VOLUME III TECHNICAL SPECIFICATIONS ANNEXURE-A PIPELINE A - 1.pdf

ANNEXURE – A PIPELINE

DOC NO: 9000043-HD-10129 (0435-JH0902-00-PP-RFQ-0019)

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP)

CONTENT LIST- PIPELINE LAYING & ASSOCIATED WORKS

Guru Gobind Singh Refinery Products Evacuation Project (GGSRPEP) Raman Mandi- Bahadurgarh and Raman MandiBhatinda Multiproduct Pipeline

CONTENT LIST – PIPELINE LAYING & ASSOCIATED WORKS 0435-JH0902-00-PL-LST-0103 22 September 2009

Sanghi Oxygen Compound 1, Mahal Industrial Estate Mahakali Caves Road Andheri (East), Mumbai - 400 093 India Phone: +91-22-67818000 Fax : +91-22-67818080 www.worleyparsons.com © Copyright 2009 WorleyParsons

Doc. No.: 0435-JH0902-00-PL-LST-0103 Rev.O

Page 1 of 9



SYNOPSIS

Disclaimer This report has been prepared on behalf of and for the exclusive use of Hindustan Petroleum Corporation Limited (HPCL), and is subject to and issued in accordance with the agreement between Hindustan Petroleum Corporation Limited (HPCL) and WorleyParsons. WorleyParsons accepts no liability or responsibility whatsoever for it in respect of any use of or reliance upon this report by any third party. Copying this report without the permission of Hindustan Petroleum Corporation Limited (HPCL) or WorleyParsons is not permitted.

PROJECT 435/JH0902 - HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) REV

DESCRIPTION

PREPARED BY

A

Issued for SDC

D. Hemanathan

S. Ishwad

N Agarwal

B

Issued for Review

D. Hemanathan

S. Ishwad

N Agarwal

O

Issued for Tender

D. Hemanathan

S. Ishwad

N Agarwal


CHECKED BY

APPROVED BY

DATE

01 Sep 09

CLIENT APPROVAL N/A

19 Sep 09

22 Sep 09

Page 2 of 9

DATE



VOLUME PIPING - LIST OF ATTCHMENTS Sr. No.

Document Title

Document No.

Revisions Rev. & Date

GENERAL 1A 1B 2A 2B 2C 2D

3 4 5 6 7 8 9 10 11 12

0435-JH0902-00-PL-SOW0004 0435-JH0902-00-PL-SOWJob Specific Requirements 0005 Schematic for Pipeline – Ramanmandi0435-JH0902-00-PL-DAGBathinda 0505 Schematic for Pipeline – Ramanmandi – 0435-JH0902-00-PL-DAGBahadurgarh 0506 Scope of Work Line Diagram – Bathinda 0435-JH0902-00-PL-DRDRoute 0507 Scope of Work Line Diagram – 0435-JH0902-00-PL-DRDBahadurgarh Route 0508 SPECIFICATIONS 0435-JH0902-00-PL-BODBasis of Design – Pipeline 0001 0435-JH0902-00-PI-SPCPiping Material specification 0001 0435-JH0902-00-PL-SPCTechnical Specification HSAW 0002 0435-JH0902-00-PL-SPCTechnical Specification LSAW 0003 0435-JH0902-00-PL-SPCTechnical Specification EW 0004 Technical Specification 3 LPE Coating 0435-JH0902-00-PL-SPC0001 Technical Specification Transportation 0435-JH0902-00-PL-SPCHandling and Storage of coating Line Pipe 0005 Technical Specification For Pipeline 0435-JH0902-00-PL-SPCConstruction 0006 Technical Specification for Pipeline Hydro 0435-JH0902-00-PL-SPCtesting 0008 Technical Specification for Magnetic 0435-JH0902-00-PL-SPCScope of work


Rev. B Rev. B Rev. B Rev. B Rev. B Rev. B

Rev. 0 Rev D Rev B Rev B Rev B Rev B Rev B Rev B Rev B Rev B

Page 3 of 9



13 14 15 16 17 18 19 20 21

Cleaning & Electronic Geometry Pigging Technical Specification for Pre Commissioning of Pipeline System General Specification for Pipeline Welding Technical Specification for field Joint coating ( Heat Shrink Sleeves ) Technical Specification for Concrete Weight Coating Technical Specification for Hot Induction Bend Technical Specification for Pipeline Crossing Roads/Rail/Minor Water Ways Technical Specification for Major Water Crossing By Trenching Technical Specification for Major Water Crossing By HDD Technical Specification-Monolithic Isolation Joint

22

Technical Specification – Barred Tees

23

Pipeline Ball Valve Specification

24

Standard Specification – Pipeline Marker

0009 0435-JH0902-00-PL-SPC0010 0435-JH0902-00-PL-SPC0011 0435-JH0902-00-PL-SPC0012 0435-JH0902-00-PL-SPC0013 0435-JH0902-00-PL-SPC0014 0435-JH0902-00-PL-SPC0015 0435-JH0902-00-PL-SPC0016 0435-JH0902-00-PL-SPC0017 0435-JH0902-00-PL-SPC0020 0435-JH0902-00-PL-SPC0021 0435-JH0902-00-PL-SPC0022 0435-JH0902-00-PL-SPC0023

Rev B Rev B Rev B Rev B Rev B Rev B Rev B Rev B Rev B Rev B Rev B Rev B Rev B

25

Standard Specification For Documentation For Pipeline Construction

0435-JH0902-00-PL-SPC0025

26

Technical Specification For Casing Insulators & End seals for Pipeline system

0435-JH0902-00-PL-SPC0026 0435-JH0902-00-PL-SPC0027 0435-JH0902-00-PL-SPC0030 0435-JH0902-00-PL-SPC0031 0435-JH0902-00-PL-SPC0032 0435-JH0902-00-PI-BOD0001 0435-JH0902-00-PI-SPC0003

27 28 29

Technical Specification for GeoTextile Bags Technical Specification for Testing of Welding in Pipeline Systems Technical Specification for Pig Launcher & Receiver

30

Technical Specification for Pig Signaler

31

Basis of Design – Piping

32

Painting and Protective Coating Specification


Rev B Rev B Rev B Rev B Rev B Rev. 0 Rev. D

Page 4 of 9



33 34 35 36

37

38

VALVE LISTS & MTO SUMMARY 0435-JH0902-70-PL-LSTValve List for Pipeline 0004 0435-JH0902-70-PL-LSTValve List for Pipeline – 4” & Below valves 0004A 0435-JH0902-70-PL-MTOValve MTO Summary – 4” & Below valves 0004A Pipeline facilities Material Take off 0435-JH0902-70-PL-MTO0001 Material Take Off Mother Pipe for Hot 0435-JH0902-00-PL-MTOformed Bends – Ramanmandi – 0202 Bahadurgarh line Material Take Off Mother Pipe for Hot 0435-JH0902-00-PL-MTOformed Bends – Ramanmandi – Bathinda 0203 Line

