2.2

Extent of Works

2.2.1 The following surfaces and materials shall require shop, pre-erection and field painting : a.

All un-insulated CS & AS equipment like columns, vessels, drums, storage tanks, heat exchangers, pumps, compressors, electrical panels and motors etc.

b.

All un-insulated carbon and low alloy piping fittings and valves (including painting of identification marks), furnace, ducts and stacks.

c.

All items contained in a package unit as necessary.

d.

All structural steel work, pipe, structural steel supports, walkways, hand rails, ladders, platforms etc .

e. f.

RCC / MS chimneys with or without refractory lining & Flare lines. Identification colour bands on all piping as required including insulated aluminum clad, galvanized, SS and non-ferrous piping.

g.

Identification lettering / numbering on all painted surfaces of equipment / piping insulated aluminum clad, galvanized, SS and non-ferrous piping.




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h.

Marking / identification signs on painted surfaces of equipment / piping for Hazardous service.

i.

Supply of all primers, paints and all other materials required for painting other than Owner's supply.

j.

Over insulation surface of equipments and pipes wherever required.

k.

Painting under insulation for carbon steel and stainless steel as specified.

l.

Repair work of damaged / pre-erection / fabrication shop primer and weld joints at field.

2.2.2 The following surfaces and materials shall not be painted unless otherwise specified: a.

Un-insulated austenitic stainless steel.

b.

Plastic and / or plastic coated materials.

c. 2.3

Non ferrous materials like Aluminum, Galvanized "piping", "gratings" and "Hand rails" etc. except G.I. Towers. Documents

2.3.1 The contractor shall perform the work in accordance with the following documents issued to him for execution of work. a.

Bill of quantities for Piping, equipment, machinery and structures etc.

b.

Piping Line List.

c.

Painting specifications including special civil defense requirement.

2.4

Unless otherwise instructed final painting on pre-erection / shop primed pipes and equipments shall be painted in the field, only after mechanical completion and testing on system are completed, as well as, after completion of steam purging wherever required.

2.5

Changes and deviations required for any specific job due to clients requirement or otherwise shall be referred to GAIL for deviation permit.

3.0

CODES & STANDARDS

3.1

Without prejudice to the provision of Clause 1.1 above and the detailed specifications of the contract, the following codes and standards shall be followed for the work covered by this contract.




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3.2

IS-5

:

Colour coding

IS-101

:

Methods of test for ready mixed paints and enamels

IS-2379:1990

:

Indian Standard for Pipe line identification – colour Code

ASTM

:

American Standard test methods for paints and coatings

ASA A 13.1-1981

:

Scheme for Identification of piping systems: American National Standards Institution.

Surface Preparation Standards: Following standards shall be followed for surface preparations:

3.2.1 Swedish Standard : SIS-05 5900-1967 / ISO-8501-1-1988 (Surface preparations standards for Painting Steel Surfaces). This standard contains photographs of the various standards on four different degrees of rusted steel and as such is preferable for inspection purpose by the Engineer-in-Charge. 3.2.2 Steel Structures Painting Council, U.S.A. (Surface Preparation Specifications (SSPC – SP) 3.2.3 British Standards (Surface Finish or Blast-cleaned for Painting) BS-4232. 3.2.4 National Association of Corrosion Engineers, U.S.A. (NACE) 3.2.5 Various International Standards equivalent to Swedish Standard for surface preparation are given in Table-I. 3.3

The contractor shall arrange, at his own cost, to keep a set of latest edition of any one of the above standards and codes at site.

3.4

The paint manufacturer's, instructions shall be followed as far as practicable at all times. Particular attention shall be paid to the following: a.

Instructions for storage to avoid exposure as well as extremes of temp.

b.

Surface preparation prior to painting.

c.

Mixing and thinning.

d.

Application of Paints and the recommended limit on time intervals between coats.




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4.0

EQUIPMENT

4.1

All tools, brushes, rollers, spray guns, abrasive material, hand cleaning and all equipments, scaffolding materials, shot / wet water blasting equipments & air compressors etc. required to suitable for the work and all in good order and shall be contractor at site and in sufficient quantity.

4.2

Mechanical mixing shall be used for paint mixing operations in case of two pack systems except that the Engineer-in-Charge may allow the hand mixing of small quantities at his discretion.

5.0

SURFACE PREPARATION, SHOP COAT, COATING APPLICATION & REPAIR AND DOCUMENTATION

5.1

General

/ power tools for abrasive blasting, be used shall be arranged by the

5.1.1 In order to achieve the maximum durability, one or more of following methods of surface preparation shall be followed, depending on condition of steel surface and as instructed by Engineer-in-Charge. Adhesion of the paint film to surface depends largely on the degree of cleanliness of the metal surface. Proper surface preparation contributes more to the success of the paint protective system: a.

Manual or hand tool cleaning

b.

Mechanical or power tool cleaning.

c.

Blast cleaning.

5.1.2 Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a clean and dry surface is obtained. The minimum acceptable standard in case of manual or hand tool cleaning shall be St.2 or equivalent, in case of mechanical or power tool cleaning it shall be St.3 or equivalent, in case of blast cleaning it shall be Sa 2 ½ or equivalent as per Swedish Standard SIS-0559001967 / ISO-8501-1-1988. Where highly corrosive conditions exist, blast cleaning shall be Sa3 as per Swedish Standard. Remove all other contaminants, oil, grease etc. by use of an aromatic solvent prior to surface cleaning. 5.1.3 Blast cleaning shall not be performed where dust can contaminate surfaces undergoing such cleaning or during humid weather conditions having humidity exceeding 85% . 5.1.4 Irrespective of the method of surface preparation, the first coat of primer must be applied on dry surface. This should be done immediately and in any case within 4 hours of cleaning of surface. However, at times of unfavorable weather conditions, the Engineer-in-Charge shall have the liberty to control the time GAIL (INDIA) LTD NEW DELHI



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period, at his sole discretion and / or to insist on re-cleaning, as may be required, before primer application is taken up. In general, during unfavorable weather conditions, blasting and painting shall be avoided as far as practicable. 5.1.5 The external surface of R. C .C. chimney to be painted shall be dry and clean. Any loose particle of sand, cement, aggregate etc. shall be removed by scrubbing with soft wire brush if necessary, acid etching with 10 - 15% HCL solution for about 15 minutes shall be carried out and surface must be thoroughly washed with water to remove acid & loose particles then dry completely before application of paint. 5.2

Procedure of Surface Preparation

5.2.1 Blast Cleaning 5.2.1.1

Air Blast Cleaning

The surfaces shall be blast cleaned using one of the abrasives: Al2O3, particles chilled cast iron or malleable iron and steel at pressure of 7 kg/cm2 at appropriate distance and angle depending on nozzle size maintaining constant velocity and pressure. Chilled cast iron, malleable iron and steel shall be in the form of shot or grit of size not greater than 0.055" maximum in case of steel and malleable iron and 0.04" maximum in case of chilled iron. Compressed air shall be free from moisture and oil. The blasting nozzles should be Venturi style with tungsten carbide or boron carbide as the materials for liners. Nozzles orifice may vary from 3/16" to 3/4". On completion of blasting operation, the blasted surface shall be clean and free from any scale or rust and must show a grey white metallic lusture. Primer or first coat of paint shall be applied within 4 hours of surface preparation. Blast cleaning shall not be done outdoors in bad weather without adequate protection or when there is dew on the metal which is to be cleaned. Surface profile shall be uniform to provide good key to the paint adhesion (i.e. 35 to 50 microns). If possible vacuum collector shall be installed for collecting the abrasives and recycling. 5.2.1.2

Water Blast cleaning

Environmental, health and safety problems associated with abrasive blast cleaning limit the application of Air Blast Cleaning in many installations. In such case water blast cleaning is resorted to. Water Blast Cleaning can be applied with or without abrasive and high pressure water blasting. The water used shall be inhibited with sodium chromate / phosphate. The blast cleaned surface shall be washed thoroughly with detergents and wiped with solvent and dried with compressed Air. For effective cleaning, abrasives are used. The most commonly used pressure for high pressure water blast cleaning for maintenance surface preparation is 3000 to 6000 psi at 35-45 liters / minute water volume and pressures up to 10000 psi and water volume of 45 liters / minute provide maximum cleaning.




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The water blast cleaned surface shall be comparable to SSPC-SP-12 / NACE NO. 5. The operation shall be carried out as per SSPC guidelines for water Blast cleaning. The indicative value for sand injection is as given below: Air

:

300 to 400 Cu. ft / min.

Water

:

5- 10 liters/min. with corrosion inhibitor

Sand

:

200 - 400 lbs / hr.

Nozzle

:

0.5 to 1" dia

Special equipments for water blast cleaning with abrasives now available shall be used. 5.2.2 Mechanical or Power tool cleaning Power tool cleaning shall be done by mechanical striking tools, chipping hammers, grinding wheels or rotating steel wire-brushes. Excessive burnish of surface shall be avoided as it can reduce paint adhesion. On completion of cleaning, the detached rust mill scale etc. shall be removed by clean rags and / or washed by water or steam and thoroughly dried with compressed air jet before application of paint. 5.2.3 Manual or hand tool cleaning Manual or hand tool cleaning is used only where safety problems limit the application of other surface preparation procedure and hence does not appear in the specifications of paint systems. Hand tool cleaning normally consists of the following: a.

Hand de-scaling and / or hammering

b.

Hand scraping

c.

Hand wire brushing

Rust, mill scale spatters, old coatings and other foreign matter, shall be removed by hammering, scrapping tools, emery paper cleaning, wire brushing or combination of the above methods. On completion of cleaning, loose material shall be removed from the surface by clean rags and the surface shall be brushed, swept, de-dusted and blown off with compressed air / steam to remove all loose matter. Finally the surface may be washed with water and dried for effective cleaning. 5.3

Non compatible shop coat primer




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The compatibility of finishing coat should be confirmed from the paint manufacturer. In the event of use of primer such as zinc Rich epoxy, inorganic zinc silicate etc. as shop coat, the paint system shall depend on condition of shop coat. If shop coat is in satisfactory condition showing no major defects, the shop coat shall not be removed. The touch up primer and finishing coat(s) shall be identified for application by Engineer-in charge. 5.4

Shop coated (coated with primer & finishing coat) equipment should not be repainted unless paint is damaged.

5.5

Shop primed equipment and surfaces will only be 'spot cleaned' in damaged areas by means of power tool brush cleaning and then spot primed before applying one coat of field primer unless otherwise specified. If shop primer is not compatible with field primer then shop coated primer should be completely removed before application of selected paint system for particular environment. For packaged units / equipment, shop primer should be as per the paint system given in this specification. However, manufacturer's standard can be followed after review.

5.6

5.7

Coating Procedure and Application :

5.7.1 Surface shall not be coated in rain, wind or in environment where injurious air bone elements exists, when the steel surface temperature is less than 50F above dew point, when the relative humidity is greater than 85% or when the temperature is below 40°F. 5.7.2 Blast cleaned surface shall be coated with one complete application of primer as soon as practicable but in no case later than 4 hrs. in the same day. 5.7.3 To the maximum extent practicable, each coat of material shall be applied as a continuous film uniform thickness free of probes. Any spots or areas missed in application shall be recoated and permitted to dry before the next coat is applied. Applied paint should have the desired wet film thickness. 5.7.4 Each coat shall be in proper state of cure or dryness before the application of succeeding coat. Material shall be considered dry for recoating when an additional coat can be applied without the development of any detrimental film irregularities, such as lifting or loss of adhesion of the under coat. Manufacturer instruction shall be followed for inter coat interval. 5.7.5 When the successive coat of the same colour have been specified, alternate coat shall be tinted, when practical, sufficiently to produce enough contrast to indicate complete coverage of the surface. The tinting material shall be compatible with the material and not detrimental to its service life. 5.7.6 Air spray application shall be in accordance with the following: a.

The equipment used shall be suitable for the intended purpose, shall be capable of properly atomizing the paint to be applied, and shall be equipped




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with suitable pressure regulators and gauges. The air caps, nozzles, and needles shall be those recommended by the manufacturer of the equipment for the material being sprayed. The equipment shall be kept in satisfactory condition to permit proper paint application. b.

Traps or separators shall be provided to remove oil and condensed water from the air. These traps or separators must be of adequate size and must be drained periodically during operations. The air from the spray gun impinging against the surface shall show no condensed water or oil.

c.

Ingredients shall be kept properly mixed in the spray pots or containers during application by continuous mechanical agitation.

d.

The pressure on the material in the pot and the air at the gun shall be adjusted for optimum spraying effectiveness. The pressure on the material in the pot shall be adjusted when necessary for changes in elevation of the gun above the pot. The atomizing air pressure at the gun shall be high enough to properly atomize the paint but not so high as to cause excessive fogging of paint, excessive evaporation of solvent, or less by overspray.

e.

Spray equipment shall be kept sufficiently clean so that dirt, dried paint, and other foreign materials are not deposited in the paint film. Any solvents left in the equipment shall be completely removed before applying paint to the surface being painted.

f.

Paint shall be applied in a uniform layer, with overlapping at the edge of the spray pattern. The spray patterns shall be adjusted so that the paint is deposited uniformly. During application, the gun shall be held perpendicular to the surface and a distance which will ensure that a wet layer of paint is deposited on the surface. The trigger of the gun should be released at the end of each stroke.

g.

All runs and sags shall be brushed out immediately or the paint shall be removed and the surface repainted.

h.

Areas inaccessible to the spray gun shall be painted by brush; if not accessible by brush, daubers or sheepkins shall be used.

i.

All name plates, manufacturer's identification tags, machined surfaces, instrument glass, finished flange faces, control valve items and similar items shall be masked to prohibit coating deposition. If these surfaces are coated, the component shall be cleaned and restored to its original condition.

j.

Edges of structural shapes and irregular coated surfaces shall be coated first and an extra pass made later.




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k.

If spray gun shows choking, immediately de-choking procedure shall be followed.

5.7.7 Airless spray application shall be in accordance with the following procedure: as per steel structure paint Manual Vol. 1 & Vol.2 by SSPC, USA. Air less spray relies on hydraulic pressure rather than air atomization to produce the desired spray. An air compressor or electric motor is used to operate a pump to produce pressures of 1,000 to 6,000 psi. Paint is delivered to the spray gun at this pressure through a single hose within the gun; a single paint stream is divided into separate streams, which are forced through a small orifice resulting in atomization of paint without the use of air. This results in more rapid coverage with less overspray. Airless spray usually is faster, cleaner, more economical and easier to use than conventional air spray. Airless spray equipment is mounted on wheels, and paint is aspirated in a hose that sucks paint from any container, including drums. The unit shall have inbuilt agitator that keep the paint uniformly mixed during the spraying. The unit shall consist of inbuilt strainer. A usually very small quantity of thinning is required before spray. Incase of High Build epoxy coatings (two pack), 30: 1 pump ratio and 0.020-0.023" tip size will provide a good spray pattern. Ideally fluid hoses should not be less than 3/8" ID and not longer than 50ft to obtain optimum results. In case of gun choking, dechoking steps shall be followed immediately. 5.7.8 Brush application of paint shall be in accordance with the following : a.

Brushes shall be of a style and quality that will enable proper application of paint.

b.

Round or oval brushes are most suitable for rivets, bolts, irregular surfaces, and rough or pitted steel. Wide flat brushes are suitable for large flat areas, but they shall not have width over five inches.

c.

Paint shall be applied into all corners.

d.

Any runs or sags shall be brushed out.

e.

There shall be a minimum of brush marks left in the applied paint.

f.

Surfaces not accessible to brushes shall be painted by spray, daubers, or sheepkin.

5.7.9 Manual Application by sling (where 6’O clock position of pipe is not approachable) A canvas strip (alternatively a tinplate strip) about 450mrn wide and 1.5m long is hold under the pipe by two men. Liquid coating is poured on the sling at each side of the pipe. The men holding this sling move it up and down and walk slowly forward while fresh coating is poured on the pipe and they manipulate the GAIL (INDIA) LTD NEW DELHI



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sling so that an even coating is obtained all round the bottom. This work shall be done very carefully and by experienced personnel. There shall not be any formation of "Whiskers" and holes in the coating. The coating film shall be inspected by mirror. 5.7.10 For each coat, the painter should know the WFT corresponding to the specified DFT and standardize the paint application technique to achieve the desired WFT. This has to be ensured in the qualification trial. 5.8

Drying of coated Surfaces

5.8.1 No coat shall be applied until the preceding coat has dried. The material shall be considered dry for re-coating when another coat can be applied without the development of any film irregularities such as lifting or loss of adhesion of undercoats. Drying time of the applied coat should not exceed maximum specified for it as a first coat; if it exceeds the paint material has possibly deteriorated or mixing is faulty. 5.8.2 No paint shall be force dried under conditions which will cause checking, wrinkling, blistering formation of pores, or detrimentally affect the condition of the paint. 5.8.3 No drier shall be added to a paint on the job unless specifically called for in the manufacturer's specification for the paint. 5.8.4 Paint shall be protected from rain, condensation, contamination, snow and freezing until dry to the fullest extent practicable. 5.9

Repair of damaged paint surface

5.9.1 Where paint has been damaged in handling and in transportation, the repair of damaged coating of pre-erection / fabrication shall be as given below. 5.9.2 Repair of damaged inorganic zinc silicate primer after erection / welding: Quickly remove the primer from damaged area by mechanical scraping and emery paper to expose the white metal. Blast clean the surface if possible. Feather the primer over the intact adjacent surface surrounding the damaged area by emery paper. 5.9.3 Repair of damaged pre-erection and shop priming in the design temperature of 90°C to 500°C.  

Surface preparation shall be done as per procedure 5.9.2. One coat of F-9 shall be applied wherever damaged was observed on preerection / pre-fabrication / shop primer of inorganic zinc silicate coating (F9). F-9 shall not be applied if damaged area is not more than 5x5 cm.

5.10 PAINT APPLICATION




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5.10.1 Shop priming / pre-erection priming with F9 or F12 shall be done only on blasted surface. 5.10.2 Shop priming / pre-erection priming with F9 or F12 shall be done only with airless spray. 5.10.3 For large flat surface field painting shall be done by airless spray otherwise brush can be used. 5.11 Documentation 

A written quality plan with procedure for qualification trials and for the actual work.



Daily progress report with details of weather conditions, particular of applications, no of coats and type of materials applied, anomalies, progress of work versus programmed.



Results of measurement of temperatures relative humidity, surface profile, film thickness, holiday detection, adhesion tests with signature of appropriate authority.



Particulars of surface preparation and paint application during trials and during the work.



Details of non-compliance, rejects and repairs.



Type of testing equipments and calibration.



Code and batch numbers of paint materials used.




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6.0

PAINT MATERIALS Paint manufacturer shall furnish all the characteristics of the paint material on printed literature, along with the test certificate for all the specified characteristics given in this specification. All the paint materials shall be of first quality and confirm to the following general characteristics as per tables 6.1, 6.2 & 6.3.




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F-14: Specially formulated polyamine cured coal tar epoxy suitable for -450C to 125°C for application under insulation F-15: Two pack cold cured epoxy phenolic coating suitable for -450C to 125°C for application under insulation F-16: Epoxy siloxane Amercoat 738 Notes: 1.0

Covering capacity and DFT depends on method of application. Covering capacity specified above are theoretical. Allowing the losses during the application, minimum specified DFT should be maintained.