Rev. C Rev. B Rev. B Rev. B

Rev. B

Rev. B

TECHNICAL NOTES 39

Technical Notes for CS Pipe

40

Technical Notes for Fasteners

41

Technical Notes for Gaskets

42

Technical Notes for Flanges

0435-JH0902-00-PI-TEN0001 0435-JH0902-00-PI-TEN0002 0435-JH0902-00-PI-TEN0003 0435-JH0902-00-PI-TEN0004

Rev. B Rev. B Rev. B Rev. B

DRAWINGS 43

Ramanmandi – Bathinda Pipeline Key plan

44

Ramanmandi – Bahadurgarh Pipeline Key plan Ramanmandi – Bathinda Pipeline overall Route Map Ramanmandi – Bahadurgarh Pipeline overall Route Map Approach Drawing Ramanmandi Dispatch Terminal Approach Drawing Bathinda Receipt Terminal Approach Drawing Bahadurgarh Dispatch Terminal

45 46 47 48 49


0435-JH0902-20-PL-DKP0001 0435-JH0902-60-PL-DKP0002 0435-JH0902-00-PL-DAL0010 0435-JH0902-00-PL-DAL0011 0435-JH0902-10-PL-DGA0001 0435-JH0902-20-PL-DGA0001 0435-JH0902-60-PL-DGA0001

Rev A Rev B Rev B Rev B Rev B Rev B Rev B

Page 5 of 9



50

G A Drawing for Common S V stations

51

G A Drawing for S V station – 04

52

Ramanmandi – Bathinda Alignment Sheets

53 54 55

56 57

58

59

60 61 62

63

64 65 66

0435-JH0902-00-PL-DGA0001 0435-JH0902-00-PL-DGA0002 0435-JH0902-00-PL-DAG0001-001 to 009

Ramanmandi – Bahadurgarh Alignment 0435-JH902-00-PL-DAGSheets 0002-001 to 073 Detail Crossing Drawings for Ramanmandi 0435-JH0902-00-PL-DAG– Bathinda Route 601 to 614 (14 Nos.) Detail Crossing Drawings for Ramanmandi 0435-JH0902-00-PL-DAG– Bahadurgarh Route 701 to 862 (162 Nos.) PIPE LINE STANDARD DRAWINGS Ramanmandi – Bathinda – Bahadurgarh 0435-JH0902-00-PL-DRDOil Pipe Line Typical Working Strip 0001-01 Ramanmandi – Bathinda – Bahadurgarh 0435-JH0902-00-PL-DRDOil Pipe Line - PIPE TRENCH DETAILS 0001-02 Ramanmandi – Bathinda – Bahadurgarh Oil Pipe Line – Minor Road/Track Crossing Open Cut Ramanmandi – Bathinda – Bahadurgarh Oil Pipe Line – Road Crossing (Non Disruptive – Cased ) Ramanmandi – Bathinda – Bahadurgarh Oil Pipe Line – Water Crossing ( H.H.H or Boring ) Ramanmandi – Bathinda – Bahadurgarh Oil Pipe Line– Water Crossing(Open Cut ) Ramanmandi – Bathinda – Bahadurgarh Oil Pipe Line Rail Crossing Trench less for Concrete Sleeved Coating Ramanmandi – Bathinda – Bahadurgarh Oil Pipe Line Concrete Identification Slab / Concrete Coating Ramanmandi – Bathinda – Bahadurgarh Oil Pipe Line – Cable / Pipeline Crossing Ramanmandi – Bathinda – Bahadurgarh Oil Pipe Line – Directional Marker Ramanmandi – Bathinda – Bahadurgarh Oil Pipe Line – Aerial Marker


0435-JH0902-00-PL-DRD0001-03 0435-JH0902-00-PL-DRD0001-04

Rev C Rev C Rev B Rev B Rev B Rev B

Rev B Rev B

REV B

REV B

0435-JH0902-00-PL-DRD0001-05

REV B

0435-JH0902-00-PL-DRD0001-06

Rev B

0435-JH0902-00-PL-DRD0001-07

REV B

0435-JH0902-00-PL-DRD0001-08 0435-JH0902-00-PL-DRD0001-09 0435-JH0902-00-PL-DRD0001-10-1A 0435-JH0902-00-PL-DRD0001-10-1B

Rev B Rev B Rev B Rev B

Page 6 of 9



67 68

69 70 71

72

73

74 75

76 77 78 79

Ramanmandi – Bathinda – Bahadurgarh Oil Pipe Line – KM Post Marker Ramanmandi – Bathinda – Bahadurgarh Oil Pipe Line – Navigable Waterway Pipeline Crossing Warning Sign Ramanmandi – Bathinda – Bahadurgarh Oil Pipe Line – Typical ROW Boundary Marker Ramanmandi – Bathinda – Bahadurgarh Oil Pipe Line – Pipeline Warning Sign Ramanmandi – Bathinda – Bahadurgarh Oil Pipe Line – Typical Details for overhead power crossing Ramanmandi – Bathinda – Bahadurgarh Oil Pipe Line – Minor Watercourse / Nala / Canal Crossing-Single & Double Sag Trenched Ramanmandi – Bathinda – Bahadurgarh Oil Pipe Line – Road Crossing Thrust Bored (cased ) Ramanmandi – Bahadurgarh Oil Pipe Line – Major Water Course Crossing (HDD) Ramanmandi – Bathinda – Bahadurgarh Oil Pipe Line – Road Crossing Thrust Bored ( Uncased ) Pipeline Standard – Typical Extra Workspace Pipeline Standard – Typical Ditch Dimensions Pipeline Standard - Trenching Operation Sequence Typical HDD with Casing pipe for HDPE

0435-JH0902-00-PL-DRD0001-10-1C

Rev B

0435-JH0902-00-PL-DRD0001-10-2A

Rev B

0435-JH0902-00-PL-DRD0001-10-2B

Rev B

0435-JH0902-00-PL-DRD0001-10-2C

Rev B

0435-JH0902-00-PL-DRD0001-11

Rev B

0435-JH0902-00-PL-DRD0001-12

REV B

0435-JH0902-00-PL-DRD0001-13

Rev B

0435-JH0902-00-PL-DRD0001-14

Rev B

0435-JH0902-00-PL-DRD0001-15

Rev B

0435-JH0902-00-PL-DRD0001-16 0435-JH0902-00-PL-DRD0001-17 0435-JH0902-00-PL-DRD0001-18 0435-JH0902-00-PL-DRD0001-19

Rev B Rev B Rev B Rev B

STANDARD INSPECTION TEST PLAN 80

ITP for Piping Fabrication

81

Welding Specification Chart for Piping Class A1, B1,C1 & D1


0435-JH0902-00-PI-ITP0107 0435-JH0902-00-PI-ITR0108

Rev. A Rev. A

Page 7 of 9



DATASHEETS 82

Datasheet for size 14” * 10” LAUNCHER

83

Datasheet for size 14” * 10” RECEVIER

84

Datasheet for size 22” * 18” LAUNCHER

85

Datasheet for size 22” * 18” RECEVIER

86

Datasheet-Pig Signaler

87


88


89

Datasheet-Monolithic Isolation Joint

90

Datasheet-Monolithic Isolation Joint

91

Datasheet – Barred Tees

92


93


94


95

Datasheet for Pipeline Ball Valves

96

Datasheet for Check Valves

97

Datasheet for Plug Valves

98

Report Pipeline at Seismic Fault Crossing

99

Soil Resistivity Survey Report


0435-JH0902-10-PL-DAS0021 0435-JH0902-20-PL-DAS0022 0435-JH0902-10-PL-DAS0023 0435-JH0902-60-PL-DAS0024 0435-JH0902-10-PL-DAS0026 0435-JH0902-20-PL-DAS0027 0435-JH0902-60-PL-DAS0028 0435-JH0902-00-PL-DAS0001 SHT 1 OF 2 0435-JH0902-00-PL-DAS0001 SHT 2 OF 2 0435-JH0902-10-PL-DAS0002 0435-JH0902-20-PL-DAS0002 0435-JH0902-60-PL-DAS0002 0435-JH0902-70-PL-DAS0002 0435-JH0902-00-PL-DAS0003 0435-JH0902-00-PL-DAS0010 0435-JH0902-00-PL-DAS0011

Rev. 0

0435-JH0902-00-PL-REP0005

Rev. B

--

Rev. 0 Rev. 0 Rev. 0 Rev. 0 Rev. 0 Rev. 0 Rev. C Rev. C Rev. C Rev. C Rev. C Rev. C Rev. C Rev. C Rev. C

--

Page 8 of 9



100

Soil Stratification survey Report

101

Crossing Details

102

Technical Deviation Proposal

-0435-JH0902-00-PL-LST1020 --

-Rev B --

IMPORTANT NOTES: 1. Contingency for bare pipe, pipe fittings, flanges, gaskets and fasteners, to be considered +/- 25%. 2. Purchase, supply for Manual Valves 4” and Below are the scope of Contractor 3. Commissioning Spares are listed below are included in SOR shall be purchased and supplied by contractor Fasteners -10% Gaskets – 100%


Page 9 of 9

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) SCOPE OF WORK – PIPELINE LAYING AND ASSOCIATED WORKS


SCOPE OF WORK – PIPELINE LAYING AND ASSOCIATED WORKS 0435-JH0902-00-PL-SOW-0004 19 Sept, 09


Doc. No. : 0435-JH0902-00-PL-0004 Rev. B

Page 1 of 23


SYNOPSIS



DESCRIPTION

PREPARED BY

CHECKED BY

APPROVED BY

A

Issued for IDC

D. Memnathan

S. Ishwad

N. Agarwal

B

Issued for Review

D. Hemnathan

S. Ishwad

N. Agarwal

C

Issued for TENDER

D. Hemnathan

S. Ishwad

N. Agarwal

Doc. No. : 0435-JH0902-00-PL-0004 Rev. B

DATE

CLIENT APPROVAL

27 August 09

N/A

02 Sept. 09

19 Sept. 09

Page 2 of 23

DATE


CONTENTS

1.0

INTRODUCTION......................................................................................................................... 4

2.0

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

3.0

WORK TENDERED .................................................................................................................... 5

4.0

SCOPE OF WORK ..................................................................................................................... 7

5.0

SCOPE OF SUPPLY ................................................................................................................ 16

6.0

LIST OF ATTACHMENTS……………………………………………………………………..…….21

Doc. No. : 0435-JH0902-00-PL-0004 Rev. B

Page 3 of 23


1.0

INTRODUCTION

1.1

M/s Hindustan Petroleum Corporation Ltd. (HPCL) proposes to lay an onshore multi product petroleum pipeline of 10”NB /18” NB, approximately 31KM/ 244 KM long, from its proposed product terminal at Ramanmandi (Punjab) to Bathinda Receipt Terminal (Punjab) and Ramanmandi (Punjab) to Bahadurgarh Receipt terminal (Haryana). The pipeline shall be designed to handle Motor Spirit (MS), Ultra Low Motor Spirit (ULMS), High Speed Diesel (HSD), Ultra Low Sulphur High Speed Diesel (ULSHSD) and Superior Kerosene Oil (SKO), ATF and Naphtha. The proposed onshore pipeline shall consist of pumping and metering facilities at proposed product dispatch terminal at Ramanmandi. Product receiving facilities are proposed at Bathinda, in Punjab and Bahadurgarh in Haryana. En-route Bahadurgarh, 6 nos. of Sectionalising Valve (SV) stations are proposed. Provision of future pumping facilities (for Phase-II) shall be kept at SV-4 at CH.-122.246 at Ramanmandi Bahadurgarh route.

1.2

The complete work has been divided into two spreads as indicated below. The limit of each spread has been indicated in schematic drawing no. 0435-JH902-00-PL-DAG505 and 506.

a)

Spread I Approx. Ch. - 4.22 km to Ch 26.06) on Ramanmandi - Bathinda Route This section covers the laying of 10”NB, approx. 31.162 km long pipeline and associated facilities from approximate Ch. -4.22 km (Dispatch Terminal at Ramanmandi) to approximate Ch 26.06 km (Receipt Terminal at Bathinda). Approx. Ch. -2.000 km to 122.246 km) on Ramanmandi Bahadurgarh Route This section covers the laying of 18”NB, approx. 124.2 km long pipeline and associated facilities from Ch. -2.00 km (Dispatch Terminal at Ramanmandi) to approximate Ch. 122.246 km (Excluding SV- 04 near Barwala)

b)

Spread II Approx. Ch. 122.246 km to 242.00 km) on Ramanmandi Bahadurgarh Route This section covers the laying of 18”NB, approx. 119.8 km long pipeline and associated facilities from approximate Ch. 122.246 km. near Barwala (including SV04) to approximate Ch. 242.00 km (Receipt Terminal at Bahadurgarh)

2.0

SCOPE

2.1

This document covers the details of work tendered, detailed scope of work, scope of supply and other requirements pertaining to laying of pipeline and Installation of Launcher and Receiver at Dispatch and Receipt terminals and facilities related to Sectionalizing Valve stations. Details of civil, structural, architectural, electrical, CP

Doc. No. : 0435-JH0902-00-PL-0004 Rev. B

Page 4 of 23


works (TCP/PCP), mechanical, instrumentation, telecom, optical fiber cable (OFC) laying, HDD at Ghaggar River and 2 nos. combined canal crossings, etc, and other requirements pertaining to pipeline and associated facilities are also covered elsewhere in this tender. 2.2

The scope of work and details mentioned in this document shall be read in conjunction with job specific requirements for pipeline and associated works document no. 0435-JH0902-00-PL-SOW-0005, SPECIFICATION FOR PIPELINE CONSTRUCTION document no. 0435-JH0902-00-PL-SPC-0006, Scheduled of rates, Standards and Specifications, Drawings and all other documents forming a part of Tender documents.