2.0

All primers and finish coats should be cold cured and air dried unless otherwise specified.

3.0

All paints shall be applied in accordance with manufacturer's instructions for surface preparation, intervals, curing and application. The surface preparation, quality and workmanship should be ensured.

4.0

Technical data sheets for all paints shall be supplied at the time of submission of quotations.




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6.4

List of recommended manufacturers The paints shall conform to the specifications given above and the best quality in their products range of the manufacturers listed in Annexure-I.

7.0

PAINT SYSTEMS The paint system should vary with type of environment envisaged in and around the plants. Three types of environment as given below are considered for selection of paint system. The paint system is also given for specific requirements. PRIMERS & FINISH COATS COVERED IN TABLE NOS.7.0 to 15.0 PRIMERS P-2

:

Chlorinated Rubber Zinc Phosphate Primer

P-4

:

Etch Primer / Wash Primer

P-6

:

Epoxy Zinc Phosphate Primer

FINISH COATS / PAINTS F-2

:

Acrylic - Polyurethane finish paint

F-3

:

Chlorinated Rubber Finish Paint

F-6

:

High Build Epoxy finish coating

F-7

:

High Build Coal Tar epoxy coating

F-8

:

Self priming surface Tolerant High Build Epoxy coating

F-9

:

Inorganic Zinc Silicate coating

F-11

:

Heat resistant Synthetic medium based Aluminum paint

F-12

:

Heat resistant Silicone Aluminum paint

F-14

:

Specially formulated polyamine cured coal for Epoxy coating

F-15

:

Epoxy phenolic coating

F-16

:

Epoxy Siloxane coating: Amercoat 738




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17.0 STORAGE: 17.1

All paints and painting materials shall be stored only in rooms to be arranged by contractor and approved by Engineer-in-charge for the purpose. All necessary precautions shall be taken to prevent fire. The storage building shall preferably be separate from adjacent building. A signboard bearing the words "PAINT STORAGE- NO NAKED LIGHT- HIGHLY INFLAMABLE" shall be clearly displayed outside.

18.0 COLOUR CODE FOR PIPING: For identification of pipelines, the colour code as per Table 18.1 shall be used. Paint materials for color coding shall be as specified in this standard in clause6.0. 18.1 Colour coding scheme for pipes, equipment, machinery & structures:




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18.2

The colour code scheme is intended for identification of the individual group of the pipeline. The system of colour coding consists of a ground colour and colour bands superimposed on it.

18.3

Ground Colours as given in Table-18.1 shall be applied throughout the entire length for un insulated pipes, on the metal cladding & on surfaces covered by Clause 2.2.2, ground colour coating of minimum 2m length or of adequate length not to be mistaken as colour band shall be applied at places requiring colour bands. Colour band(s) shall be applied at the following location. a.

At battery limit points




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b.

Intersection points & change of direction points in piping ways.

c.

Other points, such as midway of each piping way, near valves, junction joints of service appliances, walls, on either side of pipe culverts.

d.

For long stretch / yard piping at 50M interval.

e.

At start and terminating points.

18.4 Identification Sign 18.4.1 Flow direction shall be indicated by an arrow in the location stated in Para b ,c & d and as directed by Engineer-in-Charge.

a,

18.4.2 Colours of arrows shall be black or white and in contrast to the colour on which they are superimposed. 18.4.3 Product names shall be marked at pump inlet, outlet and battery limit in a suitable size as approved by Engineer-in-Charge. 18.4.4 Size of arrow shall be either of those given in 18.5. 18.5 Colour Bands 18.5.1 As a rule, minimum width of colour band shall conform to the following table.

Note: For insulated pipes, nominal pipe size means the outside diameter of the insulation. Nominal pipe size figures are to be in inches. 18.5.2 Colour band(s) shall be arranged in the sequence shown in Table 18.1 and the sequence follows the direction of flow. The relative proportional width of the first colour band to the subsequent bands shall be 4: 1, minimum width of any band shall be as per Clause 18.5.1. 18.6

Whenever it is required by the Engineer-in-Charge to indicate that a pipeline carries a hazardous material, a hazard marking of diagonal strips of black and golden yellow as per IS:2379 shall be painted on the ground colour. GAIL (INDIA) LTD NEW DELHI



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19.0 IDENTIFICATION OF VESSELS, PIPING ETC.: 19.1

Equipment number shall be stenciled in black or white on each vessel, column, equipment & machinery (insulated or un insulated) after painting. Line number in black or white shall be stenciled on all the pipe lines of more than one location as directed by Engineer-in-Charge, Size of letters printed shall be as below: Column & Vessels Pump, compressor and other machinery Piping

-

150 mm (high) 50 mm (high) 40 - 150 mm

19.2 Identification of storage tanks: The storage tanks shall be marked as detailed in the drawing. 20.0 PAINTING FOR CIVIL DEFENCE REQUIREMENTS: 21.1

Following items shall be painted for camouflaging if required by the client. a. b. c. d.

20.2

All columns All tanks in offsites. Large Vessels Spheres

Two coats of selected finishing paint as per defense requirement shall be applied in a particular pattern as per 20.3 and as per the instructions of Engineer-inCharge.

20.3 Method of camouflaging 20.3.1 Disruptive painting for camouflaging shall be done in three Colours in the ratio of 5:3:2 (Dark Green : Light Green : Medium Brown) (all matt finish). 20.3.2 The patches should be asymmetrical and irregular. 20.3.3 The patches should be inclined at 30 Degree to 60 Degree to the horizontal. 20.3.4 The patches should be continuous where two surfaces meet at an angle. 20.3.5 The patches should not coincide with corners. 20.3.6 Slits and holes shall be painted in dark shades. 20.3.7 Width of patches should be 1 to 2 meters. 21.0 INSPECTION AND TESTING 21.1

All painting materials including primers and thinners brought to site by contractor




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for application shall be procured directly from manufactures as per specifications and shall be accompanied by manufacturer's test certificates. Paint formulations without certificates are not acceptable. 21.2

Engineer-in-Charge at his discretion may call for tests for paint formulations. Contractor shall arrange to have such tests performed including batch wise test of wet paints for physical & chemical analysis. All costs there shall be borne by the contractor.

21.3

The painting work shall be subject to inspection by Engineer-in-Charge at all times. In particular, following stage wise inspection will be performed and contractor shall offer the work for inspection and approval of every stage before proceeding with the next stage. The record of inspection shall be maintained in the registers. Stages of inspection are as follows: a.

Surface preparation

b.

Primer application

c.

Each coat of paint

In addition to above, record should include type of shop primer already applied on equipment e. g. Red oxide zinc chromate or zinc chromate or Red lead primer etc. Any defect noticed during the various stages of inspection shall be rectified by the contractor to the entire satisfaction of Engineer-in-Charge before proceeding further. Irrespective of the inspection, repair and approval at intermediate stages of work, contractor shall be responsible for making good any defects found during final inspection / guarantee period / defect liability period as defined in general condition of contract. Dry film thickness (DFT) shall be checked and recorded after application of each coat and extra coat of paint should be applied to make-up the DFT specified without any extra cost to owner, the extra cost should have prior approval of Engineer-In-Charge . 21.4 Primer Application After surface preparation, the primer should be applied to cover the crevices, corners, sharp edges etc. in the presence of inspector nominated by Engineer-inCharge. 21.5

The shades of successive coats should be slightly different in colour in order to ensure application of individual coats, the thickness of each coat and complete coverage should be checked as per provision of this specification. This should be approved by Engineer-in-Charge before application of successive coats.

21.6

The contractor shall provide standard thickness measurement instrument with appropriate range(s) for measuring Dry film thickness of each coat, surface profile page for checking of surface profile in case of blast cleaning, Holiday detectors and GAIL (INDIA) LTD NEW DELHI



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pinhole detector and positector whenever required for checking in case of immersion conditions. 21.7

Prior to application of paints on surfaces of chimneys, the thickness of the individual coat shall be checked by application of each coat of same paint on M.S. test panel. The thickness of paint on test panel shall be determined by using gauge such as 'Elkometer'. The thickness of each coat shall be checked as per provision of this specification. This shall be approved by Engineer-in-Charge before application of paints on surface of chimney.

21.8

At the discretion of Engineer-in-Charge, the paint manufacturer must provide the expert technical service at site as and when required. This service should be free of cost and without any obligation to the owner, as it would be in the interest of the manufacturer to ensure that both surface preparation and application are carried out as per their recommendations.

21.9

Final inspection shall include measurement of paint dry film thickness, Adhesion, Holiday detection check of finish and workmanship. The thickness should be measured at as many points/locations as decided by Engineer-in-Charge and shall be within + 10% of the dry film thickness, specified in the specifications.

21.10 The contractor shall arrange for spot checking of paint materials for Sp. gr., flow time(ford cup) and spreading rate. 22.0 GUARANTEE 22.1

The contractor shall guarantee that the chemical and physical properties of paint materials used are in accordance with the specifications contained herein / to be provided during execution of work.

22.2

The contractor shall produce test reports from manufacturer regarding the quality of the particular batch of paint supplied. The Engineer-in-Charge shall have the right to test wet samples of paint at random, for quality of same, as stipulated in Clause 11 above. Batch test reports of the manufacturer's for each batch of paints supplied shall be made available by the contractor.

23.0 QUALIFCATION CRITERIA OF PAINTING CONTRACTOR: Painting contractor who is awarded any job for GAIL, Projects under this standard must have necessary equipments, machinery, tools and tackles for surface preparation, paint application and inspection. The contractor must have qualified, trained and experienced surface preparator , paint applicator, inspector and supervisors. The contractor supervisor, inspector, surface preparator and paint applicator must be conversant with the standards referred in this specification. The contractors capacity, capability and competency requirements for the job shall be quantified in the tender document and shall be assessed by GAIL team before awarding any job. 24.0 PROCEDURE FOR APPROVAL OF NEW COATING MATERIALS AND MANUFACTURERS GAIL (INDIA) LTD NEW DELHI



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Following procedure is recommended to be followed for approval of new manufacturers. 24.1

The manufacturer should arrange testing of the inorganic zinc silicate coating materials as per the list of tests given in para 24.5 below from one of the reputed Government laboratories.

24.2

Samples of coating materials should be submitted to the Govt. laboratory in sealed containers with batch no. and test certificate on regular format of manufacturer's testing laboratory. The sampling shall be certified and sealed by a certifying agency.

24.3

All test panels should be prepared by Govt. testing agency coloured photographs of test panels should be taken before and after the test and should be enclosed along with test report. Sample batch no. and manufacturer's test certificate should be enclosed along with the report. Test report must contain details of observation and rusting if any, as per the testing code. Suggested Government laboratories are:  RRL ,Hyderabad 

HBTI, Kanpur



DMSRDE, Kanpur



IIT, Mumbai



BIS Laboratories.



UDCT, Mumbai



RITES, Calcutta



PDIL

24.4

Manufacturers should intimate the Company, details of sample submitted for testing, name of Govt . testing agency, date, contact personnel of the Govt. testing agency. At the end of the test the manufacturer should submit the test reports to the company for approval. The manufacturer(s) shall be qualified based on the results of these tests and other assessment and the Company's decision in this regard shall be final and binding on the manufacturer.

24.5

Test required for evaluation of acceptance of coating materials for offshore application. TEST


ASTM TEST METHOD STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING


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DENSITY DIPPING PROPERIES

-

D 1475 D 823

DRYING TIME FLEXIBILITY HARDNESS

-

D 1640 D 1737 / D 522 D 3363

ADHESION ABRASION RESISTANCE DFT / COAT STORAGE STABILITY

-

D 2197 D 968 / D 1044 AS PER SSPC GUIDELINES D 1849

FILM CHARACTERSTICS

RESISTANCE TO HUMIDITY FOR 2000 HRS. SALT SPRAY FOR 2000 HRS ACCELERATED WEATHERING %Zn IN DFT 24.6

D 2247 B 117 D 822 G 53

Coating system for panel test shall be decided after discussion with GAIL.




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ANNEXURE-I LIST OF RECOMMENDED MANUFACTURERS INDIAN VENDORS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

Asian paints(1) Ltd. Berger Paints Ltd. Goodlass Nerolac paints Ltd. Jenson and Nicholson paints Ltd. & ChokuGu Jenson & Nicholson Ltd. Shalimar paints Ltd. Sigma coatings, Mumbai CDC Carboline Ltd. Premier products Ltd. Coromandel paints & chemicals Ltd. Anupam enterprises Grand polycoats Bombay paints Ltd. Vanaprabha Esters & Glycer , Mumbai Sunil paints and Varnishes Pvt. Ltd. Courtaulds coatings & Sealants India(Pvt.) Ltd. Mark-Chem Incorporated, Mumbai (for phosphating chemicals only) VCM Polyurethane Paints (for polyurethane paints only)

FOREIGN VENDORS FOR OVERSEAS PRODUCTS 1. 2. 3. 4. 5. 6.

Sigma coatings, Singapore Ameron, USA. Kansai paint, Japan Hempel paints, USA. Valspar Corporation, USA Courtaulds coatings, UK.

Note : This list is subjected to revision based on fresh approval.




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INSPECTION AND TEST PLAN FOR GASKETS




REV- 0 Page 1 of 4 Copyright GAIL – All rights reserved

SL. NO.

STAGE

COMPONENT

CHARACTER ISTICS

METHOD OF CHECK

QUANTUM OF CHECK

REFERENCE DOC.

ACCEPTANCE NORMS

RECORD

SCOPE OF INSPECTION SUB VENDOR

VENDO R

GAIL

1.0

CAF GASKETS

1.1

Raw Material Inspection

CAF Material

Physical

Visual, Dimensional, TC Verification

100 %

IS 2712 Gr. W/1

IS 2712 Gr. W/1

Manufacturer’s TC

W

R

-

1.2

In process inspection (punching & finishing)

CAF Material

Identification Verification

Visual, Dimensional

As per internal QA Plan

ANSI B 16.21, PO, Material Specification


Inspection Report

-

W

-

1.3

Final Inspection

Gasket


Visual, Dimensional

100% by Vendor, at random by GAIL



Inspection Report

-

W

R

2.0

SPIRAL WOUND

2.1

Raw Material Inspection (Review of mfr’s certificate and check test)

Metaalic spiral winding material, centering ring, Inner ring

Chemical, Visual, Dimensional

Lab Check Visual

100 % lots

Applicable Material specification


Manufacturer’s TC

-

W&R

-

2.2

Raw Material Inspection (Review of mfr’s certificate and check test)

Non- Metallic filler material

Physical

Visual Dimension TC Verification

100 %



Manufacturer’s TC

-

W&R

-





SL. NO.

STAGE

COMPONENT

CHARACTER ISTICS

METHOD OF CHECK

QUANTUM OF CHECK

REFERENCE DOC.

ACCEPTANCE NORMS

RECORD

SCOPE OF INSPECTION SUB VENDOR

VENDO R

GAIL

2.3

Raw material inspection

Spiral Wound

Compression & recovery test

Test Jig

Lots of every size / rating



Inspection report

-

W

H

2.4

Final Inspection

Gasket


Visual Dimension, Marking

100 % by vendor, at random by GAIL



Inspection report

-

W

R

3.0

RTJ GASKET

3.1

Raw material inspection (Document Review)

Seamless ring gasket material

Properties

Chemical Dimension, visual, Hardness

100 %



TC, Inspection report

W

W

R

3.2

Raw material inspection (Check Test)

Ring Gasket Material

Properties

Dimension, visual, Hardness

At random



Inspection report

-

W

-

3.3

Final Inspection

Gasket

Identification, Verification


At random




-

W

H

3.4

Final Inspection (Non CS)

Gasket

PMI Check

X-Ray Floorescence/ Emission Spectrometer

Std. Spec for PMI

Std. Spec for PMI

Material Specification

Inspection Report

-

W

H





4.0

JACKETED GASKET

4.1

Raw material Inspection

Metal Jacketed

Properties

Chemical, Dimension thickness, Visual

As per sampling plan

IS 513

IS 513


-

W

-

4.2

Raw material Inspection

Filler

Properties


At random



Inspection report

-

W

-

4.3

Final Inspection

Gasket

Identification verification


At Random




-

W

H

4.4

Final Inspection (Non CS)

Gasket

PMI Check

X-Ray Floorescence/ Emission Spectrometer

Std. Spec for PMI

Std. Spec for PMI

Material Specification

Inspection Report

-

W

H

Legend : H – Hold (Offer for witness & obtain clearance), W – Witness, R – Review, A – Approval, I – Information, X – Submit, PO – Purchase Order, PR – Purchase Requisition. In case of conflict between purchase specification , contract documents and ITP more stringent conditions shall be applicable.





STANDARD SPECIFICATION FOR POSITIVE MATERIAL IDENTIFICATION (PMI) AT VENDOR’S WORKS




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CONTENTS

1.0

SCOPE

2.0

REFERENCE DOCUMENTS

3.0

DEFINITIONS

4.0

PMI EXAMINATION

5.0

ACCEPTABLE METHODS FOR PMI

6.0

EXTENT OF PMI EXAMINATION

7.0

RECORDING AND DOCUMENTATION

8.0

MARKING




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1.0

SCOPE This specification applies to the requirements for Positive Material Identification (PMI) to be performed at the vendors’ works on Metallic Alloys Materials procured either directly by the GAIL/Owner/Contractor or indirectly through the sub-vendors.

1.2

Any post order deviation from this specification must be approved by Owner/ GAIL in the Deviation/ Waiver Permit Format enclosed with Material Requisition.

1.3

This specification covers the procedures and methodology to be adopted to assure that the chemical composition of the alloy material is consistent with the material specifications as specified in purchase documents using “Alloy Analyzer” at the time of final inspection before dispatch.

1.4

The scope of this specification shall include but shall not be limited to Positive Material Identification (PMI) to be performed on Alloy Materials listed below: -

Alloy Steel Pipes including Pipes

-

Alloy Steel Flanges & Forgings

-

Alloy Steel Fittings including Clad Fittings

-

Alloy Steel fasteners

-

Alloy Cast & Forged steel valves

-

Alloy Steel Instrumentation Items (Control Valves, Safety Valves etc.)

-

Longitudinal Pipe & Fittings Welds.

-

Gaskets (for Ring Type Joints)

Following Items shall be excluded from scope of PMI examination: -

Gasket other than for Ring Type Joints

-

Internal Components of Valves

1.5

All grades of material supplies including Stainless Steels shall be liable for PMI test at site. In case of any defective materials being found at site, the vendor shall be responsible to effect replacement of such defective materials at project site without any delays to the satisfaction of GAIL.

2.0

REFERENCE DOCUMENTS GAIL (INDIA) LTD NEW DELHI



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2.1

API Recommended Practice 578 (First Edition, May 1999) – Material Verification Programme for new and Existing Alloy Piping System.

3.0

DEFINITIONS

3.1

Vendor: Any Supplier or Manufacturer on whom an order is placed for the supply of referred items. This definition shall also include any sub-vendor or manufacturer on whom a sub- order is placed by the vendor.

3.2

Inspection Lot: A group of items offered for inspection covered under same size, Heat and Heat treatment lot.

3.3

Alloy Material: Any metallic material (including welding filler material) that contains alloying elements such as chromium, nickel, molybdenum or vanadium, which are intentionally added to enhance mechanical or physical properties and/ or corrosion resistance.