3.0

WORK TENDERED

3.1

Work tendered as a part of this tender document consists of the following:

3.1.1 Laying of (18”) 457mm OD, 242.00km (approx) long multi product pipeline from the Ramanmandi Dispatch Terminal (RDT) to Bahadurgarh Receipt terminal (BHRT). 3.1.2 Laying of (10”) 273.1mm OD, 31.162km (approx) long multi product pipeline from the Ramanmandi Dispatch Terminal (RDT) to Bathinda Receipt terminal (BART). 3.1.3 Installation of pipeline at crossings of rail, road, utilities, underground pipelines and water bodies (river, canal, drain, nala etc.). 3.1.4 Installation of scraper launching facilities within Despatch Terminal at Ramanmandi, scraper receiving facilities within Receipt Terminal at Bahadurgarh 3.1.5 Installation of scraper launching facilities within Despatch Terminal at Ramanmandi, scraper receiving facilities within Receipt Terminal at Bathinda 3.1.6 Installation of 06 (Six) nos. of Sectionalizing Valve (SV) Stations on Ramanmandi Bahadurgarh pipeline route. 3.1.7 Supply of all materials as per Scope of supply. 3.1.8 Carrying out associated mechanical, civil, structural, architectural, and electrical and instrumentation works. Laying of optical fiber cable including additional 6” CS casings with HDPE conduit at crossings only. 3.1.9 All works related to pre-testing, cleaning, magnetic cleaning, gauging, flushing, hydro-testing and swabbing pipeline section/piping facilities. 3.1.10 Carrying out all works related to magnetic cleaning & electronic geometric pigging (EGP) of pipeline 3.1.11 All works related to cathodic protection (both TCP & PCP) of pipeline and stations. 3.1.12 Pre-commissioning of pipeline sections, including providing commissioning assistance / support to Owner. Owner shall carryout final commissioning of the entire pipeline and associated facilities.

Doc. No. : 0435-JH0902-00-PL-0004 Rev. B

Page 5 of 23


3.1.13 Idle time preservation of pipeline, if required. 3.1.14 All statutory clearances, land acquisition for Anode bed stations in the name of Client, land acquisition in the name of Client for SV-04 (as per specific instruction of Client), realization of bank guarantee/ cash retention submitted by Client with various authorities for obtaining crossing permissions, interference mitigation measures in CP system, compensatory afforestation and maintenance as per the requirement of DFOs, restoration of ROU including obtaining NOCs from land owners/statutory authorities, etc. 3.2

The total pipeline is divided in to two nos. of Spreads for execution. The work involved in each spread is briefly described as under.

3.2.1

Spread - 1 a) Approx. Ch. -4.22 km, Ramanmandi DT to Ch. 26.06 km, Bathinda Receipt Depot) This section covers laying of approx. 31.162 km long pipeline and associated facilities located within the State of Punjab. This includes: • • • •

Laying of 10 “NB X 6.4 mm thk multi product pipeline from Ch -4.22 (Despatch Terminal, Ramanmandi) to approx. Ch 26.06 (Bathinda Receipt Depot). Scraper launching facility at Ramanmandi Despatch Terminal and scraper receiving facilities at Bathinda Receipt Depot Laying of Optical Fibre cable along the pipeline route. Supply & Installation of TCP and permanent CP system.

b) Approx. Ch. -2.00 km Ramanmandi DT to Ch. 122.246 km (Barwala), Excluding SV-04 This section covers laying of approx. 124.246 km of pipeline and associated facilities located in the states of Punjab and Haryana. This includes •

• • • • • 3.2.2

Laying of 18" NB, 8.7/7.9/7.1/6.4 mm thk, multi product from approx. Ch. 2.00km (Ramanmandi Dispatch Station) to approximate Ch. 122.246 km (Barwala) Scrapers launching facilities at Ramanmandi Dispatch Station. Installation of 3 (Three) nos. Sectionalizing valve stations (SV-01 to SV-03). Laying of Optical Fibre Cable along the pipeline route. Supply & Installation of TCP & Permanent CP system HDD at Ghaggar River crossing & parallel Canals

Spread 2 Approx. Ch. 122.246 km, SV- 04 at Barwala to Ch. 242 km, Bahadurgarh Receipt Station This section covers laying of approx. 119.8 km of pipeline and associated facilities located in the states of Haryana. This includes

Doc. No. : 0435-JH0902-00-PL-0004 Rev. B

Page 6 of 23


•

• • • • • •

Laying of 18" (457 mm) OD, 7.9/6.4 mm thk, multi product from approx. Ch. 122.246 km (SV-04) to approximate Ch. 242.00 km (Bahadurgarh Receipt Station) Scraper launching facilities at Ramanmandi Dispatch Station. Scraper receiving facilities at Bahadurgarh Receipt station. Installation of 3 (three) nos. Sectionalizing valve stations (SV-04 to SV-06). Laying of Optical Fibre Cable along the pipeline route. Supply & Installation of TCP & Permanent CP system HDD at parallel Canals

The battery limits pertaining of work covered in each of the spreads as described above is schematically shown in sketch no. 0435-JH902-00-PL-DAG-505 and 506 enclosed with the tender document. 4.0

SCOPE OF WORK The Contractor’s Scope of Work shall consist of, but not limited to, supply (as indicated in Scope of Supply), fabrication, installation, testing, pre- commissioning of pipeline and associated facilities complete, with all associated mechanical, civil, structural, architectural, electrical, cathodic protection (temporary and permanent), instrumentation and Optical Fibre Cable (OFC) laying works including providing commissioning assistance as required and carrying out all such works which though specifically not indicated here but will otherwise be required to complete the work in all respects. The scope indicated below shall be read in conjunction with job specific requirements the schedule of rates, drawings, specifications and other requirements forming part of the Bid/Contract document.

4.1

Main pipeline

4.1.1 "Receiving and Taking-over" as defined in specifications of Owner supplied bare and externally corrosion coated free-issue line pipes from Coating Contractor at Owner's designated dump sites listed subsequently in this document, transportation including loading, unloading, handling, stacking, hauling and stringing of line pipes from Owner's designated dumpsite(s)/place(s) of issue to Contractor's own stock yard(s)/ work site(s)/ workshop(s)/ pipeline right-of-use, including arranging all pipe trailers, cranes etc., arranging all necessary intermediate storage area(s) thereof till the pipes are installed in permanent installation. 4.1.2 Carrying out inspection of Owner supplied free-issue bare and coated line pipe at the time of receiving and taking-over and recording of pipe/coating defects, etc. noticed in the presence of Owner's representative and carrying out all repairs including supply of all repair materials. 4.1.3 Carrying out repairs of pipe and pipe coating not attributable to the Owner including defects/damages occurring during transportation and/or handling after receiving and taking-over including supply of all materials. 4.1.4 For pipes where cutting out involves more than 25mm from pipe ends, ultrasonic inspection shall be carried out at pipe ends as per clause 9.8.5 of line pipe specification no. 0435-JH0902-00-PL-SPC-0003(LSAW), 0435-JH0902-00-PL-SPCDoc. No. : 0435-JH0902-00-PL-0004 Rev. B

Page 7 of 23


0004(EW) line Pipes including supply of all equipments. Contractor shall take prior approval from Owner for the agency engaged for carrying out ultrasonic inspection. 4.1.5 Loading, unloading, handling, stacking, storing and transportation to workshop(s)/ work site(s) of all materials (other than 3LPE coated pipes and bare pipes) that may be used for the construction of pipeline system either supplied by Owner and/or by Contractor as the case may be including transportation of bare/coated line pipes to ROU for installation. 4.1.6 Cutting / up rooting of trees within ROU, of all types and sizes, counting the number and type of trees cut during the pipeline laying works in presence of DFO/concerned authorities and keeping record thereof, stacking and handing over of all cut trees as per direction of Owner representative. Contractor shall also obtain demand notes, if any, from the authorities for depositing money. Owner shall reimburse to contractor all fees paid to Govt. bodies on production of original receipt. All liaisons shall be done by the contractor. Contractor shall be responsible for plantation of new trees, as per the quantity directed by concern authorities and there after maintenance and records keeping of such planted trees up to the period given by concern authorities. 4.1.7 All requirement and stipulations of statutory authorities shall be adhered. 4.1.8 Carrying out all additional topographical survey and/or soil investigations, as required for local detours or otherwise for construction purposes, during execution, including preparation of plan, alignment sheet and profile drawings as directed by Owner representative. 4.1.9 Owner is getting the hydrological and geo-technical survey done for the following River/ Nala i) ii)

Ghaggar river (At approx. ch. 51.275 km) Lisara Nala (At approx. ch. 15.142 km)

However, any additional survey/ investigations required by the Contractor for designing and execution of these crossings shall be carried out by him. For rivers and water bodies other than those listed above, the Contractor shall carry out hydrological survey and geo-technical investigation in accordance with relevant specification and other requirements of the tender document, if required. The Contractor shall submit survey data/reports to Owner within six weeks of award of contract. 4.1.10 Thorough internal cleaning of all pipes to remove debris, shots, grit etc. that may present inside the pipes to the satisfaction of Engineer-in-Charge. 4.1.11 Staking, clearing, grading, fencing of Right of Use (ROU) wherever required, trenching to all depths in all types of soil including soft and hard rock, including blasting, preservation and restoration of top soil as per drawing no. 0435-JH0902-00PL-DRD-0001-18, chiseling or otherwise cutting etc. to a width to also accommodate the optical fiber cable/ cable conduit as per the relevant standards, drawings, specifications etc., providing sand/soft soil/or any other material containing no gravel ,rock or lump of hard soil padding in the trench wherever required including supply of sand/soft soil, aligning, bending, welding, NDT including radiography, field weld joint Doc. No. : 0435-JH0902-00-PL-0004 Rev. B

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coating, external corrosion coating of long radius bends and buried fittings/valves including supply of coating material as per the field joint coating specification, laying and lowering including maintaining the specified minimum spacing between parallel proposed pipelines & existing pipeline (if any), carrying out road, rail, utility and submerged minor & major water crossings Including bank stabilization of water crossings as required including arranging all temporary land/area required for construction purposes; and for stringing purpose at crossings; supply and installation of anti-buoyancy measures viz. continuous concrete coating, Geotextile Bags of Pipe Sak make or equivalent system of anti buoyancy, select backfill, extra cover, etc. on pipeline, back filling including supply of select backfill material where required, backfill of top soil cover minimum 300 mm as per drawing No. 0435-JH0902-00-PL-DRD0001-18, Providing slope-breakers in steep slope areas including supply of all materials, clean-up, pigging, flushing, hydrostatic testing with the quantity of corrosion inhibitor as required, de-watering with the addition of approved chemicals to neutralize the effect of inhibitor added during hydro-test, swabbing, precommissioning, providing commissioning assistance / support including supply of all materials such as required type and quantity of pigs, consumables and manpower that are required during pre-commissioning and commissioning activities including all coordination with and assistance to other agencies/Contractors during commissioning operations and all associated works. NOTE: Field weld joint coating and corrosion coating of Hot Induction (HI) Long Radius (LR) bends shall be by heat shrink sleeve as per specifications No. 0435-JH0902-00-PLSPC-0012 enclosed with bid package. 4.1.12 Providing engineered select backfill consisting of loosely compacted cohesion less soil like sand at the fault locations described in Job Specific Requirement 0435JH0902-00-PL-SOW-0005 and at pipeline entry/exit locations at SV-04 and Scrapper launcher/receiver; including supply of cohesion less soil like sand as per job standards. 4.1.13 At all other locations, the trenching and backfilling shall be as per the job standard for normal and rocky soil. 4.1.14 Making provision of drain, as may be required, in the ROU, along the pipeline route in the reserved forest areas / other areas along the route. The provision of drain may be kept essentially to avoid wash out/erosion of the ROU during monsoons as the reserved forest is prone to incessant rain during monsoons. In addition to above, the sides of ROU shall be stabilized using rock-pitching, as required, slope breakers, soil stabilization mat and select back fill may also be provided, as required, to arrest soil erosion in the ROU in specific areas as per the instruction of Engineer-in-charge. 4.1.15 Installation of pipeline in the Ghaggar River (ROW width 90mtr) and 2 nos. below mentioned Canals crossings are intended to be installed by HDD method. Contractor shall design the HDD and submitted HDD philosophy, Method of statements, operation procedure, required space and time and required calculation for these HDD crossings and additional tape coating requirement while doing HDD. Contractor shall engage a specialist agency for execution of HDD crossings, if the contractor does not possess required experience 1) Adjoin Canals at Ch.93.656 and Ch.93.683 KM @ ROW 110 MTR 2) Adjoin Canals at Ch.210.683 and Ch.210.729 KM @ ROW 112 MTR Doc. No. : 0435-JH0902-00-PL-0004 Rev. B