4.0

PMI EXAMINATION

4.1

The vendor shall submit a procedure of PMI to comply with the requirements of this Specification Approval of PMI Procedure shall be obtained from Owner/ GAIL/ TPI prior to commencing manufacture/ inspection of product.

4.2

PMI examination of alloy materials is independent of any certification, markings or colour coding that may exist and is aimed at verifying that the alloy used are as per specified grades.

4.3

The Vendor shall identify all incoming alloy materials and maintain full traceability of all alloy materials, including all off-cuts. Transfer of identification marks shall be undertaken prior to cutting to ensure maintenance of identification on off-cuts.

4.4

The Vendor shall ensure that all alloy materials are segregated and stored in separately identified locations to prevent the mix up of materials of different alloy specifications or alloy material with carbon steel. Non ferro-magnetic materials shall be segregated at all times from ferro-magnetic materials.

4.5

PMI examination is subject to surveillance inspection by Owner/ GAIL/ TPI.

5.0

ACCEPTABLE METHODS FOR PMI

5.1

The method used for PMI examination shall provide a quantitative determination of the alloying elements like Cr, Mo, Ni, V in Alloy Steel items.




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5.2

Instrument or methods used for PMI examination shall be able to provide quantitative, recordable, elemental composition results for positive identification of alloying elements present.

5.3

The acceptable instruments for alloy analyzer shall be either “Portable X-Ray Fluorescence” or Optical Emission” type each capable of verifying the percentage of alloy elements within specified range.

5.4

Chemical spot testing, magnets, alloy sorters and other methods using eddy current or triboelectric testing methods are not acceptable for PMI examination.

5.5

The PMI instruments shall have the sensitivity to detect the alloying elements in the specified range.

5.6

All PMI instruments shall have been serviced within a 6 month period of the time of use to verify the suitability of batteries, sources etc, the data of the last service shall be stated on the PMI Report Form (Sample enclosed).

5.7

Each analyzer must be calibrated according to the manufacturer’s specification at the beginning and end of each shift. Instrument must be checked against known standard for each alloy type to be inspected during the shift.

5.8

Certified samples, with full traceability, of a known alloy materials shall be available for use as a random spot check on the instrument calibration.

5.9

The surfaces to be examined shall be prepared by light grinding or abrasive paper and solvent cleaner. Evidence of Arc burn resulting from examination shall be removed by light grinding or abrasive paper.

5.10 Alloy Steel ring type joint gaskets shall be inspected by using portable X-Ray Flourescence instrument. 5.11 Testing shall be done as per the procedures outlined by the manufacturers of alloy analyzer being used. Modification of these procedures if any, must be approved by Owner/ GAIL. 5.12 The persons performing PMI shall demonstrate their capabilities to the satisfaction of Owner/ GAIL visiting engineer. If the vendor has qualified operator on their rolls, he may perform the examination. Otherwise PMI examination shall be sub-contracted to an independent testing agency approved by GAIL. 5.13 Whenever material is identified as not meeting requirements by the visiting engineer a rejection note shall be issued.




REV-0 Page 5 of 7

6.0

EXTENT OF PMI EXAMINATION

6.1

Following sampling plan shall be applicable for PMI examination of various alloy items: A. Flanges, Fittings, Valves, RTJ Gaskets

_

B. Pipes

_

100% 100% (for pipes procured from traders)

- 2 random samples drawn from each size/ Heat/ Lot (for pipes procured directly from Mills) C. Fasteners Lot Size

Sample Size

Upto 100

2% (Min2)

101 to 500

1% (Min 3)

501 and above

0.5% (Min5)

Note: a.

For Welded Pipes and Fittings, PMI shall be performed on base metal as well as weldments.

b

Whenever any sample drawn to PMI test on the basis of percentage selection in B & C above, fails to meet specification requirements, 100% of items of lot shall be tested for PMI

7.0

RECORDING AND DOCUMENTATION The results of PMI examination shall be recorded in aReport Format as enclosed with this specification.

8.0

MARKING

8.1

All alloy materials tested by PMI shall be identified using either of the following methods by indicating “PMI OK”

8.2

a) Bar Code/ Hologram Sticker b) A low stress stamp marking GAIL (INDIA) LTD NEW DELHI



REV-0 Page 6 of 7

POSITIVE MATERIAL IDENTIFICATION REPORT

Page

of

BULK MATERIAL Project:

Client

Job No

PMI Report No.

Vendor/ sub- Vendor

Purchase Order No:

Testing Agency

Purchase Requisition No:

PMI Location

Bulk Item Type (as per requisition) Material Specification/ Grade Number of Items in Lot Requisition Item No./ Description

Alloy content, Weight (%)

Remarks Accept/ Reject

Element

Cr

Mo

Ni

V

t

Specified range Actual Observations 1. 2. 3. 4 5 6 7 8 Instrument Type/ ID Last Service date


Inspection Agency


Witnessed by


REV-0 Page 7 of 7

NOTES: 1.

ALL DIMENSIONS ARE IN MM UNLESS SPECIFICED OTHERWISE.

2.

DIFFERENT ROU DIMENSIONS MAY BE ADOPTED BASED ON SITE CONDITIONS, CONSTRUCTION METHOD, PIPELINE SIZE, NO. OF PIPELINES AND PROVISION FOR FUTURE PIPELINES.

3.

THE LOCATION OF PIPELINE IN ROU MAY BE CHANGED TO SUIT SITE CONDITIONS, AFTER OBTAINING WRITTEN APPROVAL FROM COMPANY.

4.

FOR LOCATION OF PIPELINE AMRKET WITH RESPECT TO PIPELINE CENTERLINE, REFER APPLICABLE STANDARDS FOR MARKERS.


TYPICAL RIGHT OF USE FOR PIPE LINES


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5.

ROU WIDTH (A) AND LOCATION OF PIPELINE IN ROU (B) SHOWN IN THIS STANDARD SHALL BE APPLICABLE FOR NEW CONSTRUCTION OF SINGLE PIPELINE IN NORMAL TERRAIN.FOR RESTRICTIONS, IF ANY IN ROU, REFER PROJECT SPECIFIC REQUIREMENTS OF CONTRACT.


TYPICAL RIGHT OF USE FOR PIPE LINES


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NOTES: 1.

ALL DIMENSIONS ARE IN MM UNLESS SPECIFICED OTHERWISE.

2.

TRENCH DIMENSIONS / COVER REQUIREMENTS SHOWN IN THIS STANDARD ARE MINIMUM REQUIRED DIMENSIONS. ANY INCREASE IN TRENCH WIDTH / COVER SHALL BE SPECIFIED IN THE PROJECT SPECIFIC REQUIREMENTS OF CONTRACT.

3.

MINIMUM COVER REQUIREMENT SHALL BE SUBJECT TO APPROVAL OF CONCERNED AUTHORITIES HAVING JURISDICTION OVER THE AREA.

4.

EXTRA COVER REQUIREMENTS SHALL BE PROVIDED AT OVER BENDS AND SAG BENDS AS REQUIRED DURING CONSTRUCTION.

5.

FOR MINIMUM COVER REQUIREMENTS AT PIPELINE CROSSING ROADS, RAILWAY TRACKS, RIVERS, MARSHY AREAS, WATER (CANAL) BODIES ETC., REFER RELEVENT STANDARD.

6.

FOR ALL PIPELINES TO BE CONSTRUCTED UNDER THE JURISDICTION OF GOVT. OF INDIA, THE MINIMUM COVER TO BE ADOPTED SHALL BE 1000 MM, IN ACCORDANCE WITH PETROLEUM AND MINERAL PIPELINES (ACQUSITION OF RIGHT OF USER IN LAND) ACT NO. 50, 1962 AND AMENDMENTS THREON, OF GOVT. OF INDIA.

7.

REFER APPLICABLE STANDARDS AND DRAWINGS FOR OFC.


TYPICAL TRENCH DIMENSIONS FOR PIPE LINES


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DOCUMENT NO. PIPE LINE SYMBOLS

S-04-01-003

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DOCUMENT NO. TOPOGRAPHICAL SYMBOLS

S-04-01-004

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NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 2. A MODIFIED PIPELINE WARNING SIGN SHALL BE INSTALLED WHERE THE PIPELINE CROSSES AN EXISTING PIPELINE CARRYING HAZARDOUS FLUID. 3. CONCRETE SLAB SHALL BE PCC M15 AS PER IS 456 / PLASTIC GRATING SHALL BE 6 MM THK. 4. PLASTIC GRATING OR CONC. SLAB NEED NOT BE PROVIDED BETWEEN AN EXISTING PIPELINE AND A NEW CASED PIPELINE. 5. APPROVAL OF CROSSING SHALL BE OBTAINED FROM CONCERNED AUTHORITIES. 6. DIMENSION ‘A’ SHALL BE CALCULATED USING FORMULS A = (D1+D2+---+Dn)+(n-1) X500 WHERE D1, D2 _ _ _ IS THE DIAMETER OF PIPELINES IN MM IN THE SAME TRENCH AND n IS NO. OF PIPELINES IN SAME TRENCH.


EXISTING PIPELINE ON SLEEPER CROSSING


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7. DIMENSION ‘D’ SHALL BE THE LARGEST DIAMETER OF THE PIPELINE LAID IN SAME TRENCH. 8. TRENCH DIMENSIONS SHALL BE IN ACCORDANCE WITH RELEVENT STANDARDS / SPECIFICATIONS.


EXISTING PIPELINE ON SLEEPER CROSSING


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NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 2. ROAD / HIGHWAY CROSSING SHALL BE RESTORED TO ORIGINAL CONDITION TO THE ENTIRE SATISFACTION OF COMPANY AND CONCERNED AUTHORITIES HAVING JURISDICTION. 3. REFER API 1102 REQUIREMENTS.

(LATEST

EDITION)

FOR

OTHER

DESIGN

AND

INSTALLATION

4. ANGLE OF INTERSECTION BETWEEN PIPE LINE AND THE ROAD / HISGHWAY SHALL BE AS CLOSE TO 900 AS POSSIBLE, BUT IN NO CASE LESS THAN 300. 5. IN CASE PIPE LINE COATING IS LIABLE TO GET DAMAGED WHILE BORING / JACKING, A PROTECTIVE COATING OF CONCRETE OR ANY OTHER SUITABLE MATERIAL SHALL BE PROVIDED ON CARRIER PIPE IN ACCORDANCE WITH SPECIFICATIONS AND AS DIRECTED BY COMPANY. 6. CONTRACTOR SHALL VERIFY THE ACTUAL DIMENSIONS WITH RESPECT TO SURVEY DETAILS FOR EACH ROAD / HIGHWAY CROSSED AND PREPARE DETAILED DRAWING FOR INDIVIDUAL CROSSING FOR COMPANY’S APPROVAL BEFORE COMMENCEMENT OF CONSTRUCTION.


PIPE LINE ROAD / HIGHWAY UNCASED CROSSING


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NOTES: 1. ALL DIMENSIONS ARE IN mm, UNLESS SPECIFIED OTHERWISE. 2. VENT AND DRAIN OFF TO FACE LEFT WHEN LOOKING IN DIRECTION OF FLOW AND SHALL BE PARALLEL TO CROSSING. 3. VENT AND DRAIN OFF PIPE SHALL BE API 5L Gr. B OR IS 1239. 4. PORTION OF VENT AND DRAIN OFF PIPES WHICH ARE UNDER GROUND OR WHICH MAY BE UNDER WATER ARE TO BE COATED WITH COAL TAR EPOXY (MIN. 300 MICRON THK.) PAINTING FOR PORTION ABOVE GROUND / WATER LEVEL SHALL BE AS PER STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING NO. S-05-02-014. 5. VENT PIPES MAY BE USED FOR MOUNTING WARNING SIGNS. 6. FOR CASING PIPE REFER, STANDARD NO. S-04-01-008, SCOPE OF WORK AND SOR.


DETAILS OF CASING VENT AND DRAIN OFF


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NOTES: 1. THE CASING PIPE SHALL BE DESIGNED IN ACCORDANCE WITH API 1102 (LATEST EDITION). 2. CASING PIPE, NORMALLY, IS NOT TO BE COATED. HOWEVER, IN HIGHLY CORROSIVE AREAS THE CASING SHALL BE COATED, WRAPPED AND CATHODIC PROTECTION PROVIDED WITH SACRIFICIAL ANODE. 3. AT BOTH ENDS OF CASING PIPE, A DOUBLE SET OF INSULATORS SHALL BE INSTALLED. 4. THE MAXIMUM SPACING BETWEEN INSULAORS AS PER MANUFACTURER’S RECOMMENDATION, BUT IN NO CASE MORE THAN 2500 MM. 5. ELECTRICAL INSULATION BETWEEN THE CASING AND CARRIER PIPE SHALL BE CHECKED WITH SUITABLE MEGGER. 6. CASING INSULATORS AND END SEALS SHALL BE AS PER THE SPECIFICATIONS ISSUED FOR THE SAME. 7. END SEALS SHOWN HERE ARE ONLY INDICATIVE, POSSIBILITY OF PROVIDING OHER TYPES OF FLEXIBLE END SEALS MAY BE CONSIDERED. 8. TO PREVENT DAMAGE TO COATING AND WRAPPING (IF APPLIED) TO CASING PIPE IN CASE OF BORED / JACKED CROSSING, A PROTECTIVE COATING OF CONCRETE OR SUITABLE MATERIAL SHALL BE PROVIDED ON CASING PIPE.


DOCUMENT NO. CASING PIPE DETAILS

S-04-01-008

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NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 2. A MODIFIED PIPELINE WARNING SIGN SHALL BE INSTALLED WHERE THE PIPELINE CROSSES AN EXISTING PIPELINE CARRYING HAZARDOUS FLUID. 3. CONCRETE SLAB SHALL BE PCC M15 AS PER IS 456 / PLASTIC GRATING SHALL BE 6 MM THK. 4. PLASTIC GRATING OR CONC. SLAB NEED NOT BE PROVIDED BETWEEN AN EXISTING PIPELINE AND A NEW CASED PIPELINE. 5. SUITABLE CATHODIC PROTECTION BONDING SHALL BE PROVIDED BETWEEN CROSSING PIPELINES. IN SOME CASES THE NEW PIPELINE MAY REQUIRE ELECTRICAL ISOLATION. CP DETAILS ARE COVERED SEPARATELY. 6. DIMENSION ‘A’ SHALL BE CALCULATED USING FORMULS A = (D1+D2+---+Dn)+(n-1) X500 WHERE D1, D2 _ _ _ IS THE DIAMETER OF PIPELINES IN MM IN THE SAME TRENCH AND n IS NO. OF PIPELINES IN SAME TRENCH. 7. DIMENSION ‘D’ SHALL BE THE LARGEST DIAMETER OF THE PIPELINE LAID IN SAME TRENCH.


EXISTING UNDER GROUND PIPE CROSSING (TYPE – I)

DOCUMENT NO. S-04-01009

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8. TRENCH DIMENSIONS SHALL BE IN ACCORDANCE WITH RELEVENT STANDARDS / SPECIFICATIONS. 9. APPROVAL OF THE CROSSING SHALL BE OBTAINED FROM CONCERNED AUTHORITIES.


EXISTING UNDER GROUND PIPE CROSSING (TYPE – I)

DOCUMENT NO. S-04-01009

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NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 2. A MODIFIED PIPELINE WARNING SIGN SHALL BE INSTALLED WHERE THE PIPELINE CROSSES AN EXISTING PIPELINE CARRYING HAZARDOUS FLUID. 3. CONCRETE SLAB SHALL BE PCC M15 AS PER IS 456 / PLASTIC GRATING SHALL BE 6 MM THK. 4. PLASTIC GRATING OR CONC. SLAB NEED NOT BE PROVIDED BETWEEN AN EXISTING PIPELINE AND A NEW CASED PIPELINE. 5. SUITABLE CATHODIC PROTECTION BONDING SHALL BE PROVIDED BETWEEN CROSSING PIPELINES. IN SOME CASES THE NEW PIPELINE MAY REQUIRE ELECTRICAL ISOLATION. CP DETAILS ARE COVERED SEPARATELY. 6. DIMENSION ‘A’ SHALL BE CALCULATED USING FORMULS A = (D1+D2+---+Dn)+(n-1) X500 WHERE D1, D2 _ _ _ IS THE DIAMETER OF PIPELINES IN MM IN THE SAME TRENCH AND n IS NO. OF PIPELINES IN SAME TRENCH. 7. DIMENSION ‘D’ SHALL BE THE LARGEST DIAMETER OF THE PIPELINE LAID IN SAME TRENCH.


EXISTING UNDER GROUND PIPE CROSSING (TYPE – II)


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EXISTING UNDER GROUND PIPE CROSSING (TYPE – II)


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NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 2. A MODIFIED PIPELINE WARNING SIGN SHALL BE INSTALLED WHERE THE PIPELINE CROSSES AN EXISTING PIPELINE CARRYING HAZARDOUS FLUID. 3. CONCRETE SLAB SHALL BE PCC M15 AS PER IS 456 / PLASTIC GRATING SHALL BE 6 MM THK. 4. PLASTIC GRATING OR CONC. SLAB NEED NOT BE PROVIDED BETWEEN AN EXISTING PIPELINE AND A NEW CASED PIPELINE. 5. IN CASE OF ARMOURED AC CABLE, SUITABLE CATHODIC PROTECTION BONDING SHALL BE PROVIDED BETWEEN PIPELINE AND CABLE ARMOUR. IN CASE OF UNARMOURED AC CABLE, ARRANGEMENT FOR ELECTROMAGNETIC SHIELDING (BY PROVIDING CASING ON EITHER PIPE OR CABLE) SHALL BE CONSIDERED. CP DETAILS ARE COVERED SEPARATELY. 6. DIMENSION ‘A’ SHALL BE CALCULATED USING FORMULS A = (D1+D2+---+Dn)+(n-1) X500 WHERE D1, D2 _ _ _ IS THE DIAMETER OF PIPELINES IN MM IN THE SAME TRENCH AND n IS NO. OF PIPELINES IN SAME TRENCH. 7. DIMENSION ‘D’ SHALL BE THE LARGEST DIAMETER OF THE PIPELINE LAID IN SAME TRENCH.


DOCUMENT NO. UNDER GROUND CABLE CROSSING

S-04-01-011

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DOCUMENT NO. UNDER GROUND CABLE CROSSING

S-04-01-011

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DOCUMENT NO. OVERHEAD POWER LINE CROSSING

S-04-01-012

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NOTE: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 2. THIS STANDARD IS APPLICABLE FOR 11 KV AND ABOVE POWER LINES ONLY. 3. SUITABLE MEASURES SHALL BE TAKEN FOR THE PROTECTION OF THE LINE AND SECURITY OF PERSONNEL WHEREVER FOUND NECESSARY. 4. APPROVAL OF CROSSING MAY HAVE TO BE OBTAINED FROM CONCERNED AUTHORITIES. 5. DIMENSION ‘A’ SHALL BE CALCULATED USING FORMULS A = (D1+D2+---+Dn)+(n-1) X500 WHERE D1, D2 _ _ _ IS THE DIAMETER OF PIPELINES IN MM IN THE SAME TRENCH AND n IS NO. OF PIPELINES IN SAME TRENCH. 6. DIMENSION ‘D’ SHALL BE THE LARGEST DIAMETER OF THE PIPELINE LAID IN SAME TRENCH. 7. CONCRETE SLAB SHALL BE PCC M15 AS PER IS 456 / PLASTIC GRATING SHALL BE 6 MM THK.


DOCUMENT NO. OVERHEAD POWER LINE CROSSING

S-04-01-012

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NOTE: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 2. FOR ALL THE PIPELINES TO BE CONSTRUCTED UNDER THE JURISDICATION OF GOVT. OF INDIA, THE MINIMUM COVER REQUIREMENT IS 1000 MM IN ACCORDANCE WITH GOVT. OF INDIA PETROLEUM PIPELINES (ACQUISITION OF ROU IN LAND) ACT, NO. 50 (1962) AND NO. 13 (1977). ANY EXTRA REQUIREMENT SHALL BE IN ACCORDANCE WITH SPECIFICATION. 3. THE MINIMUM COVER SHALL BE SUBJECT TO APPROVAL OF CONCERNED AUTHORITIES. 4. THE MINIMUM COVER IS FOR STRAINGHT PIPE RUNS. EXTRA COVER REQUIREMENTS TO BE ESTABLISHED AT ALL OVER BENDS, SAG BENDS AND HORIZONTAL BENDS. 5. FOR MINIMUM COVER AT PIPELINE CROSSING ROADS, RAILWAY TRACKS, RIVERS, MARSHY AREAS ETC. REFER RELEVENT STANDARD. 6. DIMENSION ‘A’ SHALL BE CALCULATED USING FORMULS A = (D1+D2+---+Dn)+(n-1) X500 WHERE D1, D2 _ _ _ IS THE DIAMETER OF PIPELINES IN MM IN THE SAME TRENCH AND n IS NO. OF PIPELINES IN SAME TRENCH. 7. DIMENSION ‘D’ SHALL BE THE LARGEST DIAMETER OF THE PIPELINE LAID IN SAME TRENCH. 8.

CLEAR SPACING BETWEEN PIPELINES IS ONLY FOR STRAIGHT LENGTHS. SPACING BETWEEN PIPELINES AT BENDS, RAILWAY CROSSINGS, ROAD CROSSINGS, CANAL CROSSINGS, OTHER WATER CROSSINGS, MARSHY AREAS SHALL BE AS PER APPROVED DRAWINGS / SPECIFICATIONS. CLEAR SPACING SHALL BE REVIEWED IN CASE PIPELINES OPERATING AT TEMPERATURES OTHER THEN AMBIENT.


TYPICAL TRENCH DIMENSIONS FOR TWO OR MORE PIPELINES IN COMMON TRENCH


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DETAIL - X


DOCUMENT NO. KM POST

S-04-01-014

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S-04-01-014

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NOTES: 1.

ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE.

2.

SCHEME OF PAINTING AND COLOURING:

3.

4.

A.

UNDERGORUND STEEL STRUCTURES (EXCEPT THAT EMBEDDED IN CONCRETE): COAL TAR EPOXY (MINIMUM 300 MICRONS THK.).

B.

OVERGROUND STEEL STRUCTURE: AS PER STANDARD S-05-02-014.

C.

FIGURES SHALL BE STENCILED ON BOTH SIDES OF THE POSTS IN BLACK.

D.

COLOUR SCHEME FOR PIPELINE CO. MONOGRAM SHALL BE AS DIRECTED BY COMPANY.

E.

POST SHALL BE PAINTED WITH 250MM WIDE ALTERNATIVE BANDS OF BLACK AND WHITE PAINT.

F.

ALL OTHER ABOVE GROUND STEEL SHALL BE PAINTED YELLOW.

LOCATION: A.

KM POST SHALL BE INSTALLED AT EVERY KILOMETER AS PER REQUIREMENTS OF CONTRACT AND AS DIRECTED BY COMPNAY.

B.

COMPANY NAME PLATE SHALL FACE THE PIPE LINE.

C.

KM POST SHALL BE 3000 MM TO THE LEFT OF THE PIPE CENTERLINE VIEWING TOWARDS THE DIRECTION OF FLOW AND AS INDICATED IN LOCATION SKETCH ABOVE.

MATERIAL FOR MARKERS SHALL BE: 

PLATE

-

IS 2062 Gr. A



PIPE

-

IS-1239

5.

THE FOUNDATION SHALL BE MADE OF CONCRETE M20.

6.

THE HEIGHT OF KM POST MAY BE VARIED TO SUIT FIELD REQUIREMENTS.



S-04-01-014

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LOCATION PLAN FOR BOUNDARY MARKER


DOCUMENT NO. TYPICAL ROU BOUNDARY MARKER

S-04-01-015

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NOTES: 1.


2.

BOUNDARY MARKERS SHALL BE INSTALLED AT THE ROU LIMITS ON EITHER SIDES AT 250 M INTERVALS AND ALSO AT ALL TURNING POINTS, AS PER SPECIFICATIONS AND AS SPECIFIED BY COMPANY. BOUNDARY MARKERS SHALL PREFERABLY BE PLACED ON FIELD BENDS / UNCULTIVABLE PATCHES.

3.

ALL BOUNDARY MARKERS SHALL BE PRECAST AND INSCRIPTIONS SHALL BE ENGRAVED CENTRALLY IN THE MOULD ON ONE FACE.

4.

LETTERS SHALL BE 60 MM HIGH AND 5 MM DEEP.

5.

INSCRIPTIONS SHALL FACE THE PIPELINE.

6.

CONCRETE FOR BOUNDARY MARKERS SHALL BE M20.

7.

ABOVE GROUND PART OF BOUNDARY MARKERS SHALL BE PAINTED YELLOW WITH MINIMUM THREE COATS OF WATER PROOF CEMENT PAINT AS PER IS-5410. INSCRIPTIONS SHALL BE PAINTED BLACK.


DOCUMENT NO. TYPICAL ROU BOUNDARY MARKER

S-04-01-015

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DOCUMENT NO. AERIAL MARKER

S-04-01-016

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S-04-01-016

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NOTES: 1.


2.

SCHEME OF PAINTING AND COLOURING:

3.

4.

A.


B.


C.


D.


E.


F.


LOCATION: A.

AERIAL MARKER SHALL BE INSTALLED AT EVERY 5 KILOMETERS AS PER REQUIREMENTS OF CONTRACT AND AS DIRECTED BY COMPNAY.

B.

COMPANY NAME PLATE SHALL BE FIXED ON BOTH SIDES OF THE POST.

C.

AERIAL MARKER SHALL BE 3000 MM TO THE LEFT OF THE PIPE CENTERLINE VIEWING TOWARDS THE DIRECTION OF FLOW AND AS INDICATED IN LOCATION SKETCH ABOVE.


PLATE

-

IS 2062 Gr. A



PIPE

-

IS-1239

5.


6.

THE HEIGHT OF POST MAY BE VARIED TO SUIT FIELD REQUIREMENTS.



S-04-01-016

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DOCUMENT NO. DIRECTION MARKER

S-04-01-017

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NOTES: 1.


2.

SCHEME OF PAINTING AND COLOURING: A.


B.


C.


D.


E.


F.




S-04-01-017

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3.

4.

LOCATION: A.

DIRECTION MARKER SHALL BE INSTALLED AT LOCATIONS AS PER SPECIFICATIONS AS INDICATED IN APPROVED DRAWINGS AND AS DIRECTED BY COMPNAY.

B.

COMPANY NAME PLATE SHALL FACE THE PIPELINE.

C.

DIRECTION MARKER SHALL BE INSTALLED AT 3000 MM TO THE LEFT OF THE PIPE CENTERLINE VIEWING TOWARDS THE DIRECTION OF FLOW AND AS INDICATED IN LOCATION SKETCH ABOVE.


PLATE

-

IS 2062 Gr. A



PIPE

-

IS-1239

5.

DIRECTION MARKER SHALL SHOW THE CHANGE IN DIRECTION OF THE PIPELINE. ALIGNMENT.

6.


7.

THE HEIGHT OF POST MAY BE VARIED TO SUIT FIELD REQUIREMENTS.



S-04-01-017

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DOCUMENT NO. PIPELINE WARNING SIGN

S-04-01-018

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NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 2. SCHEME OF PAINTING AND COLOURING: A.


B.


C.

AREAS SHOWN AS “■” ARE TO BE PAINTED AND AREAS SHOWN AS “□” ARE TO BE PAINTED YELLOW.

D.

ALL LETTERS SHALL BE PAINTED BLACK EXCEPT “WARNING” WHICH SHALL BE PAINTED RED.



S-04-01-018

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E.


F.


G.


3. LOCATION: A.

THE PIPE LINE WARNING SIGN SHALL BE INSTALLED IN ACCORDANCE WITH CONTRACT REQUIREMENTS AND AS DIRECTED BY COMPANY. IT SHALL BE INSTALLED TO THE LEFT OF THE PIPE CENTER LINE VIEWING IN THE DIRECTION OF FLOW AT 300 MM FROM THE PIPE LINE OD AND THE WARNING SIGN PLATE SHALL FACE THE UTILITY BEING CROSSED.

B.

THE WARNING SIGN PLATE MAY BE MOUNTED ON VENT PIPES OR KM POSTS WHEREVER FEASIBLE.

4. MATERIAL FOR MARKERS SHALL BE: 

PLATE

-

IS 2062 Gr. A



PIPE

-

IS-1239

5. FOR FLUIDS COVERED BY ASME B 31.8, MENTION GAS IN LOCATION “- - -“. FOR FLUIDS COVERED BY ASME B 31.4, MENTION “PETROLEUM” AND OTHER FLUIDS, MENTION THE NAME OF THE FLUID. 6. THE FOUNDATION SHALL BE MADE OF CONCRETE M20. 7. IN CASE THE WARNING SIGN IS TO BE USED WHERE THE PIPE LINE CROSSES A HAZARDOUS FACILITY LIKE A H.T CABLE OR ANOTHER PETROLEUM / GAS PIPE LINE, THEN THE WARNING SIGN SHALL READ “HIGH PRESSURE GAS PIPE LINE CROSSING H.T CABLE (OR THE CONCERNED FACILITY)” IN LETTERS OF SIZE AS DECIDED BY COMPANY. 8. SIGN PLATE IN REGIONAL LANGUAGE SHALL BE PREPARED BY CONTRACTOR ON SMALLER LINES AND GET APPROVED BY COMPANY.



S-04-01-018

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PIPE LINE ROAD / HIGHWAY CASED CROSSING


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NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 2. REFER API 1102 REQUIREMENTS.

(LATEST

EDITION)

FOR

OTHER

DESIGN

AND

INSTALLATION

3. FOR CASING PIPE DETAILS, REFER SCOPE OF WORK AND SOR. 4. AT EACH CROSSING, PIPE LINE CROSSING WARNING SIGN SHALL BE INSTALLED ON EITHER SIDE OF THE CROSSING. THE WARNING PLATE MAY BE MOUNTED ON VENT PIPE. 5. CATHODIC PROTECTION TEST LEAD TERMINAL BOX MAY BE MOUNTED ON VENT PIPE. FOR CP LEAD TERMINAL BOX DETAILS, REFER RELEVENT STANDARD. 6. CONTRACTOR SHALL VERIFY THE ACTUAL DIMENSIONS WITH RESPECT TO SURVEY DETAILS OF EACH CROSSING AND PREPARE DETAILED DRAWINGS FOR INDIVIDUAL CROSSING FOR COMPANY / CONCERNED AUTHORITIES APPROVAL BEFORE COMMENCEMENT OF CONSTRICTION. 7. ALL PIPELINE JOINTS SHALL BE RADIOGRAPHED. 8. ELECTRICAL INSULATION BETWEEN CASING AND CARRIER PIPES SHALL BE CHECKED WITH SUITABLE MEGGER. 9. AFTER INSTALLATION OF CASING AND CARRIER PIPES, THE ROAD SHALL BE RESTORED TO THE SATISFACTION OF COMPANY / CONCERNED ROAD AUTHORITIES. 10. PIPELINE SECTION SHALL BE PRETESTED HYDROSTATICALLY, SEPARATELY FROM THE MAIN LINE TESTING WHEN REQUIRED BY CONCERNED AUTHORITIES / COMPANY. 11. ANGLE OF INTERSECTION BETWEEN PIPE LINE AND THE ROAD / HISGHWAY SHALL BE AS CLOSE TO 900 AS POSSIBLE, BUT IN NO CASE LESS THAN 300. 12. JACKING / BORE THRU TECHNIQUE SHALL BE USED FOR THE CROSSING UNLESS SPECIFIED OTHERWISE. 13. FOR VENT, DRAIN AND CASING PIPE DETAILS, REFER RELEVENT SPECIFICATIONS / DRAWINGS / STANDARDS.


PIPE LINE ROAD / HIGHWAY CASED CROSSING


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NOTES: 1. ALL DIMENSIONS ARE IN mm, UNLESS SPECIFIED OTHERWISE. 2. SINGLE SAG CROSSING SHALL NORMALLY BE USED WHERE THERE IS NO EVIDENCE OF EROSION OF BANKS AND SCOURING OR SHIFTING OF STREAM BOITOM AND WHERE BED WIDTH DOES NOT PROHIBIT ITS USE. 3. DOUBLE SAG CROSSING SHALL BE USED WHERE THERE IS EVIDENCE OF EROSION OF BANKS, SCOURING OR SHIFTING OF STREAM BOTTOM.


DOCUMENT NO. TYPICAL STREAM CROSSING

S-04-01-021

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4. IN DOUBLE SAG CROSSING, GENERALLY COLD FIELD BENDS SHALL BE USED. USE OF FACTORY MADE R=6D BENDS SHALL BE MINIMIZED. R=6D BENDS SHALL BE USED ONLY WITH PRIOR APPROVAL OF COMPANY. 5. UNLESS OTHERWISE SPECIFIED, THE MINIMUM COVER OVER THE PIPE MEASURED BELOW THE LOWEST BED LEVEL SHALL BE 1500 MM. 6. THE TYPE AND EXTENT OF BUOYANCY CONTROL MEASURES SHALL BE AS PER SPECIFICATION AND AS DIRECTED BY COMPANY FOR INDIVIDUAL CROSSING AND SHALL BE SHOWN ON THE AUGNMENT SHEETS. 7. THE FILL AT THE BANKS SHALL BE TAMPED FIRMLY AND REINFORCED WITH SACKED EARTH, LEAN CONCRETE, RIP RAP OR BY OTHER MEANS AS DIRECTED BY COMPANY. ADDITIONAL BANK PROTECTION MEASURES AS PER SPECIFICATIONS SHALL BE ADOPTED WHEN THERE IS EVIDENCE OF EROSION AND SLUMPING OF BANKS OR WHEN THE BANKS ARE STEEP. 8. THE LOCATON OF CROSSING SWLL BE IN A LONG STRAIGHT STRDCH OF THE STREAM IF POSSIBLE. 9. EXACT POSITION AND ANGLE OF COLD BENDS SHALL BE DETERMINED IN FIELD. 10. AFER INSTALLATION OF THE CROSSING, THE WATER COURSE SHALL BE RESTORED TO ITS ORIGINAL CONDITION TO THE ENTIRE SATISFACTION OF THE AUTHORITIES HAVING JURISDICTION OVER THE SAME. WHERE THE EXCAVATED MATERIAL IS UNSUITABLE, TRENCH SHALL BE BACKFILLED WITH MATERIAL APPROVED BY COMPANY. 11. WIDTH OF CROSSING SHALL BE THAT CORRESPONDING TO THE HIGHEST WATER LEVEL. THE HIGHEST WATER LEVEL SHALL BE DETERMINED BASED ON THE FOLLOWING: (i)

HISTORICAL RECORDS (TO THE EXTENT AVAILABLE)

(ii)

BANK CONDITION VIS-A-VIS EROSION, ETC.

(iii)

EVIDENCE OF EXTINCTION OF VEGITATION ALONG BANKS.

(iv)

DISCUSSIONS WITH LOCAL PEOPLE.

12. THE NUMBER OF WARNING SIGNS SHALL BE a.

1 (ONE) FOR CROSSINGS LESS THAN 15 M WIDTH AT UP STREAM BANK

b.

2 (TWO) FOR CROSSINGS ABOVE 15 M WIDTH.

13. STRAIGHT LENGTH OF PIPE SHALL BE USED AT LEAST FOR THE ENTIRE WIDTH OF CROSSING. 14. CONTRACTOR SHALL VERIFY THE ACTUAL DIMENSIONS WITH RESPECT TO SURVEY DETAILS FOR EACH CROSSING AND WHEN DIRECTED BY COMPANY, CONTRACTOR SHALL PREPARE DETAILED DRAWINGS FOR INDIVIDUAL CROSSINGS FOR COMPANY APPROVAL BEFORE COMMENCEMENT OF CONSTRUCTION.


DOCUMENT NO. TYPICAL STREAM CROSSING

S-04-01-021

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DOCUMENT NO. TYPICAL SLOPE BREAKER DETAILS

S-04-01-022

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NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 2. SLOPE BREAKER BAGS TO BE GUNNY BAGS FILLED WITH 10:1 SAND:PORTLAND CEMENT MIXTURE. 3. HIGHEST SLOPE BREAKER TO BE PLACED 2.0 M FROM THE OVER-BEND AND THE LOWEST SLOPE BREAKERS TO BE PLACED 2.0 M FROM THE SAG BEND. 4. DISTANCE “L” BETWEEN BREAKERS AND NUMBER OF LAYERS OF BAGS (IN VERTICAL DIRECTION) FOR SLOPE BREAKER SHALL BE DECIDED ON CASE TO CASE BASIS DEPENDING UPON SLOPE OF THE GROUND AND CHARACTERSTICS OF SOIL BAGS. BAGS SHALL BE PLACED IN SUCH A MANNER SO AS TO HAVE A STABLE ARRANGEMENT. HOWEVER, DISTANCE “L” SHALL NOT EXCEED 7 M. 5. BAGS TO BE PLACED VERTICAL IN THE TRENCH AND NOT IN 900 TO THE PLANE OF PIPE.



S-04-01-022


6. BREAKERS SHALL BE INSTALLED IN STEEP SLOPE AREAS (GENERALLY SLOPE 10% OR MORE) AS SHOWN IN DRAWINGS AND WHEREVER INSTRUCTED BY ENGINEER-IN-CHARGE. 7. TOP LAYER OF TRENCH SHALL BE BACKFILLED WITH SOIL OR CRUSHED ROCK (EXCAVATED MATERIAL). 8. THE REMAINING TRENCH AREA SHALL BE BACKFILLED AS REQUIRED. 9. WHERE ROCK, GRAVEL, LUMPS OF HARD SOIL OR LIKE MATERIALS ARE ENCOUNTERED, SELECT BACKFILL MATERIALS LIKE SOIL, CLAY OR OTHER MATERIALS CONTAINING NO GRAVEL, ROCK OR LUMPS OF HARD SOIL SHALL BE PLACED AROUND THE PIPE.