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Incase Contractor proposes to install any additional crossings by HDD; contractor may do so at his own risk, time and cost. Owner shall not make any extra payment, what so ever on this account. However, contractor may execute other crossings with HDD method, with prior approval of the owner. The rates quoted by the Contractor for all other crossings shall remain applicable irrespective of the method of installation (HDD/any other equivalent method or Open cut/boring method ) adopted. However, Owner may suggest to adopt HDD method for crossing/ laying of pipeline at any specific location. Payment for the same shall be made as per the provisions available in SOR. 4.1.16 The rates quoted for the crossing shall be applicable for the pipeline within the limits of the crossing defined in the drawings enclosed with bid package. Any additional length of pipe installed during crossing installation (beyond limit of crossing defined in the drawings) in order to comply with the minimum requirements of cover/ burial depth specified for the crossing or for any installation convenience shall not be considered as part of crossing and shall be paid as per the rates quoted for the normal laying of the pipeline. No additional compensation shall be admissible in this regard. 4.1.17 Owner shall arrange in principle approval from statutory Authorities for various crossings / Govt. land etc. The responsibility of the Owner ends with providing in principle approvals. Further responsibility for obtaining all necessary approvals/ clearance/work permits including approvals for shifting/re-location of telephone/electrical poles, hume pipe etc. as required for laying the pipeline and completing works as per approval obtained to the entire satisfaction of concerned Authorities lies with contractor. The conditions mentioned in the in principle approvals from statutory Authorities already obtained by the Owner are enclosed with the tender document and shall be binding on the Contractor. For obtaining the crossing permission from various authorities, HPCL have submitted Bank guarantees / cash retention as security deposit towards safe execution of the job. Contractor shall get these security deposits released along with the completion certificate and submit the same to HPCL. Completion of this activity will not be linked to Price Reduction clause for contractual completion of project. However, CPBG (Contract Performance Bank guarantee) shall be released by the Owner only after completion of this activity. 4.1.18 Disposal of surplus excavated soil from trench outside ROU with permission from concerned authorities / land owners and submitting NOC for the same to Owner. 4.1.19 Contractor shall carry out safety measurements for Seismic fault location for Ramanmandi – Bahadurgarh Pipeline route. Chainage of fault location given below Location of Fault Taragwali Fault Jandali Khurd fault Bad Chhapar Fault Kherwali fault

Doc. No. : 0435-JH0902-00-PL-0004 Rev. B

Chainage 10.920 86.671 167.201 201.267

Type of Fault Major Minor Minor Minor

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In case the dug out soil of the trench at fault location indicated above, is of cohesive in nature, the same soil shall be replaced by loosely compacted cohesion less soil like sand for one (1) km on either side of the major fault zone and 500mtr on either side of the minor fault zone. 4.1.20 Installation of all on-line instruments, valves, insulating joints, appurtenances, etc. 4.1.21 Welding of all tie-in joints including tie-in joints for pipeline section laid across other utility crossings and golden joints along with the specified NDT. 4.1.22 Installation of casing pipes (by open cut / jacking / boring) assembly, as required including supply of all materials viz., casing pipe, casing insulators, vent/drains and end seals etc., complete at cased crossings. 4.1.23 Cased crossings shall be installed at locations indicated in alignment sheets. The number of crossings indicated in alignment sheets is subject to change based on engineering, construction and statutory requirements or the requirements of the Authority having jurisdiction over a utility crossing. 4.1.24 Supply of externally painted (as per specification 0435-JH0902-00-PI-SPC-0003) casing pipes. Installation of CS casing pipes for installation of HDPE conduit / OFC cable at crossings and other locations, as required. 4.1.25 Loading, unloading, handing over and transportation of all surplus Owner supplied free issue materials including short length pipes to Owner's designated store and stacking the same as directed by Owner representative. 4.1.26 Supply and installation of all types of pipeline markers including their painting, suitable for normal corrosive environment as per specification 0435-JH0902-00-PISPC-0003 (irrespective of paint system shown on respective standards) and all the associated civil works. 4.1.27 Carrying out flushing, gauging (where applicable), testing and pre-commissioning of pipeline and associated facilities at Dispatch Terminal, Sectionalizing Valve Stations and Receipt Terminal up to the respective battery limits as per Document No 0435JH0902-00-PL-SPC-0008 and 0435-JH0902-00-PL-SPC-0010. 4.1.28 Carrying out magnetic cleaning and electronic geometric pigging of the pipeline including supply of all types of pigs, pig locating and tracking device, spares, consumables, manpower etc as applicable in accordance with specification enclosed and repair of defects found during caliper pigging and electronic geometric pigging including locating, digging, cutting , welding, coating, NDT and backfilling etc. 4.1.29 Providing all equipments, manpower, machinery, consumables including pigs and support/assistance during commissioning of the pipeline system as per Document No 0435-JH0902-00-PL-SPC-0010 4.1.30 Contractor shall carry out safety measurements for AC Mitigation from Chainage 230.501 (IP 259/2) to 234.412 (IP 263/2) at Ramanmandi – Bahadurgarh route (Refer respective alignment sheets), for that Contractor shall perform detailing and submitted to WP for approval.

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4.1.31 Idle time preservation of the pipeline, if required and as directed by Owner representative 4.1.32 Restoration of land, facilities, boundary wall etc. at associated facilities after completion of works as required. 4.1.33 Contractor shall follow Documentation procedure as per specification no. 0435JH0902-00-PL-SPC-0025 4.1.34 Final clean-up and restoration of complete Right of Use including temporary approach routes/ temporary works, roads, canals, water crossings, cultivable land, barren lands etc. to the original condition and to the entire satisfaction of Owner and/or concerned Authorities, Landowners having jurisdiction thereof, including disposal of surplus materials from all work areas. Contractor shall submit ROU restoration certificate to Owner duly signed by plot owners / concerned village officer / statutory body. Contractor to carry out walk-in survey for identification of leftover material, if any, along the pipeline route and return the same to Owner. 4.1.35 Preparation of as-built drawings of the pipeline laid and terminal facilities installed, pipe books, project records and digital photographs and video recording of important activities as per specifications and instructions of Engineer-in-Charge. These records shall also be submitted in a soft/retraceable form. Contractor to make video-film of the entire project right from the beginning to end thru a specialized professional agency. Final film should be submitted along with the final documents. 4.1.36 In addition to details required as per Specification No. 0435-JH0902-00-PL-SPC0025, the as–built pipeline drawings shall show top of the pipe level and co-ordinates of each turning point. The co-ordinates shall be recorded using DGPS of adequate carousel (+/-) 1 metre. The co-ordinates shall be indicated in UTM grid. The drawings shall also show final graded ground profile. 4.1.37 Repair of leaks/burst, not attributable to Contractor, occurring in Owner supplied material shall be carried out by the Contractor and the Contractor shall be compensated as per provisions of the contract. However repair of such defects attributable to Contractor shall be carried out by Contractor at no extra cost to Owner. 4.1.38 In case any activity though not specifically covered in scheduled of rates description but same is covered under scope of work/ /Job specific requirement/ Specification /drawings, it is understood that the contractor shall do such performance & provisions so mentioned without any time implication. 4.1.39 Any other works not specifically listed herein but are required to complete the installation work of pipeline and associated facilities in all respects.