S-04-01-022



BANK PROTECTION DETAILS FOR WATER CROSSINGS


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NOTES: 1. ALL DIMENSIONS ARE IN MM. 2. MATTRESSES SHALL BE INSTALLED AFTER COMPLETION OF GRADING. 3. IF MORE THAN ONE MATTRESSIS USED, ADJACENT MATTRESSES SHALL BE LACED TOGETHER. 4. DIMENSIONS ‘X’ SHALL BE 2 M OR 10 M AS PER STANDARD SPECIFICATIONS S-04-02-026 AND S-04-02-027. INSTALLATION PROCEDURE: 1. OPEN MESH BUNDLE AND STRETCH OUT BASE PANEL. 2. LACE TOGETHER THE SIDE, END PANELS AND DIAPHRAGM. 3. FILL WITH GRADED STONES OF 75-150 MM 4. LACE TOP PANEL TO THE SIDE AND END PANELS AND DIAPHRAGMS. 5. ANCHOR THE TOP MATTRESS. GAIL (INDIA) LTD NEW DELHI



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DOCUMENT NO. TYPICAL DETAILS OF RAILWAY CROSSING

S-04-01-024


NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 2. CATHODIC PROTECTION TEST LEADS TERMINAL BOX MAY BE MOUNTED ON THE VENT PIPE. FOR CP LEAD TERMINAL BOX DETAILS REFER RELEVANT STD./ SPECIFICATION. 3. AT EACH CROSSING, A PIPELINE WARNING SIGN SHALL BE INSTALLED ON EITHER SIDE OF CROSSING. WARNING SIGN PLATE MAY BE MOUNTED ON THE VENT PIPE. 4. REFER API RP 1102 FOR OTHER DESIGN AND INSTALLATION REQUIREMENTS. 5. ELECTRICAL INSULATION BETWEEN CASING AND CARRIER PIPES SHALL BE CHECKED WITH SUITABLE MEGGER. 6. AFTER INSTALLATION OF CASING AND CARRIER PIPES, THE AREA SHALL BE RESTORED TO THE SATISFACTION OF THECONCERNED AUTHORITIES/COMPANY.



S-04-01-024


7. CASING PIPE SHALL BE AS PER SCOPE OF WORK AND SOR. 8. CONTRACTOR SHALL VERIFY THE ACTUAL DIMENSIONS WITH RESPECT TO SURVEY DETAILS FOR EACH CROSSING AND PREPARE DETAILED DRAWINGS FOR COMPANY'S / CONCERNED AUTHORITY'S APPROVAL BEFORE COMMENCEMENT OF CONSTRUCTION. 9. PIPELINE SECTION SHALL BE PRE-TESTED HYDROSTATICALLY, SEPARATELY FROM THE MAIN LINE TESTING WHEN REQUIRED BY THE AUTHORITIES CONCERNED AND/OR AS DIRECTED BY THE COMPANY. 10. ANGLE OF INTERSECTION BETWEEN PIPELINE AND RAILWAY SHALL BE AS CLOSE TO 900 AS POSSIBLE BUT IN NO CASE LESS THAN 850. 11. CASING PIPE SHALL BE EXTENDED FOR A DISTANCE OF UPTO 14.00m FROM CENTRE LINE OF OUTERMOST RAILWAY TRACK OR 0.6m BEYOND RAILWAY ROW LIMITS ON EITHER SIDE, WHICHEVER IS MORE. 12. JACKING / BORE THRU' TECHNIQUE SHALL BE USED FOR THE CROSSING. 13. SEPARATE C.S. CONDUIT FOR OFC SHALL BE INSTALLED AT MINIMUM DISTANCE FROM CASING FOR CARRIER PIPE, IF SPECIFIED. 14. ALL CARRIER PIPE JOINTS SHALL BE RADIOGRAPHED. 15. COATING OF CASING PIPE SHALL BE AS PER REQUIREMENT OF AUTHORITIES. 16. FOR VENT, DRAIN, CASING PIPE, INSULATORS, INSULATOR SPACING, CASING END SEASL ETC. REFER RELEVENT STANDARDS (S-04-01-007 & S-04-01-008)



S-04-01-024


NOTES: 1. ALL DIMENSIONS ARE IN MM. 2. SELECT BACK FILL MUST HAVE MIN. AS PLACED DRY DENSITY OF 1800 KG/M3. IF FOUND NECESSARY IN FIELD, THE SELECT BACK FILL SHALL BE COMPACTD TO ACHIEVE A DRY DENSITY OF MIN. 1800 KG/M3.


SELECT BACK FILL FOR STATION APPROACH


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3. MINIMUM PIPE LINE COVER SHALL BE 1000 MM. ANY EXTRA COVER REQUIREMENT SHALL BE IN ACCORDANCE WITH SPECIFICATIONS / STANDARDS / DRAWINGS. 4. MINIMUM COVER REQUIREMENT SHALL BE SUBJECT TO APPROVAL OF CONCERNED AUTHORITIES WHEREVER REQUIRED. 5. FOR MINIMUM COVER REQUIREMENT AT PIPELINE CROSSING ROADS, RAILWAY TRACKS, RIVERS, MARSHY AREAS ETC. REFER GAIL STANDARDS / DRAWINGS. 6. TRENCH CROSS SECTION SHALL BE VIEWED IN DIRECTION OF FLOW.


SELECT BACK FILL FOR STATION APPROACH


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SLOPE STABILIZATION IN GHAT / HILL AREAS


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NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 2. FOR ALL PIPELINES TO BE CONSTRUCTED IN THE LAND, MINIMUM COVER SHALL BE 1000 MM. ANY EXTRA COVER REQUIREMENT SHALL BE IN ACCORDANCE WITH SPECIFICATIONS / STANDARDS / DRAWINGS. 3. MINIMUM COVER REQUIREMENT SHALL BE SUBJECT TO APPROVAL OF CONCERNED AUTHORITIES WHEREVER REQUIRED. 4. FOR MINIMUM COVER REQUIREMENT AT PIPELINE CROSSING ROADS, RAILWAY TRACKS, WATER BODIES, MARSHY AREAS ETC. REFER GAIL STANDARDS. 5. SUITABLE DRAIN SHALL BE PROVIDED PARALLEL, ALL ALONG THE PIPE LINE TRENCH AND ACROSS AT EVERY 250 M.


SLOPE STABILIZATION IN GHAT / HILL AREAS


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SOIL STABILIZATION IN HILLY AREAS


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NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 2. MATTRESSES SHALL BE INSTALLED AFTER COMPLETION OF GRADING. 3. IF MORE THAN ONE MATTRESSIS USED, ADJACENT MATTRESSES SHALL BE LACED TOGETHER. INSTALLATION PROCEDURE: 1. OPEN MESH BUNDLE AND STRETCH OUT BASE PANEL. 2. LACE TOGETHER THE SIDE, END PANELS AND DIAPHRAGM. 3. FILL WITH GRADED STONES OF 75-150 MM 4. LACE TOP PANEL TO THE SIDE AND END PANELS AND DIAPHRAGMS. 5. ANCHOR THE TOP MATTRESS.




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NOTES: 1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE SPECIFIED. 2. CATHODIC PROTECTION TEST LEADS TERMINAL BOX MAY BE MOUNTED ON THE VENT PIPE. THE NUMBER OF WARNING SIGNS SHALL BE: a. b.

1 (ONE) FOR CROSSINGS LESS THAN 15 M WIDTH. 2 (TWO) FOR CROSSINGS ABOVE 15 M WIDTH.

3. FOR SYMBOLS, TRENCH DIMENSIONS, ROW DETAILS, MARKER ETC. REFER RELEVANT JOB STANDARDS. 4. ELECTRICAL INSULATION BETWEEN CASING AND CARRIER PIPES SHALL BE CHECKED WITH SUITABLE MEGGER. 5. AFTER INSTALLATION OF CASING AND CARRIER PIPES, THE CANAL SHALL BE RESTORED TO THE SATISFACTION OF THE CONCERNED AUTHORITIES/COMPANY. 6. CASING PIPE SHALL BE AS PER SCOPE OF WORK AND SOR. 7. CONTRACTOR SHALL VERIFY THE ACTUAL DIMENSIONS WITH RESPECT TO SURVEY DETAILS FOR EACH CANAL CROSSED AND PREPARE DETAILED DRAWINGS FOR COMPANY'S / CONCERNED AUTHORITY'S APPROVAL BEFORE COMMENCEMENT OF CONSTRUCTION. 8. PIPELINE SECTION SHALL BE PRE-TESTED HYDROSTATICALLY, SEPARATELY FROM THE MAIN LINE TESTING WHEN REQUIRED BY THE CONCERNED AUTHORITIES AND/OR AS DIRECTED BY THE COMPANY REPRESENTATIVE. 9. SEPARATE CASING PIPES SHALL BE INSTALLED FOR OFC AT MINIMUM DISTANCE FROM CASING FOR CARRIER PIPE, IF SPECIFIED. GAIL (INDIA) LTD NEW DELHI

TYPICAL LINED CANAL CASED CROSSING DETAIL


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10. JACKING/BORE THRU' TECHNIQUE SHALL BE USED FOR THE CROSSING. 11. ALL PIPELINE JOINTS SHALL BE RADIOGRAPHED. 12. FOR DRAIN, VENT, CASING PIPE, INSULATOR, INSULATOR SPACING, END SEALS ETC. REFER RELEVENT STANDARD / SPECIFICATIONS.


TYPICAL LINED CANAL CASED CROSSING DETAIL


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NOTES: 1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE SPECIFIED. 2. CANAL CROSSING SHALL BE RESTORED TO ORIGINAL CONDITION TO THE SATISFACTION OF COMPANY AND CONCERNED AUTHORITIES HAVING JURISDICTION.

ENTIRE

3. THE NUMBER OF WARNING SIGNS SHALL BE: a. b.

1 (ONE) FOR CROSSING LESS THAN 15 M WIDTH. 2 (TWO) FOR CROSSINGS ABOVE 15 M WIDTH.

4. FOR SYMBOLS, TRENCH DIMENSIONS, ROW DETAILS, MARKERS ETC. REFER RELEVENT JOB STANDARDS. 5. ANGLE OF INTERSECTION BETWEEN PIPELINE AND THE CANAL SHALL BE AS CLOSE TO 900 AS POSSIBLE IN NO CASE LESS THAN 300. 6. IN CASE PIPELINE COATING IS LIABLE TO DAMAGE WHILE BORING / JACKING, A PROTECTIVE COATING OVER CORROSION COATING OF SUITABLE MATERIAL (APPROVED BY COMPANY) SHALL BE PROVIDED AS DIRECTED BY ENGINEER-IN-CHARGE. 7. CONTRACTOR SHALL VERIFY THE ACTUAL DIMENSIONSWITH RESPECT TO SURVEY DETAILS FOR EACH CANAL CROSSED AND PREPARE DETAILED DRAWINGS FOR COMPANY’S / CONCERNED AUTHORITY’S APPROVAL BEFORE COMMENCEMENT OF CONSTRUCTION.


TYPICAL LINED CANAL UNCASED CROSSING DETAIL


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NOTES: 1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE SPECIFIED. 2. A DRAIN SHALL BE PROVIDED TO DRAIN OFF WATER FROM ROU. THIS DRAIN SHALL BE CONNECTED TO THE NEAREST STREAM/NALA. CROSS DRAINS SHALL ALSO BE PROVIDED AT SUITABLE LOCATIONS AS PER INSTRUCTIONS OF ENGINEER-IN-CHARGE. 3. WHENEVER THE PIPELINE IS CROSSING ANY STREAM/ NALA, ENTIRE WIDTH OF SUCH STREAM/ NALA SHALL BE PROVIDED WITH A MINIMUM 100 MM THICK LAYER OF PCC TO PREVENT SOIL WASH OFF DURING RAINS. THE PCC LAYER SHALL COVER THE ENTIRE WIDTH OF PREPARED ROU. 4. REFER APPLICABLE STANDARD/ DRAWINGS FOR DETAILS OF OFC. 5. FOR TRENCH DETAILS REFER STD. NO. S-04-01-002. 6. THE BACKFILLING OF THE TRENCH AND OTHER TRENCH STABILIZATION MEASURES SHALL BE AS INDICATED IN APPROVED FOR CONSTRUCTION ALIGNMMENT SHEETS OR AS DIRECTED BY ENGINEER-IN-CHARGE. 7. RESTORATION OF ROU SHALL BE CARRIED OUT AS PER THE INSTRUCTIONS OF ENGINEER-INCHARGE.


TYPICAL CROSS SECTION FOR ROU PREPARATION IN HILL AREAS


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JACK SCREW FOR SPECTACLE BLIND FIG 8 (150#, 300#, 600# RF)

STANDARD S-05-01-001

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JACK SCREW FOR SPACERS AND BLINDS (150#, 300#, 600# RF)


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VENTS AND DRAINS (ON LINES 1-1/2” AND BELOW)


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VENTS AND DRAINS (ON LINES 2” AND ABOVE)


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WELLS INSTALLATION 1-1/2” DIA TAPS


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WELLS INSTALLATION 1-1/2” DIA TAPS


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PRESSURE TAPPING (PA, PG, PC, PT, PIC ETC)


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DIMESIONS FOR HANDLE PROJECTION FOR SPACERS AND BLINDS: ½” – 24” NB (150#, 300#, 600# FF)


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T – STRAINER TYPE-1 2” – 4” (150# RF, 300# RF AND RTJ, 600# RF AND RTJ)


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T – STRAINER TYPE-1 6” – 24” (150# RF, 300# RF AND RTJ, 600# RF AND RTJ)


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DOCUMENT NO. ORIENTATION OF ORIFICE TAPS

S-05-01-010

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DOCUMENT NO. STUB-IN STANDARD

S-05-01-011

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DOCUMENT NO. STUB-IN STANDARD

S-05-01-011

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WELDING OF PIPEWITH DIFFERENT THICKNESS


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DOCUMENT NO. FILLET WELD DETAILS

S-05-01-013

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WELDING DETAILS FOR BRANCH CONNECTION


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METHOD OF CUTTING AND DIMENSIONS OF FIELD MANUFACTURED CONCENTRIC REDUCERS


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NOTES: A. ±3 MM MAX. FROM INDICATED DIMENSIONS FOR FACE TO FACE, CENTER TO FACE LOCATION OF THE ATTACHMENTS ETC. TOLERENCE CAN NOT BE ADDED. B. ± 1.5 MM MAX. LATERAL TRANSLATION IN ANY DIRECTION FROM THE INDICATED POSITION. C. ± 1.5 MM MAX. ROTATION FROM THE INDICATED POSITION, MEASURED AS SHOWN. D. ± 1 MM MAX. OUT OF ALIGNMENT FROM THE INDICATED POSITION MEASURED ACROSS ANY DIAMETER AS SHOWN. GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. TOLERENCE FOR FABRICATION

S-05-01-016

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E. FLATTENING, MESAURED AS DIFFERENCE BETWEEN MAX. AND MIN. OD AT ANY CROSS SECTION. -3% MAX. FOR PIPE WITH EXTERNAL PRESSURE. 8% MAX. FOR PIPE WITH INTERNAL PRESSURE.


DOCUMENT NO. TOLERENCE FOR FABRICATION

S-05-01-016

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MATERIAL: SHOE INSULATION THK. UP TO 75 76 TO 125 126 TO 175 GUIDE PLATE: IS 2062


H 100 150 200

SHOE SIZE A B C

CUT FROM ISMB 200 300 400

PIPE SHOE FOR HOT INSULATED CS PIPE , SIZE 2” THRU 8” TYPE - S1 (FOR TEMP.UPTO 3430C)

X 44 46 49


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MAXIMUM ALLOWABLE LOAD ON FILLET WELD OF RESTRAINT (KG/CM) TEMPERATURE IN DEG C WELD SIZE (MM) 200 250 300 6 340 250 220 8 450 340 300 10 560 420 370

350 200 270 330

NOTE: 1. LOADS ON FILLET WELDS OF GUIDE / CROSS GUIDE / ANCHOR SHALL BE LIMITED TO VALUES TABULATED ABOVE AGAINST VARIOUS TEMPERATURES, FOR RESPECTIVE WELD SIZE, RUNNING LENGTH OF WELD. LOADS MAY BE INTERPOLATED FOR INTERMEDIATE TEMPERATURES. 2. SHOE LENGTH SHALL BE TAKEN AS 300 MM FOR FIG. 1,2,3 AND 6 AND 400 MM FOR FIG. 4 AND 5, UNLESS SPECIFIED OTHERWISE. FOR FIG. 1, 2 OR 3, FOR AXIAL MOVEMENTS EXCEEDING 100 MM, SHOE LENGTH SHALL BE INCREASED ACCORDINGLY. 3. FOR FIG. 3 & 4, IF THE REQUIRED GUIDE GAP IS MORE THAN 3 MM, THE DIMENSIONS OF GUIDE PLATE SHALL BE SUITABLY MODIFIED. 4. GUIDE PLATES SHALL BE WELDED ON BOTH SIDES. 5. FOR CROSS GUIDES IN FIG. 4 & 5, LENGTH OF ANGLE SHALL BE SAME AS SHOE WIDTH. 6. IN CASE OF BEAM TYPE SUPPORTED STEEL, PLATES SHALL BE PROVIDED ON BOTH SIDES AS SHOWN IN FIG. 5. HEIGHT OF PLATE SHALL BE BASED ON SIZE OF THE SUPPORTING STEEL MEMBER. 7. LONGITUDINAL PIPE MOVEMENT NOT TO EXCEED 150 MM AND SHOE LENGTH NOT TO EXCEED 400 MM.


PIPE SHOE FOR HOT INSULATED CS PIPE , SIZE 2” THRU 8” TYPE - S1 (FOR TEMP.UPTO 3430C)


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Note: 1. LOADS ON FILLET WELD OF GUIDES / CROSS-GUIDE / ANCHOR SHALL BE LIMITED TO THE VALUES TABULATED AGAINST VARIOUS TEMPERATURES FOR THE RESPECTICE WELD SIZE, FOR RUNNING LENGTH OF WELD. LOADS MAY BE INTERPOLATED FOR INTERMEDIATE TEMPERATURES. 2. SHOE LENGTH SHALL BE TAKEN AS 300MM FOR FIG. 1,2,3 AND 6 AND AS 400MM FOR FIG. 4 AND 5, UNLESS SPECIFIED OTHERWISE. FOR FIG. 1,2 OR 3, FOR AXIAL MOVEMENT EXCEEDING 100MM, SHOE LENGTH SHALL BE INCREASED CORRESPONDINGLY.


PIPE SHOE FOR HOT INSULATED CS PIPE , SIZE 10” THRU 30” TYPE – S2 (FOR TEMP.UPTO 3430C)


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3. FOR FIG. 3 AND 4, IF THE REQUIRED GUIDE-GAP IS MORE THAN 3MM, DIMENSIONS OF THE GUIDE PLATE SHALL BE SUITABLE MODIFIED. 4. GUIDEPLATES SHALL BE WELDED ON BOTH SIDES. 5. FOR CROSS GUIDE IN FIG. 4 AND 5, LENGTH OF ANGLE SHALL BE SAME AS SHOE WIDTH. 6. IN CASE OF BEAM TYPE OF SUPPORTING STEEL, PLATES SHALL BE PROVIDED ON BOTH SIDES AS SHOWN IN FIG. 5. HEIGHT OF PLATE SHALL BE BASED ON THE SIZE OF THE SUPPORTING STEEL BEAM. 7. FOR FIG. 4 AND 5, IF THE VERTICALMOVEMENT IS 15MM, PROVIDE 3 NO.S OF GUSSET PLATES (IS-2062) EQUALLY SPACED. 8. LONGITUDINAL PIPE MOVEMENT NOTTO EXCEED 150MM AND SHOE LENGTH NOT TO EXCEED 400MM. 9. PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR ROLLED FROM PLATE OF MATERIAL EQUIVALENT TO THAT OF PIPE. THICKNESS OF PROTECTION SHIELD SHALL BE SAME AS THAT OF LINE PIPE OR 12MM, WHICHEVER IS LESS.


PIPE SHOE FOR HOT INSULATED CS PIPE , SIZE 10” THRU 30” TYPE – S2 (FOR TEMP.UPTO 3430C)


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MAXIMUM ALLOWABLE LOAD ON FILLET WELD OF RESTRAINT (KG/CM) TEMPERATURE IN DEG C WELD SIZE (MM) 200 250 300 6 340 250 220 8 450 340 300 10 560 420 370


PIPE SADDLE FOR CS BARE PIPE, SIZE 14” THRU 48”, TYPE – S6A (FOR TEMP. UP TO 3430C)

350 200 270 330


REV-0 Page 1 of 2


NOTE: 1. LOADS ON FILLET WELDS OF GUIDE / CROSS GUIDE / ANCHOR SHALL BE LIMITED TO VALUES TABULATED ABOVE AGAINST VARIOUS TEMPERATURES, FOR RESPECTIVE WELD SIZE, RUNNING LENGTH OF WELD. LOADS MAY BE INTERPOLATED FOR INTERMEDIATE TEMPERATURES. 2. IN CASE THE PIPE SCHEDULE IS NOT THE SAME AS TABULATED ABOVE, THE DIMENSIONS ‘A’ AND ‘h’ SHALL BE MODIFIED ACCORDINGLY. 3. PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR ROLLED FROM PLATE OF MATERIAL EQUIVALENT TO THAT OF PIPE. THICKNESS OF PROTECTION SHIELD SHALL BE SAME AS LINE PIPE OR 12 MM WHICHEVER IS LESS. 4. GUIDE PLATES SHALL BE OF IS-2062. THEY SHALL BE WELDED ON BOTH SIDES. 5. IN CASE OF SIZE REDUCTION (S) IN STRAIGHT RUN WITH BOP, PROTECTION SHIELS THICKNESS FOR ALL SIZES SHALL BE EQUAL TO THAT FOR THE LARGEST DIAMETER PIPE.


PIPE SADDLE FOR CS BARE PIPE, SIZE 14” THRU 48”, TYPE – S6A (FOR TEMP. UP TO 3430C)


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PIPE SHOE FOR HOT INSULATION EXCEEDING 175MM / SLOPE LINE PIPE, SIZE 2” THRU 6” TYPE – S9A / S9B / S9C


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Note: 1. LOADS ON FILLET WELD OF GUIDES / CROSS-GUIDE / ANCHOR SHALL BE LIMITED TO THE VALUES TABULATED AGAINST VARIOUS TEMPERATURES FOR THE RESPECTICE WELD SIZE, FOR RUNNING LENGTH OF WELD. LOADS MAY BE INTERPOLATED FOR INTERMEDIATE TEMPERATURES. 2. SHOE LENGTH SHALL BE TAKEN AS 300MM FOR FIG. 1,2,3 AND 6 AND AS 400MM FOR FIG. 4 AND 5, UNLESS SPECIFIED OTHERWISE. FOR FIG. 1,2 OR 3, FOR AXIAL MOVEMENT EXCEEDING 100MM, SHOE LENGTH SHALL BE INCREASED CORRESPONDINGLY. 3. FOR FIG. 3 AND 4, IF THE REQUIRED GUIDE-GAP IS MORE THAN 3MM, DIMENSIONS OF THE GUIDE PLATE SHALL BE SUITABLE MODIFIED. 4. GUIDEPLATES SHALL BE WELDED ON BOTH SIDES. 5. FOR CROSS GUIDE IN FIG. 4 AND 5, LENGTH OF ANGLE SHALL BE SAME AS SHOE WIDTH. 6. IN CASE OF BEAM TYPE OF SUPPORTING STEEL, PLATES SHALL BE PROVIDED ON BOTH SIDES AS SHOWN IN FIG. 5. HEIGHT OF PLATE SHALL BE BASED ON THE SIZE OF THE SUPPORTING STEEL BEAM. 7. LONGITUDINAL PIPE MOVEMENT NOTTO EXCEED 150MM AND SHOE LENGTH NOT TO EXCEED 400MM. 8. PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR ROLLED FROM PLATE OF MATERIAL EQUIVALENT TO THAT OF PIPE. THICKNESS OF PROTECTION SHIELD SHALL BE SAME AS THAT OF LINE PIPE OR 12MM, WHICHEVER IS LESS.


PIPE SHOE FOR HOT INSULATION EXCEEDING 175MM / SLOPE LINE PIPE, SIZE 2” THRU 6” TYPE – S9A / S9B / S9C


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LOW SUPPORT SLIDING FOR BARE AND INSULATED PIPE, SIZE 2” THRU 36” TYPE – L1 AND L1A


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NOTE: 1. INSERT AND SLIDING PLATE MATERIAL SHALL BE CARBON STEEL WHER TEMP. IS ≥4000C WITH h ≤ 200 MM. SLIDING PLATE MATERIAL SHALL BE EQUIVALENT TO PIPE MATERIAL. 2. DIMENSION ‘M’ LOCATES THE POINT OF MATERIAL TRANSITION ON THE SUPPORT. THE STUB MATERIAL SHALL BE EQUIVALENT TO THAT OF LINE PIPE AND THE LOWER SUPPORT PIPE SHALL BE CARBON STEEL. MINIMUM VALUE OF ‘M’ SHALL BE ‘INSULATION THICKNESS + 25 MM’. A. B.

FOR CARBON STEEL LINE PIPE, THE ENTIRE SUPPORT PIPE SHALL BE CS I.E. M=0. FOR ALLOY STEEL / STAINLESS STEEL LINE PIPE, SUPPORT PIPE SHALL CONSIST OF THE FOLLOWING: 

FOR h≤ 500 MM, ENTIRE SUPPORT PIPE MATERIAL SHALL BE EQUIVALENT TO THAT OF LINE PIPE I.E. M = h. FOR h > 500 MM, SUPPORT PIPE SHALL BE COMPOSITE WITH ‘M = INSULATION THICKNESS + 25 MM ‘ OR 100 MM WHICHEVER IS GREATER.



3. IN CASE SIZE AND / OR SCHEDULE OF SUPPORT PIPE (D1) LISTED IN THE TABLE IS NOT AVAILABLE USE NEXT HIGHER SIZE AND / OR NEAREST HIGHER THICKNESS AVAILABLE. 4. PROTECTION SHIELD (LENGTH = K MM) CUT FROM LINE PIPE OR EQUIVALENT PLATE SHALL BE PROVIDED ON HORIZONTAL LINE AS FOLLOWS: A.

FOR CLASS #150 & #300 PIPING: CS & AS LINES SS LINES -

B.

10” AND ABOVE 2” AND ABOVE

FOR CLASS #600 AND HIGHER CS, AS AND SS -

10” AND ABOVE

5. DIMENSION ‘C’ IS TO BE MODIFIED IF OTHER THAN R=1.5D ELBOWS ARE USED. 6. IN CASE CLACULATED h EXCEEDS THE MAXIMUM VALUE, PEDESTAL SHALL BE RAISED ACCORDINGLY.


LOW SUPPORT SLIDING FOR BARE AND INSULATED PIPE, SIZE 2” THRU 36” TYPE – L1 AND L1A


REV-0 Page 2 of 2


NOTE: 1.

FOR THE APPLICABLE SIZE NOS., DIMENSIONS TABLE AND NOTES, REFER GAIL STANDARD S-05-01-021.

2.

REFER VIEW A-A OF GAIL STANDARD S-05-01-021.


LOW SUPPORT FIXED FOR BARE AND INSULATED PIPE, SIZE 2” THRU 36” TYPE – L3 AND L3A


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LOW SUPPORT SLIDING FOR BARE PIPE SIZE 3/4” THRU 36”, TYPE – L5 AND L5A (FOR TEMP. UP TO 4000C)


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NOTE: 1.

WELDED ATTACHEMENT (6MM THICK) REQUIRED ONLY IN CASE OF STAINLESSSTEEL / ALLOY STEEL LINE PIPE. MATERIAL OF WELDED ATTACHMENT SHALL BE SAME AS THAT OF LINE PIPE.


LOW SUPPORT SLIDING FOR BARE AND INSULATED PIPE, SIZE 2” THRU 36”, TYPE – L6


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2.

PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR EQUIVALENT PLATE AND SHALL BE AS PER VIEW A-A OF GAIL STANDARD S-05-01-021.

3.

FOR LINE TEMPERATURES UP TO 4000C, CONNECTING PLATE SHALL BE CARBON STEEL. FOR HIGHER TEMPERATURES IT SHALL BE SAME AS THAT OF LINE PIPE.

4.

IN CASE CALCULATED H/h EXCEEDS THE MAXIMUM VALUE, PEDESTAL SHALL BE RAISED ACCORDINGLY.


LOW SUPPORT SLIDING FOR BARE AND INSULATED PIPE, SIZE 2” THRU 36”, TYPE – L6


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(PLEASE REFER NOTES MENTIONED IN NEXT PAGE)


LOW SUPPORT FIXED / RESTRAINED FOR BARE AND INSULATED PIPE, SIZE 2” THRU 36”, TYPE – L7 AND L7A


REV-0 Page 1 of 3


NOTE: 1.

WELDED ATTACHEMENT (6MM THICK) REQUIRED ONLY IN CASE OF STAINLESSSTEEL / ALLOY STEEL LINE PIPE. MATERIAL OF WELDED ATTACHMENT SHALL BE SAME AS THAT OF LINE PIPE.




REV-0 Page 2 of 3


2.

PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR EQUIVALENT PLATE AND SHALL BE AS PER VIEW A-A OF GAIL STANDARD S-05-01-021.

3.

FOR LINE TEMPERATURES UP TO 4000C, CONNECTING PLATE SHALL BE CARBON STEEL. FOR HIGHER TEMPERATURES IT SHALL BE SAME AS THAT OF LINE PIPE.

4.

IN CASE CALCULATED H/h EXCEEDS THE MAXIMUM VALUE, PEDESTAL SHALL BE RAISED ACCORDINGLY.




REV-0 Page 3 of 3


NOTE: 1.

FOR THE APPLICABLE SIZE NOS., DIMENSION TABLE, NOTES AND VIEW A-A, REFER GAIL STANDARD S-05-01-021.


RESTRAINED LOW SUPPORT FOR BARE AND INSULATED PIPE, SIZE 2” THRU 36”, TYPE – L8 AND L8A


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INSTALLATION PROCEDURE: 1.

PLACE SUPPORT UNDER PIPE BEFORE CONNECTING PIPE TO EQUIPMENT. TURN ADJUSTING NUT UNTIL PIPE FLANGE IS ALIGNED WITH EQUIPMENT OR VALVE FLANGE.

NOTES: 1.

ALL PLATES SHALL BE CARBON STEEL WHERE DESIGN TEMPERATURE ≥ 4000C WITH h≤ 200mm. BASE PLATE MATERIAL SHALL BE EQUIVALENT TO PIPE MATERIAL.

2.

REFER NOTES 2, 4, 5 & 6 AND VIEW A-A OF GAIL STANDARD S-05-01-021.

3.

IN CASE SIZE AND / OR SCHEDULE OF SUPPORT PIPE (D1) LISTED IN TABLE ABOVE IS NOT AVAILABLE, USE THE NEXT HIGHER SIZE AND / OR NEARESR HIGHER THICKNESS AVAILABLE.

4.

HEX HEAD OF SLIDING BOLT TO BE GROUND SMOOTH.


ADJUSTABLE LOW SUPPORT SLIDING FOR BARE AND INSULATED PIPE, SIZE 2” THRU 6”, TYPE – L10 AND L10A


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NOTES: 1.

FOR DETAILS OF U-BOLT TYPE C-4, REFER GAIL STANDARD S-05-01-021.

2.

U-BOLT MATERIAL SHALL BE EQUIVALENT TO THAT OF LINE PIPE.


LOW SUPPORT SLIDING AND FIXED FOR BARE AND INSULATED PIPE, SIZE 3/4” THRU 1-1/2”, TYPE – L15


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3.

FOR DETAIL-M, FOR CARBON STEEL (CS) PIPE, USE CS ANGLE. IN CASE OF ALLOY STEEL / STAINLESS STEEL USE 6MM THK. PLATE MATERIAL EQUIVALENT TO THAT OF LINE PIPE.

4.

IN CASE CALCULATED H EXCEEDS THE MAXIMUM VALUE, THE PEDESTAL SHALL BE RAISED ACCORDINGLY.


LOW SUPPORT SLIDING AND FIXED FOR BARE AND INSULATED PIPE, SIZE 3/4” THRU 1-1/2”, TYPE – L15


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LOW SUPPORT STANCHION FOR BARE AND INSULATED CS / AS / SS PIPE, TYPE – L16


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NOTES: 1.

ALL PLATES SHALL BE CARBON STEEL.

2.

REFER NOTES 2, 4, 5 & 6 AND VIEW A-A OF GAIL STANDARD S-05-01-021.


ADJUSTABLE LOW SUPPORT WITH FOUR BOLTS FOR PIPE SIZES 8” THRU 24”, TYPE – L17 AND L17A


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3.



ADJUSTABLE LOW SUPPORT WITH FOUR BOLTS FOR PIPE SIZES 8” THRU 24”, TYPE – L17 AND L17A


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NOTES: 1.

ALL PLATES SHALL BE CARBON STEEL. THE STUB PIPE MATERIAL SHALL BE EQUIVALENT TO THAT OF LINE PIPE AND THE LOWER SUPPORT PIPE SHALL BE OF CARBON STEEL.

2.

REFER NOTES 4, 5 & 6 AND VIEW A-A OF GAIL STANDARD S-05-01-021.

3.



ADJUSTABLE LOW SUPPORT FOR BARE AND INSULATED PIPE, SIZES 2” THRU 24”, TYPE – L18 AND L18A


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NOTES: 1.

ALL PLATES SHALL BE CARBON STEEL. THE STUB PIPE MATERIAL SHALL BE EQUIVALENT TO THAT OF LINE PIPE AND THE LOWER SUPPORT PIPE SHALL BE OF CARBON STEEL.

2.

REFER NOTES 4, 5 & 6 AND VIEW A-A OF GAIL STANDARD S-05-01-021.


ADJUSTABLE LOW SUPPORT WITH GUIDE AND CROSS GUIDE FOR BARE AND INSULATED PIPE, SIZES 2” THRU 24”, TYPE – L19 AND L19A

DOCUMENT NO.

REV-0 Page 1 of 2

S-05-01-032 Copyright GAIL – All rights reserved

3.



ADJUSTABLE LOW SUPPORT WITH GUIDE AND CROSS GUIDE FOR BARE AND INSULATED PIPE, SIZES 2” THRU 24”, TYPE – L19 AND L19A

DOCUMENT NO.

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S-05-01-032 Copyright GAIL – All rights reserved


PIPE CLAMP FOR BARE CS / AS / SS PIPE, SIZE ½” THRU 24”, TYPE – C1


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U-BOLT FOR BARE CS PIPE, SIZE ½” THRU 24”, TYPE – C4 (FOR TEMP. UP TO 3430C)


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NOTES:

α TO BE GIVEN IN CASE SUPPORT IS WELDED TO VERTICAL

1.

REFERENCE LEVEL AND SUPPORT.

2.

DIMENSION “M” LOCATES THE POINT OF MATERIAL TRANSITION ON THE SUPPORT. THE STUB MATERIAL SHALL BE EQUIVALENT TO THAT OF LINE PIPE AND THE REST OF SUPPORT PIPE SHALL BE CARBON STEEL. MINIMUM VALUE OF “M” SHALL BE INSULATION THICKNESS + 25MM. 

FOR CARBON STEEL LINE PIPE, THE ENTIRE SUPPORT PIPE SHALL BE CARBON STEEL I.E. M=0.


DUMMY PIPE SUPPORT FOR BARE PIPE, SIZE 2” THRU 24”, TYPE-B39


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

3.

FOR ALLOY STEEL / STAINLESS STEEL LINE PIPE, SUPPORT PIPE SHALL CONSIST OF THE FOLLOWING: -

FOR (L-0.50) ≤ 500MM, ENTIRE SUPPORT PIPE MATERIAL SHALL BE EQUIVALENT TO THAT OF LINE PIPE I.E. M= (L-0.50).

-

FOR (L-0.50) > 500MM, SUPPORT PIPE SHALL BE COMPOSITE WITH M = 25MM + INSULATION THICKNESS OR 100MM WHICHEVER IS GREATER.

IN CASE SIZE AND / OR SCHEDULE OF SUPPORT PIPE (d) LISTED IN ABOVE TABLE IS NOT AVAILABLE, USE NEXT HIGHER SIZE AND / OR NEAREST HIGHER THIOCKNESS AVAILABLE.


DUMMY PIPE SUPPORT FOR BARE PIPE, SIZE 2” THRU 24”, TYPE-B39


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NOTES:

α TO BE GIVEN IN CASE SUPPORT IS WELDED TO VERTICAL

1.

REFERENCE LEVEL AND SUPPORT.

2.

DIMENSION “M” LOCATES THE POINT OF MATERIAL TRANSITION ON THE SUPPORT. THE STUB MATERIAL SHALL BE EQUIVALENT TO THAT OF LINE PIPE AND THE REST OF SUPPORT PIPE SHALL BE CARBON STEEL. MINIMUM VALUE OF “M” SHALL BE INSULATION THICKNESS + 25MM. 

FOR CARBON STEEL LINE PIPE, THE ENTIRE SUPPORT PIPE SHALL BE CARBON STEEL I.E. M=0. DOCUMENT NO. REV-0 DUMMY PIPE SUPPORT FOR GAIL (INDIA) LTD INSULATED PIPE, SIZE 2” THRU 24”, Page 1 of 2 S-05-01-036 NEW DELHI TYPE- B40 Copyright GAIL – All rights reserved



3.

FOR ALLOY STEEL / STAINLESS STEEL LINE PIPE, SUPPORT PIPE SHALL CONSIST OF THE FOLLOWING: -

FOR (L-0.50) ≤ 500MM, ENTIRE SUPPORT PIPE MATERIAL SHALL BE EQUIVALENT TO THAT OF LINE PIPE I.E. M= (L-0.50).

-

FOR (L-0.50) > 500MM, SUPPORT PIPE SHALL BE COMPOSITE WITH M = 25MM + INSULATION THICKNESS OR 100MM WHICHEVER IS GREATER.

IN CASE SIZE AND / OR SCHEDULE OF SUPPORT PIPE (d) LISTED IN ABOVE TABLE IS NOT AVAILABLE, USE NEXT HIGHER SIZE AND / OR NEAREST HIGHER THIOCKNESS AVAILABLE.


DUMMY PIPE SUPPORT FOR INSULATED PIPE, SIZE 2” THRU 24”, TYPE- B40


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DOCUMENT NO. PIPE SUPPORT BRACKETS, TYPE- B42

S-05-01-037

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GUIDE SUPPORT FOR BARE PIPE, SIZE ½” THRU 24”, TYPE- G1


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GUIDE SUPPORT FOR BARE PIPE, SIZE ½” THRU 24”, TYPE- G2 AND G2A (FOR TEMP. UP TO 3430C)


REV-0 Page 1 of 2


NOTES: 1.