4.2

Associated Works for Pipeline Construction

4.2.1 Design, detailed engineering, supply, installation, testing, pre-commissioning and commissioning of temporary cathodic protection and permanent cathodic protection

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system for the pipeline and associated facilities in accordance with relevant specification and other requirements covered elsewhere in the tender document. 4.3

Associated station works

4.3.1 Works related to spread-1 Ramanmandi – Bathinda Pipeline: Facilities to be installed at Ramanmandi – Bathinda Pipeline route are limited to installation of scraper launching facility at Ramanmandi and Scraper receiving facility at Bathinda. These battery limits as shown in the sketch no. 0435-JH0902-00-PLDAG-505, Equipment layout, P&IDs, piping GAD and other documents including associated works indicated subsequently in tender document. Ramanmandi – Bahadurgarh Pipeline: Facilities to be installed at Ramanmandi – Bahadurgarh Pipeline Route is limited to installation of scraper Launching facility at Ramanmandi and SV Station no. 01,02 and 03 and pipeline up to approx, chanage 122.246 KM (excluding SV-04 Installation). These battery limits are shown in the sketch no. 0435-JH0902-00-PLDAG-506, Equipment layout, P&Dds, typical piping GAD and other documents including associated works indicated subsequently in tender document.

4.3.3 Works related to spread-2 SV station 04 to Bahadurgarh Scraper receiver: A facility to be installed at Ramanmandi – Bahadurgarh Pipeline Route is limited to installation of SV Station 04, 05, 06 and Scraper receiving facility at Bahadurgarh. These battery limits are as shown in the sketch no. 0435-JH0902-00-PL-DAG-506, Equipment layout, P&IDs, typical piping GAD and other documents including associated works indicated subsequently in tender document. Preliminary equipment layouts and typical Station approach drawing for the terminals/stations are enclosed with this Tender. These drawings are indicative only and are enclosed to enable the Bidder to understand the nature of work involved. Owner is getting the detailed engineering carried out for the terminal/station works and Approved for Construction (AFC) piping General Arrangement Drawing’s (GADs) shall be progressively furnished by the Owner to the Contractor, at an appropriate time at project execution stage. Contractor shall carry out all works strictly in accordance with the ‘Approved for Construction’ (AFC) drawings and reference specifications/standards, documents, data sheets etc. enclosed with this tender document and instructions of Owner/ Engineer-in-Charge and other provisions of Contract document. Scope of work for Terminal/station piping indicated below shall be read in conjunction with the Schedule of Rates, drawings, specifications, standards, Job Specific requirements and other documents forming a part of the Contract document. The

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Contractor's Scope of Work for Terminal/station piping shall consist of, but not limited to, the following. 4.3.5

Associated Station works (applicable for all spreads) Works involved at facilities detailed above shall be carried out as per respective P&ID’s, Equipment Layouts, Approved for construction Piping GAD,s, Alignment sheets and other documents including associated works indicated subsequently herein as detailed below:

a)

Providing all equipments, manpower, machinery, consumables for fabrication, installation, inspection, testing and pre-commissioning and assistance / support for commissioning; all types of safety tools, tackles, devices and apparatus, equipment etc. including ladders and scaffolding etc. complete as required including providing of all types of consumables, tools, tackles and facilities for inspection and interpretation of testing results by Owner/ Owner’s Representative as per document no 0435JH0902-00-PL-SPC-0006. Furnishing and mobilizing at site(s) of all construction equipment, tools and tackles, fully equipped and fully manned with other required support facilities etc. needed for successful execution of the works.

b)

"Receiving and Taking-over" as defined in specifications of all Owner supplied materials including equipments from the Owner’s designated place(s) of issue defined elsewhere, transportation including loading, unloading, handling from Owner’s designated place(s) of issue to Contractor's own stock yard(s)/ work site(s)/ workshop(s), including arranging all necessary intermediate storage area(s) thereof till the materials are installed in permanent installation.

c)

Transportation of all materials other than that are supplied by the Owner from the manufacturer’s works, including loading, unloading, handling, staking, storing and transportation to workplace(s) including arranging all intermediate storage area(s) thereof as required. Transportation of material, supplied as free issue by Owner, from the Owner designated storage/stack yards to the installation/work site(s) shall also be in Contractor’s scope.

d)

Filling (wherever required) and grading of stations areas as specified for avoiding any flooding.

e)

Obtaining all statutory clearances, approvals and permissions for the works as required. Obtaining hot work permits from Owner/ concerned authorities having jurisdiction thereof to work within existing and operating terminals including strictly complying with all stipulations/conditions/recommendations of the concerned authorities and providing all safety appliances, gas detectors, fire screens required during execution of the work as per the direction of Owner/Engineer-in-charge. Coordinating all activities with Owner for movement of men and material from and to existing and operating terminals shall be the responsibility of the Contractor.

f)

Preparation of detailed procedures for fabrication, installation, testing and precommissioning. Such procedures shall be submitted to Engineer-in-Charge for review and approval.

g)

Preparation of isometrics and/or fabrication drawings required for the purpose of fabrication during execution of work.

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h)

Fabrication, erection, installation, testing of all above-ground/buried piping system including piping for scraper launcher/receiver etc. consisting of pipes, valves (manual and actuated), flanges, fittings, flow tees, pig signalers etc; carrying out all applicable works associated with buried pipeline within the battery limit of stations/SV stations boundary wall/fence (wherever applicable), foundation work including installation of equipments such as scraper launchers, scraper receivers, pig handling devices, carrying out welding, NDT including radiography; hydro-testing, pre-commissioning, providing commissioning assistance including supply of all materials and manpower that are required during pre-commissioning and commissioning and all associated works.

i)

Installation of all in-line and on-line instruments, Skin Temperature measurement assemblies etc. as shown in the P&ID’s except those separately covered elsewhere in the tender document.

j)

Carrying out welding including cutting, edge preparation (inclusive of grinding the edges of pipe, fittings, flanges, etc. to match with the matching edges of different thickness wherever required), fit-up, bending, pre heating wherever required, NDT including radiography and other non-destructive tests as specified.

k)

Hydro-testing, dewatering, pre-commissioning and support/assistance for commissioning activities related to piping system of all sizes as per Document No 0435-JH0902-00-PL-0008 and 0435-JH0902-00-PL-0010.

l)