LOADS ON FILLET WELDS OF GUIDES SHALL BE LIMITED TO THE VALUES TABULATED ABOVE AGAINST VARIOUS TEMPERATURES FOR RESPECTIVE WELD SIZE, FOR RUNNING LENGTH OF WELD. LOADS MAY BE INTERPOLATED FOR INTERMEDIATE TEMPERATURES.

2.

GUIDE PLATES / ANGLES SHALL BE WELDED ON BOTH SIDES.

3.

GUIDE ANGLES SHALL BE SUITABLY TRIMMED WHENEVER THEY ARE OBSTRUCTING ADJACENT GUIDE ANGLES.

4.

PROTECTION SHIELD SHALL BE PROVIDED ON ALL LINES 14” AND ABOVE. IT SHALL BE CUT FROM LINE PIPE OR ROLLED FROM PLATE OF MATERIAL EQUIVALENT TO LINE PIPE. THICKNESS OF PROTECTION SHIELD SHALL BE SAME AS LINE PIPE OR 12MM, WHICHEVER IS LESS.


GUIDE SUPPORT FOR BARE PIPE, SIZE ½” THRU 24”, TYPE- G2 AND G2A (FOR TEMP. UP TO 3430C)


REV-0 Page 2 of 2


NOTES: 1.

LOADS ON FILLET WELDS OF CROSS GUIDES SHALL BE LIMITED TO THE VALUES TABULATED ABOVE AGAINST VARIOUS TEMPERATURES FOR RESPECTIVE WELD SIZE, FOR RUNNING LENGTH OF WELD. LOADS MAY BE INTERPOLATED FOR INTERMEDIATE TEMPERATURES.


CROSS GUIDE FOR BARE PIPE, SIZE 2” THRU 24”, TYPE- G3 (FOR TEMP. UP TO 3430C)


REV-0 Page 1 of 2


2.

FOR AS AND SS LINES, SIZES 2” THRU 12”, PROTECTION SHIELD AS PER NOTE-3 IS TO BE PROVIDED.

3.

PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR ROLLED FROM PLATE OF MATERIAL EQUIVALENT TO LINE PIPE. THICKNESS OF PROTECTION SHIELD SHALL BE SAME AS LINE PIPE OR 12MM, WHICHEVER IS LESS.

4.

IN CASE OF BEAM TYPE SUPPORTING STEEL, PLATES SHALL BE PROVIDED ON BOTH SIDES AS SHOWN. HEIGHT OF THE PLATE SHALL BE BASED ON THE SIZE OF THE SUPPORTING STEEL MEMBER.


CROSS GUIDE FOR BARE PIPE, SIZE 2” THRU 24”, TYPE- G3 (FOR TEMP. UP TO 3430C)


REV-0 Page 2 of 2



CROSS GUIDE FOR BARE PIPE ON SLEEPER / RCC BEAM, SIZE 2” THRU 24”, TYPE- G4 (FOR TEMP. UP TO 3430C)


REV-0 Page 1 of 2


NOTE: 1. LOADS ON FILLET WELDS OF GUIDES SHALL BE LIMITED TO THE VALUES TABULATED ABOVE AGAINST VARIOUS TEMPERATURES FOR RESPECTIVE WELD SIZE, FOR RUNNING LENGTH OF WELD. LOADS MAY BE INTERPOLATED FOR INTERMEDIATE TEMPERATURES. 2. FOR AS / SS LINES OF SIZES 2” THRU 12”, PROTECTION SHIELD AS PER NOTE-3 IS TO BE PROVIDED. 3. PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR ROLLED FROM PLATE OF MATERIAL EQUIVALENT TO LINE PIPE. THICKNESS OF PROTECTION SHIELD SHALL BE SAME AS LINE PIPE OR 12MM, WHICHEVER IS LESS. 4. FOR SUPPORTING DETAILS OF PIPE SIZES 2” THRU 6”, REFER GAIL STANDARD S-05-01-040.


CROSS GUIDE FOR BARE PIPE ON SLEEPER / RCC BEAM, SIZE 2” THRU 24”, TYPE- G4 (FOR TEMP. UP TO 3430C)


REV-0 Page 2 of 2



ANCHOR FOR BARE PIPE ON SLEEPER / RCC BEAM, SIZE 2” THRU 24”, TYPE- G5 (FOR TEMP. UP TO 3430C)


REV-0 Page 1 of 2


NOTES: 1.

LOADS ON FILLET WELDS OF ANCHORS SHALL BE LIMITED TO THE VALUES TABULATED ABOVE AGAINST VARIOUS TEMPERATURES FOR RESPECTIVE WELD SIZE, FOR RUNNING LENGTH OF WELD. LOADS MAY BE INTERPOLATED FOR INTERMEDIATE TEMPERATURES.

2.

FOR AS / SS LINES OF SIZES 2” THRU 12”, PROTECTION SHIELD AS PER NOTE-3 IS TO BE PROVIDED.

3.

PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR ROLLED FROM PLATE OF MATERIAL EQUIVALENT TO LINE PIPE. THICKNESS OF PROTECTION SHIELD SHALL BE SAME AS LINE PIPE OR 12MM, WHICHEVER IS LESS.

4.

FOR SUPPORTING DETAILS OF PIPE SIZES 2” THRU 6” , REFER GAIL STANDARD S-05-01-040. CROSS GUIDE GAP SHALL BE MADE ZERO AND RESTRAINT FACE SHALL BE WELDED TO SLEEPER INSERT PLATES ON EITHER SIDE.


ANCHOR FOR BARE PIPE ON SLEEPER / RCC BEAM, SIZE 2” THRU 24”, TYPE- G5 (FOR TEMP. UP TO 3430C)


REV-0 Page 2 of 2



SUPPORTING ARRANGEMENT FOR ANGLE AND RELIEF VALVES, TYPE – SP2


REV-0 Page 1 of 1



TYPICAL ANTI VIBRATION SUPPORT FOR CONTROL VALVE MANIFOLD, TYPE – SP3


REV-0 Page 1 of 1


Valve Manufacturer Actuator Manufacturer Valve Tag No. Purchaser’s spec.: S – 04 – 02 - 007 Design standard: API 6D SIZE, mm (IN) NB: Ends: BOTH ENDS BW PER ASME B 16.25 VALVE DESIGN CONDITIONS: Corrosion Allowance: 1.5 mm Service R-LNG Design factor: 0.5

-------------

AS

ANSI Rating: Piping class: VALVE BORE: Face finish flanges: Temperature, 0c: Installation: Valve Operating time, Sec

of

600# D1A FULL / REDUCED BORE NOT APPLICABLE

-28 TO 65 BURIED 60

CONNECTING PIPE DETAILS: Diameter (NB), mm Wall Thickness, mm VALVE OPERATOR REQUIREMENT Type of Operator GAS POWERED ACTUATOR Operator Spec. No.: S – 04 – 02 - 012 Operator Data Sheet:

STEM EXTENSION REQUIREMENT Stem Extension REQUIRED Length of Stem extension, m

VALVE MATERIAL SPECIFICATION: PART DESCRIPTION SPECIFIED MATERIAL Body ASTM A 216 Gr. WCB/ ASTM A 234 Gr. WPB (REFER NOTE-1) Ball (ASTM A 216 Gr. WCB/ ASTM A 234 Gr. WPB) + 0.003” ENP Body Seat Rings (AISI 4140 + 0.003” ENP) / AISI 410 Seat Seal (Secondary) VITON Stem (AISI 4140 + 0.003” ENP) / AISI 410 Stem seal PTFE / VITON Stud, Bolts ASTM A 193 Gr. B7/ Gr. B7M Nuts ASTM A 194 Gr. 2H/ Gr. 4/ Gr. 7

2.5 (APPROX.)

MATERIAL OFFERED

Note: 1. Material for body shall have guaranteed minimum yield strength of 46,700 psi. In case the same can not be guaranteed, Valves shall be supplied with PUP pieces of 500mm length, integrally welded to the valve, whose strength shall be equivalent to connecting pipe specifications. 2. For the welding end, the out of roundness (i.e. difference between maximum and minimum ID at pipe end) shall be 5.0mm. 3. Compressed asbestos filler (CAF) shall not be used for body sealing/ gasket materials. 4. All valves shall be suitable for location operation & remote actuated operation as per specification No. S-04-02-012.


DOCUMENT NO. DATA SHEET FOR BALL VALVES

0001-01-04-04-BV-001

REV-0 Page 1 of 1


Valve Manufacturer Actuator Manufacturer Valve Tag No. Purchaser’s spec.: S – 04 – 02 - 007 Design standard: API 6D SIZE, mm (IN) NB: Ends: BOTH ENDS BW PER ASME B 16.25 VALVE DESIGN CONDITIONS: Corrosion Allowance: 1.5 mm Service R-LNG Design factor: 0.5

-------------

AS


of


-28 TO 65 ABOVE GROUND 60

CONNECTING PIPE DETAILS: Diameter (NB), mm Wall Thickness, mm VALVE OPERATOR REQUIREMENT Type of Operator GAS POWERED ACTUATOR Operator Spec. No.: S – 04 – 02 - 012 Operator Data Sheet:

STEM EXTENSION REQUIREMENT Stem Extension NOT APPLICABLE Length of Stem extension, m


-----

MATERIAL OFFERED

Note: 1. Material for body shall have guaranteed minimum yield strength of 46,700 psi. In case the same can not be guaranteed, Valves shall be supplied with PUP pieces of 500mm length, integrally welded to the valve, whose strength shall be equivalent to connecting pipe specifications. 2. For the welding end, the out of roundness (i.e. difference between maximum and minimum ID at pipe end) shall be 5.0mm. 3. Compressed asbestos filler (CAF) shall not be used for body sealing/ gasket materials. 4. All valves shall be suitable for location operation & remote actuated operation as per specification No. S-04-02-012.


DOCUMENT NO. DATA SHEET FOR BALL VALVES

0001-01-04-04-BV-002

REV-0 Page 1 of 1


Valve Manufacturer Actuator Manufacturer Valve Tag No. Purchaser’s spec.: S – 04 – 02 - 007 Design standard: API 6D SIZE, mm (IN) NB: Ends: BOTH ENDS BW PER ASME B 16.25 VALVE DESIGN CONDITIONS: Corrosion Allowance: 1.5 mm Service R-LNG Design factor:

0.5

-------------

AS


of


-28 TO 65 BURIED GROUND 60

/

ABOVE

CONNECTING PIPE DETAILS: Diameter (NB), mm Wall Thickness, mm VALVE OPERATOR REQUIREMENT Type of Operator GEAR OPERATED Operator Spec. No.: Operator Data Sheet:

STEM EXTENSION REQUIREMENT Stem Extension NOT APPLICABLE ----Length of Stem extension, m


MATERIAL OFFERED

Note: 1. Material for body shall have guaranteed minimum yield strength of 46,700 psi. In case the same can not be guaranteed, Valves shall be supplied with PUP pieces of 500mm length, integrally welded to the valve, whose strength shall be equivalent to connecting pipe specifications. 2. For the welding end, the out of roundness (i.e. difference between maximum and minimum ID at pipe end) shall be 5.0mm. 3. Compressed asbestos filler (CAF) shall not be used for body sealing/ gasket materials.


DOCUMENT NO. DATA SHEET FOR BALL VALVE

0001-01-04-04-BV-003

REV-0 Page 1 of 1


Valve Manufacturer Actuator Manufacturer Valve Tag No. Purchaser’s spec.: S – 04 – 02 – 008 Design standard: API 6D SIZE, mm (IN) NB: Ends: BOTH ENDS BW PER ASME B 16.25 VALVE DESIGN CONDITIONS: Corrosion Allowance: 1.5 mm Service R-LNG Design factor: 0.5

------------ANSI Rating: Piping class: AS

Face finish flanges: Temperature, 0c: Installation:

600# D1A of

NOT APPLICABLE

-28 TO 65 ABOVE GROUND

CONNECTING PIPE DETAILS: Diameter (NB), mm Wall Thickness, mm 7.9 Grade API 5L Gr. X60 VALVE OPERATOR REQUIREMENT Type of Operator Manual (Note-1) Operator Spec. No.: Operator Data Sheet: -

STEM EXTENSION REQUIREMENT Stem Extension Not Required Length of Stem extension, m

VALVE MATERIAL SPECIFICATION: PART DESCRIPTION SPECIFIED MATERIAL Body ASTM A 216 Gr. WCB/ ASTM A 234 Gr. WPB Plug (ASTM A 216 Gr. WCB/ ASTM A 234 Gr. WPB) + 0.003” ENP Cover ASTM A 216 Gr. WCB/ ASTM A 234 Gr. WPB Stem (AISI 4140 + 0.003” ENP) / AISI 410 Stem seal PTFE / GRAPHITE / VITON Stud, Bolts ASTM A 193 Gr. B7 Nuts ASTM A 194 Gr. 2H

MATERIAL OFFERED

Note: Requirement of Manual operator (Wrench / Hand Wheel / Gear operator) shall be as per Specification - S–04–02–008. 2. Separate wrench shall be provided with each wrench operated valve. 3. Data Sheets shall be read in conjunction with Valve specifications - S–04–02–008. 1.


DOCUMENT NO. DATA SHEET FOR PLUG VALVES

0001-01-04-04-PV-001

REV-0 Page 1 of 1


Valve Manufacturer Actuator Manufacturer Valve Tag No. Purchaser’s spec.: S – 04 – 02 – 008 Design standard: API 6D SIZE, mm (IN) NB: Ends: BOTH ENDS BW PER ASME B 16.25 VALVE DESIGN CONDITIONS: Corrosion Allowance: 1.5 mm Service R-LNG Design factor: 0.5

------------ANSI Rating: Piping class: AS

Face finish flanges: Temperature, 0c: Installation:

600# D1A of

NOT APPLICABLE

-28 TO 65 BURIED

CONNECTING PIPE DETAILS: Diameter (NB), mm Wall Thickness, mm 7.9 Grade API 5L Gr. X60 VALVE OPERATOR REQUIREMENT Type of Operator Manual (Note-1) Operator Spec. No.: Operator Data Sheet: -

STEM EXTENSION REQUIREMENT Stem Extension Required 2.5 M (Approx.) Length of Stem extension, m

VALVE MATERIAL SPECIFICATION: PART DESCRIPTION SPECIFIED MATERIAL Body ASTM A 216 Gr. WCB/ ASTM A 234 Gr. WPB Plug (ASTM A 216 Gr. WCB/ ASTM A 234 Gr. WPB) + 0.003” ENP Cover ASTM A 216 Gr. WCB/ ASTM A 234 Gr. WPB Stem (AISI 4140 + 0.003” ENP) / AISI 410 Stem seal PTFE / GRAPHITE / VITON Stud, Bolts ASTM A 193 Gr. B7 Nuts ASTM A 194 Gr. 2H

MATERIAL OFFERED

Note: Requirement of Manual operator (Wrench / Hand Wheel / Gear operator) shall be as per Specification - S–04–02–008. 2. Separate wrench shall be provided with each wrench operated valve. 3. Data Sheets shall be read in conjunction with Valve specifications - S–04–02–008. 1.


DOCUMENT NO. DATA SHEET FOR PLUG VALVES

0001-01-04-04-PV-002

REV-0 Page 1 of 1


DATA SHEETS GATE VALVE BELOW 2” SPUR LINES OF CHAINSA - JHAJJAR

DATA SHEET GATE VALVE BELOW 2”


DATA SHEET 0001-01-05-04-GV-001

REV-0 Page 1 of 3


Client

:

Gail (India) Ltd

Client

:

Gail (India)Ltd

Project

:

Std. Specification

Location :

New Delhi

Tag No:

GATE VALVE SPECIFICATION TAG NO. : RATING : SIZE RANGE : 0.25" TO 1.5"

STANDARD : API-602 ENDS : SW 3000 TO B-16.11

DESCRIPTION

CONSTRUCTION

BODY

FORGED

ASTM A 105

BONNET

BOLTED

ASTM A 105

STEM

RISING

13% CR.STEEL (NO CASTING)

WEDGE DISC

SOLID

STELLITED

BODY SEAT RING

RENEWABLE

STELLITED

STEM PACKING

RENEWABLE WITH VALVE OPEN ON STREAM

GRAPHITED ASBESTOS WITH SACRIFICIAL CORR. INHIB.& INCONEL WIRE REINFORCEMENT

HAND WHEEL

NON RISING

MALLEABLE IRON/CAST ST/FAB.ST/DUCT. IRON

MATERIAL

BONNET BOLTS

ASTM A193 GR B7

BONNET NUTS

ASTM A194 GR 2H

BONNET GASKET

SP WND SS316 - CA F1LLER

SPECIAL SERVICE CONDITIONS

MAX TEMP. 427 DEG. C. INTEGRAL

OTHERS

O.S & Y.

HYDROSTATIC TEST PRESSURE

BODY : 2975 PSIG.

TEST PRESSURE WITH AIR

80 PSIG

1

of

1

MANUF'S OFFER

PIPING CLASS : A10A, A11A, A13A, A1A, A20A, A32A, A33A, A3A, A6A, A9A, B13A, B1A, B32A, B6A, B9A, D1A

BACK SEAT & SHOULDER

Sheet No. STANDARD: MFGRS CAT/FIG: RATING: ENDS:

CONSTRUCTION

MATERIAL

SEAT : 2175 PSIG

NOTES 1 2 3 4 5

THIS VALVE SPEC SHEET SHALL BE READ IN CONJUNCTION WITH TECHNICAL NOTES FOR VALVES. BIDDER SHALL CLEARLY WRITE ALL/ ANY DEVIATION AGAINST EACH PART/ MATERIAL OF VALVE IN THE SPACE PROVIDED FOR. WHEREVER BIDDER AGREES WITH SPEC BIDDER SHALL INDICATE "AGREED". NO CUTTING/ OVERWRITING BY BIDDER ON SPEC IS ALLOWED. TESTING SHALL BE AS PER API 598



DATA SHEET 0001-01-05-04-GV-001

REV-0 Page 2 of 3


Project

:

Location :

Std. Specification New Delhi

Tag No:

GATE VALVE SPECIFICATION TAG NO. RATING : 800 SIZE RANGE : 0.5" TO 1.5" DESCRIPTION

CONSTRUCTION

BODY

FORGED

ASTM A 350 GR.LF2

BONNET

BOLTED

ASTM A 350 GR.LF2

STEM

RISING

SS 304/SS316 (NO CASTING)

WEDGE DISC

SOLID

STELLITED

BODY SEAT RING

RENEWABLE

STELLITED

STEM PACKING

RENEWABLE WITH VALVE OPEN ON STREAM

ASBESTOS IMPREGNATED WITH PTFE

HAND WHEEL

NON RISING

MALLEABLE IRON/CAST ST/FAB.ST/DUCT. IRON

MATERIAL

BONNET BOLTS

ASTM A320 GR L7

BONNET NUTS

ASTM A194 GR 4/GR 7

BONNET GASKET

SP WND SS316 - CA FILLER LT

BACK SEAT & SHOULDER

INTEGRAL

OTHERS

O.S & Y.

HYDROSTATIC TEST PRESSURE

BODY : 2975 PSIG.

TEST PRESSURE WITH AIR

80 PSIG

1

of

1

MANUF'S OFFER

PIPING CLASS : A4A, B4A, D4A STANDARD : API-602 ENDS : SW 3000 TO B-16.11

SPECIAL SERVICE CONDITIONS

Sheet No.

STANDARD: MFGRS CAT/FIG: RATING: ENDS: CONSTRUCTION

MATERIAL

UPTO -45 DEG. C.

SEAT : 2175 PSIG

NOTES 1 2 3 4 5 6

THIS VALVE SPEC SHEET SHALL BE READ IN CONJUNCTION WITH TECHNICAL NOTES FOR VALVES. BIDDER SHALL CLEARLY WRITE ALL/ ANY DEVIATION AGAINST EACH PART/ MATERIAL OF VALVE IN THE SPACE PROVIDED FOR. WHEREVER BIDDER AGREES WITH SPEC BIDDER SHALL INDICATE "AGREED". NO CUTTING/ OVERWRITING BY BIDDER ON SPEC IS ALLOWED. TESTING SHALL BE AS PER API 598 & BS-6364. VALVES SHALL BE PROVIDED WITH EXTENDED BONNET AS PER BS 6364 (NON COLD BOX APPLICATION). VALVES TO COMPLY WITH DESIGN REQUIREMENTS OF BS-6364 ALSO.



DATA SHEET 0001-01-05-04-GV-001

REV-0 Page 3 of 3


ITEM REFERENCE SPECIFICATION

PIPE LINE FLOW TEE (BARRED TEE) SPEC. NO.: S – 04 – 02 - 016

INSTALLATION CONDITIONS: LOCATION SULTANPUR PIG LAUNCHER STATION, NEEMRANA PIG RECEIVER STATION INSTALLATION ABOVE GROUND DESIGN CONDITIONS: BARRED TEE SIZE (NB, INCHES) DESIGN CODE DESIGN FACTOR CORROSION ALLOWANCE DESIGN PRESSURE DESIGN TEMPERATURE IMPACT TEST TEMPERATURE TRANSPORTED GAS SOUR SERVICE POST WELD HEAT TREATMENT OF FIELD WELDS RADIOGRAPHY INSPECTION PAINTING MATERIALS: TEE GUIDE BARS NO. OF BARS TEST RING (1 NO.)

18 X 18 X 18 ASME B 31.8 0.5 NIL 99.93 KG/CM2 (G) (-) 28 TO 650C (-) 280C NATURAL GAS NO NO IF WALL THICKNESS OF TEE IS GREATER THAN 20MM, RI SHALL BE REPLACED WITH UT AS PER CLAUSE 6.0 OF SPECIFICATION NO. S – 04 – 02 - 016

MSS SP-75, Gr. WPHY-70 MANUFACTURER TO SPECIFY 9 18” X 500MM X 9.3 MM

CONNECTING PIPE DETAILS HEADER PIPE DETAILS BRANCH PIPE DETAILS O.D X W.T (mm) SPEC. O.D X W.T (mm) SPEC. 457 X 9.3 API 5L Gr. 70 457 X 9.3 API 5L Gr. 70


DATA SHEET FOR BARRED TEE SIZE – 18” X 18” X 18”

DOCUMENT NO. 0001-01-04-04-FLT-001

REV-0 Page 1 of 1




INSTALLATION CONDITIONS: LOCATION DHARUHERA TOP, BHIWADI-CHOPANKI TOP, KHUSHKHERA TOP INSTALLATION UNDER GROUND DESIGN CONDITIONS: BARRED TEE SIZE (NB, INCHES) DESIGN CODE DESIGN FACTOR CORROSION ALLOWANCE DESIGN PRESSURE DESIGN TEMPERATURE IMPACT TEST TEMPERATURE TRANSPORTED GAS SOUR SERVICE POST WELD HEAT TREATMENT OF FIELD WELDS RADIOGRAPHY INSPECTION PAINTING MATERIALS: TEE GUIDE BARS NO. OF BARS TEST RING (1 NO.)



CONNECTING PIPE DETAILS HEADER PIPE DETAILS BRANCH PIPE DETAILS O.D X W.T (mm) SPEC. O.D X W.T (mm) SPEC. 457 X 9.3 API 5L Gr. 70 323.9 X 7.9 API 5L Gr. 60



DOCUMENT NO. 0001-01-04-04-FLT-002

REV-0 Page 1 of 1




INSTALLATION CONDITIONS: LOCATION TOP IN U/S OF SV-1 & SV-3 IN SULTANPURNEEMRANA SPUR LINE INSTALLATION UNDER GROUND DESIGN CONDITIONS: BARRED TEE SIZE (NB, INCHES) DESIGN CODE DESIGN FACTOR CORROSION ALLOWANCE DESIGN PRESSURE DESIGN TEMPERATURE IMPACT TEST TEMPERATURE TRANSPORTED GAS SOUR SERVICE POST WELD HEAT TREATMENT OF FIELD WELDS RADIOGRAPHY INSPECTION PAINTING MATERIALS: TEE GUIDE BARS NO. OF BARS TEST RING (1 NO.)



CONNECTING PIPE DETAILS HEADER PIPE DETAILS BRANCH PIPE DETAILS O.D X W.T (mm) SPEC. O.D X W.T (mm) SPEC. 457 X 9.3 API 5L Gr. 70 219.1 X 6.4 API 5L Gr. 56



DOCUMENT NO. 0001-01-04-04-FLT-003

REV-0 Page 1 of 1


PIG SIGNALLER TAG NO.

ON EQUIPMENT DATA SHEET NO.

PIG SIGNALLER MANUFACTURER PURCHASER'S SPECIFICATIONS PIG SINGALLER MODEL QUANTITY

12-PL-01, 13-PR-01 0001-01-04-04-PSG-001 * S – 04 – 02 - 018 * 4

DESIGN CONDITIONS DESIGN PRESSURE (KG/CM²) DESIGN TEMPERATURE (ºC) DESIGN CODE CORROSION ALLOWANCE (MM) ANSI RATING (#) DESIGN FACTOR SERVICE END CONNECTION INSTALLATION ELECTRICAL AREA CLASSIFICATION

99.93 -28 TO 65 ASME B31.8 & OISD 226 1.5 600 0.5 NATURAL GAS BE ABOVE GROUND IEC - ZONE-1, GAS GROUP-IIA & IB, TEMP. CLASS - T3

PIG SIGNALLER MATERIAL SPECIFICATION BODY INTERNALS

ASTM A105 (CHARPY) SS-316

MICRO SWITCH DETAILS RATING ENCLOSURE CABLE CONNECTION


POTENTIAL FREE CONTACT OF RATING 24V DC, 2A, SPDT WEATHER PROOF TO IP55 & FLAME PROOF EXD. ENCLOSURE CERTIFIED FOR AREA CLASSIFICATION 1/2" NPTF

DOCUMENT NO. DATA SHEET FOR PIG SIGNALER

0001-01-04-04-PSG-001

REV-0 Page 1 of 1


DATA SHEET FOR GAS POWERED ACTUATOR Actuator Manufacturer

:

Specification for Gas Powered Actuator

:

____________________ S-04-02-012

Vendor to take the following data for sizing the actuator and furnish the filled in torque figures in Table-1 after sizing the actuator. 1.

Tag Nos.

:

2.

Service

:

3.

Actuator Shut off Pressure

4.

Actuator Valve Description Item No. 1 2 3 4

Size, NB mm (in) 18” 12” 10” 8”

Corrosion Allowance 5.

:

NATURAL GAS 92 kg/cm2 (g)

Bore Size Full Bore & Reduced Bore

:

ANSI Rating 600# 600# 600# 600#

1.5 mm

Process Condition: Power Gas Gas Temperature Line gas Pressure Molecular Weight Cp/Cv Compressibility Factor

: : : : : :

Natural Gas -29 to 650C 92 KG/CM2 (MAX.) 17.4 – 17.64 1.50 – 1.60/ 1.65 – 1.75 0.84-0.86 / 0.78 – 0.81 / 0.83 – 0.87

6.

Actuator Type

:

As per Specification

7.

Power Gas feed from Connection from Mainline

:

3/4" NPT

8.

Actuator Remote Operation (for open/close)

:

Required

9.

Valve Position Limit Switch

:

Required (SPDT contact for open and SPDT contact for close positions separately)


DATA SHEET FOR GAS POWERED VALVE ACTUATOR

DOCUMENT NO. 0001-01-04-04-GVA-001

REV-0 Page 1 of 4


10.

Local/ Remote Selector Switch and its Status contact

:

Required (shall be wired up to junction box as per circuit diagram)

11.

Pneumatic Limit Valves and solenoid, pilot valves to shut off gas supply to actuator when valve reaches one of its end positions

:

Required

12.

Self Retaining System for retaining momentary open and close signals in the control circuit

:

Required

13.

Electrical Conduit connection (Cable entry to junction box for Purchaser’s cable)

:

1" NPT

14.

Operating Voltage :

24 V DC ± 15 %

Limit Switches L/R switch (status)

:

2 Amp at 24 V DC

16.

Pad Lock with L/R Switch

:

Required

17.

Enclosure for

a) b) 15.

Solenoid Valves Relays

Contact Rating a) b)

a)

Actuator

:

Certified Weather Proof as per IP55

b)

Electrical Items like Limit Switches, Solenoid valves, Junction Boxes, Relays, Cable Glands

:

Certified Weather Proof as per IP55 and Flame proof certified suitable for IEC Zone-1, Gas group IIA &IIB, Temp. Class T3

18.

Area Classification

:

IEC Zone-I, Gas Group II A & IIB, Temp. Class T3

19.

Material of Construction for all tubing, valves, piping and fittings

:

SS316

20.

Accessories Required

:

Required as per Specification

21.

Manual/Hydraulic Override

:

Required as per Specification



DOCUMENT NO. 0001-01-04-04-GVA-001

REV-0 Page 2 of 4


22.

Maximum time required to open/close the valve

:

As per Data sheets

Note: Complete actuator including control panel/ systems shall be manufactured and supplied by actuator manufacturer only. All circuit diagram / documents/ drawings pertaining to actuator shall be furnished by actuator manufacturer. All inspection and testing shall be carried out at actuator manufacturer’s shop as per clause 6.1 of Spec. No. S-04-02-012.



DOCUMENT NO. 0001-01-04-04-GVA-001

REV-0 Page 3 of 4


TABLE - 1

DATA FROM BALL VALVE VENDOR ITEM NO.

TAG NO. BREAK TORQUE (NM)

RUNNING TORQUE (NM)

MAX. ALLOWABLE STEM TORQUE (NM)

BALL VALVE TORQUE FIGURES WITH A SAFETY FACTOR 1.25

ACTUATOR GENERATED TORQUE AT 10 KG/CM2 (G) REGULATED PRESSURE (NOTE 1)

BREAK TORQUE (NM)

BREAK TORQUE (NM)

RUNNING TORQUE (NM)

MODEL SELECTED

RUNNING TORQUE (NM)

Notes: 1. These figures shall be used as basis for testing the actuator performance during factory testing. The actuator acceptance would be carried out after verifying successful testing complete of ball valves with actuator assembly. 2. All torque figures must be in Nm.



DOCUMENT NO. 0001-01-04-04-GVA-001

REV-0 Page 4 of 4


A = OVERALL LENGTH OF IJ TO BE CONFIRMED BY MANUFACTURER. 1. INSULATING JOINTS MFR. 2. PURCHASER'S SPECIFICATION NO. 3. RATING 4. DESIGN PRESSURE 5. DESIGN TEMPERATURE 6. SERVICE 7. CORROSION ALLOWANCE 8. SIZE NB (INCHES) 9. END CONNECTION 10. DESIGN CODE 11. DESIGN FACTOR 12. 13. 14. 15.

: : : : : : : : : : :

S – 04 – 02 - 019 600# 99.93 KG/CM2 (G) -29 TO 65°C Natural Gas 1.5 MM 18” / 12” / 10” / 8” BUTT-WELD AT BOTH ENDS ASME SECTION-VIII DIV-I 0.4 (FOR CLASS-4 LOCATION) 0.5 (FOR ALL OTHER AREAS) HYDROSTATIC TEST PRESSURE : 138 KG/CM2 (G) CHARPY TEST : REQUIRED AS PER SPEC. HARDNESS TEST : REQUIRED AS PER SPEC. MATERIALS SPECIFICATION (EQUIVALENT OR SUPERIOR) A) BODY

:

B) PUPS

:

C) INSULATING MATERIAL: 16. CONNECTING PIPE SPECIFICATION : SIZE, NB, MM (INCHES) WALL THICKNESS, MM GRADE 17. SPECIAL REQUIREMENTS


: : : :

ASTM A-694, GRADE AS PER CONNECTING PIPE GRADE API 5L (GR. &THK. TO SUIT CONNECTING PIPE) AS PER MANUFACTURER'S STANDARD 18" / 12” / 10” / 8” AS PER AREA CLASSIFICATION API 5L Gr. X-70 (18”) API 5L Gr. X-60 (12” & 10”) API 5L Gr. X-56 (8”) INSULATION JOINT SHALL BE SUITABLE FOR ABOVE GROUND INSTALLATION

DATA SHEET FOR INSULATING JOINTS

DOCUMENT NO. 0001-01-04-04-IJ-001

REV-0 Page 1 of 1


VENDOR LIST The materials required to be supplied by the contractor under this contract shall be procured only from GAIL approved vendors. However, current validity and range of approval as per GAIL enlistment letter, workload, stability and solvency need to be verified by the contractor before placement of order. Approved list of vendors for some of the items are mentioned below or elsewhere in the Bidding document. Where the makes of materials are not indicated in the bidding document, contractor shall furnish the details of makes and shall obtain prior approval of Engineer in charge of vendors/sub-vendors before placing orders. 1)

Fasteners -

2)

Fittings Block forged – Carbon Steel -

3)

Eby Fasteners, India Leader Valves Ltd, India M.S. Fittings Mfg. Co Pvt Ltd, India R.N. Gupta & Co. Ltd, India

Fittings from Seamless Pipe – Carbon Steel -

4)

AEP Company, India Boltmaster India Pvt Ltd, India Deepak Fasteners Limited, India Fasteners & Allied Products Pvt Ltd, India Hardwin Fasteners Pvt Ltd, India J.J. Industries, India Multi Fasteners Pvt Ltd, India Nexo Industries, India Pacific Forging & Fasteners Pvt Ltd, India Pioneer Nuts & Bolts Pvt Ltd, India Precision Auto Engineers, India President Engineering Works, India Sandeep Engineering Works, India Syndicate Engineering Industries, India

Eby Industries, India Gujarat Infrapipes Pvt Ltd, India M.S. Fittings Mfg. Co Pvt Ltd, India Teekay Tubes Pvt Ltd

Flanges - Forged Carbon Steel -

CD Engineering Co., India CD Industries (Ghaziabad), India Chaudhry Hammer Works Ltd, India Echjay Industries Pvt Ltd, (Rajkot), India

VENDOR LIST - PIPING

Page 1 of 4

5)

Flow Tee (Barred TEE) -

6)

Jindal Saw Ltd. (Kosi Works), India PSL Limited (Gandhidham – Mfrg), India

Quick Opening End Closure -

10)

IGP Engineers Pvt. Ltd., India Nouva Giungas SRL, Italy Zunt Italiana SRL., Italy

Long Radius Bends -

9)

IGP Engineers Pvt. Ltd., India Madras Industrial Products, India Starflex Sealing India Pvt Ltd, India

Insulating Joints -

8)

Multitex Filtration Engineers Ltd., India Pipeline Engineering, UK Technoforge SPA, Italy

Gaskets Spiral Wound -

7)

Golden Iron & Steel Works, India J.K. Forgings, India JAV Forgings (P) Ltd, India Kunj Forgings Pvt Ltd, India Metal Forgings Pvt Ltd, India Pradeep Metal Limited, India Punjab Steel Works, India (The) R.N. Gupta & Co. Ltd, India R.P. Engineering Pvt Ltd, India Shri Ganesh Forgings Ltd., India Uma Shankar Khandelwal & Co., India

Forain S.R.L. GD Engineering, India Perry Equipment Corporation, India Pipeline Engineering, UK Siirtec Nigi SPA TD Williamson Inc., USA

Scraper Trap, Pig Signaller -

Cardew Ltd., Alexeander Forain S.R.L. GD Engineering, India Multitex Filtration Engineers Ltd., India


Page 2 of 4

11)

Pipe – Carbon Steel (Seamless) to ASTM STDS. -

12)

Larsen & Toubro Ltd, India

Ball Valves, Pipe Line (API 6D) -

14)

BHEL (Trichy), India Heavy Metals & Tubes Ltd (Mehsana), India Indian Seamless Metal Tubes Ltd, Ahmednagar, India Indian Seamless Metal Tubes Ltd, Baramati, India Jindal Saw Ltd (Nashik Works), India Mahalaxmi Seamless Ltd, India Maharashtra Seamless Ltd, India Sainest Tubes Pvt Ltd, India Wuxi Erquan Special Steel Tube Co. Ltd.

Pressure Balanced Plug Valve (NFS) -

13)

Pipeline Engineering, UK Siirtec Nigi SPA Tectubi S.R.L.

Cooper Cameron Valv Italy SRL-FRM, Italy Franz Schuck GmbH (Formerly Borsig) ITAG Kitamura Valve Manufacturing Co Ltd Larsen & toubro Ltd, India Microfinish Valves Ltd, India MSA A.S. OMS Saleri PCC Ball Valves SRL Perar SPA (Enq. to T.R.P. SRL) Petrol Valves SRL Pibiviesse SPA Tormene Gas Technology SPA Virgo Engineers Ltd, India Weir Valves & Controls UK Ltd

Gate Valve, Forged Carbon Steel -

Associated Toolings India Pvt Ltd, India BDK Engineering Industries Ltd, India BHEL (Trichy), India Econo Valves Pvt Ltd, India KSB Pumps Ltd (Coimbattore), India Larsen & toubro Ltd, India Leader Valves Ltd, India Niton Valve Industries Private Ltd, India Oswal Industries Ltd, India Panchvati Valves & Flanges Pvt Ltd, India


Page 3 of 4

15)

Pressure Balanced Plug Valve (NFS) - FCS -

16)

Larsen & Toubro Ltd, India

Pipe - Carbon Steel to Indian Standards -

17)

Petrochemical Engineering Enterprises, India Steel Strong Valves India Pvt Ltd, India

Advance Steel Tube Ltd., India Asian Mills Pvt Ltd, India BMW Industries Ltd(Bansal Mech Works) , India Goodluck Steel Tubes Ltd, India Indus Tube Limited, India Jindal Pipes Ltd, India Jindal Saw Ltd (Kosi Works) , India Lalit Profiles & Steel Ind Ltd. , India Lloyd Metals & Engineers Ltd. , India Maharashtra Seamless Ltd, India Man Industries Ltd, India Mukat Pipes Ltd., Mukat Tanks & Vessels Ltd., India North Eastern Tubes Ltd. Pratibha Pipes & Strl Pvt Ltd PSL Limited (Nani Chirai) PSL Limited (Chennai) Ratnamani Metals & Tubes Ltd Sri Sarbati Steel Tubes Ltd Steel Authority of India Ltd Surindra Engineering Co Ltd (Rajpura), India Surindra Engineering Co Ltd (Mumbai), India Surya Roshni Ltd, India Swastik Pipes Ltd,, India The Tata Iron & Steel Co Ltd, India Welspun Gujarat Stahl Rohren Ltd, India

Air Conditioning System – package Unit -

Batliboi & Co Ltd, India Blue Star Ltd, India Emerson Network Power (I) Pvt Ltd, India Eta Engineering Pvt Ltd., India Voltas Ltd. , India


Page 4 of 4

tender146vol-II.pdf

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