Repair of leaks/burst, not attributable to Contractor, occurring in Owner supplied material shall be carried out by the Contractor and the Contractor shall be compensated as per provisions of the contract. However repair of such defects attributable to Contractor shall be carried out by Contractor at no extra cost to Owner.

m)

Excavation, cutting, beveling and welding of tie-ins required for installation of valve assembly, as required.

n)

Installation of all types of valves (manual / actuated), inline and online instruments, safety valves, tapping for thermo wells, sample connections, pressure gauges, corrosion coupons, corrosion probes etc. for all sizes and ratings including installation of all types of strainers including fixing of gaskets, bolts, studs and nuts of all sizes, ratings and materials.

o)

Hook-up of piping facilities by welding or by flanged connection (as shown in AFC drawings) with equipments/valves/piping and at the battery limit with the facilities installed by others including cutting, fit-up, welding, NDT, radiography, interface/coordination as required with other Contractor(s)/Agencies.

p)

Painting of all equipments, pipe supports, piping and all miscellaneous items as required including surface preparation and supply of paints. Paints shall be suitable for normal corrosive environment for all SV stations in accordance with specification no. 0435-JH0902-00-PI-SPC-0003

q)

Epoxy Coating of all underground and aboveground valves pup pieces portion shall be as per specification 0435-JH0902-00-PL-0003. For above ground refer Option-1

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table and for Underground combination of P03 + F04 = 350+150 = minimum 500 micron thk. r)

Corrosion protection coating (Heat shrink Sleeves) of all field weld joints for buried piping of all sizes including supply of all materials.

s)

Idle time preservation of the pipeline facilities, if required. For idle time preservation contractor to analyze quality and quantity of corrosion inhibitor required for the period of preservation to be adopted. The period of preservation to be adopted shall be as per the instruction of Owner. Contractor to provide relevant test reports of water sample and detailed calculation to owner for approval.

t)

Final clean up and restoration of site, facilities etc. as per the requirement of Owner representative

u)

Transportation of all surplus Owner supplied free issue material to Owner’s designated stores or as directed by Owner representative after completion of works.

v)

All associated geo-technical, civil, structural, electrical, telecom, architectural, mechanical and general civil works including supply of all material required, unless covered separately elsewhere in the tender, including construction of foundations for equipment and pipe supports and sleepers, fabrication & erection of pipe supports/ dummy supports including support elements such as shoes, clamps, brackets, anchors, guides, insert plates, structural column etc.

w)

Preparation of As-built drawings, documents and project records as per the instruction of Engineer-in-Charge.

x)

In case any activity though not specifically covered in scheduled of rates description but same is covered under scope of work/ Specification/ specific requirement/ drawings, it is understood that the contractor shall do such performance & provisions so mentioned with out any time implication.

y)

Any other works not specifically listed herein but required for completion of the works in all respects.

5.0

SCOPE OF SUPPLY

5.1

Materials to be supplied by Owner Owner shall supply the following Pipeline/ Terminal piping materials required for permanent installation to the Contractor at an appropriate time during the execution stage as free issue materials:

5.1.1 Line pipes All free issue line pipes (bare/ coated) shall be made available by the Owner at designated dumpsites. The distributions of coated/bare line pipes at various dumpsites for the purpose of making them available to Contractor are detailed below. Distribution of Line Pipe at Dump sites

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Dumpsite

Sl. No

Line pipe details (API 5L Gr. B and Gr. B)

Chainage (km)

Pipeline Length (m)

Spread – 1 – Ramanmandi- Bhatinda Pipeline

Ramanmandi, DS-01

1.

Dumpsite

Sl. No

Near Ch. 0.00

273.1mm OD, 6.4 W.T., API 5L Gr.B

31500

273.1mm OD, 6.4 W.T., API 5L Gr.B

70*

Line pipe details (API 5L Gr. X-60)

Chainage (km)

Pipeline Length (m

Spread-2 & 3 – Ramanmandi – Bahadurgarh Pipeline

Ramanmandi, DS-01

1

Dumpsite

Sl. No

2

Barwala, DS-02

Dumpsite

Sl. No

3

Bahadurgarh, DS-03

Near Ch. 0.00

457mm OD, 7.9 W.T., API 5L Gr.X-60 LSAW 457mm OD, 7.1 W.T., API 5L Gr.X-60 LSAW 457mm OD, 6.4 W.T., API 5L Gr.X-60 LSAW 457mm OD, 8.7 W.T., API 5L Gr.X-60 HSAW

Chainage (km)


Near Ch. 120.00

457mm OD, 7.9 W.T., API 5L Gr.X-60 LSAW 457mm OD, 6.4 W.T API 5L Gr.X-60 LSAW

Chainage (km)


Near Ch. 242.00

457mm OD, 6.4 W.T API 5L Gr.X-60 LSAW 457 mm OD, 8.7 W.T., API 5L Gr.X-60 LSAW

37200 20000 32200 600 Pipeline Length (m

34000 76000 Pipeline Length (m

48600 500*

* The pipe shall be supplied bare without any coating Notes: 1. 2. 3.

4.

5.

Line pipes of 457mm OD shall be LSAW/HSAW type. Line pipes of 273.1mm OD shall be EW type. Contractor shall note that actual dumpsite locations indicated in the document may vary slightly from that indicated above. Contractor shall be responsible for performing all works as per scope of work at the finally selected dumpsite locations at no extra time/ cost to the Owner. Quantity of line pipe mentioned above includes the quantities required for other works that will form a part of pipeline Contractor to be installed within SVs station facility. Contractor to note that the quantities of line pipes indicated above includes surplus quantities over and above the actual requirement. Surplus pipes shall be returned to the Company as per the provisions indicated elsewhere in the contract.

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6.

In addition to the above, following bare line pipes of size & thickness shall be used for fabrication of Hot Induction (HI) LR bends by the Contractor in addition to their usage in station piping. The contractor shall ensure the total quantity of line pipes required is adequate enough for fabrication of HI LR bends.

LINE PIPE DETAILS FOR HI BEND

LENGTH (m)

Spread-1

273.1 mm OD, 8.7 W.T., API 5L Gr. B, EW

70

Spread-2

457 mm OD, 8.7 W.T., API 5L Gr.X-60, LSAW

200

Spread-3

457 mm OD, 8.7 W.T., API 5L Gr.X-60, LSAW

200

SPREAD

5.1.2

Pipeline Materials (other than free issue line pipes) Owner shall supply following pipeline specialty long delivery items, in required quantities, as free issue material to the Contractor at appropriate time during execution of the work at the Owner designated storage yards: - Scraper launchers/receivers of all sizes complete with pig handling system including Jib crane and pig trolleys) and pig signalers mounted on scraper traps and pipeline. - Pig signallers of all sizes to be installed at locations other than scraper traps. - All motor operated AG and UG pipeline ball valves of sizes 10” & 18”. - OFC cables - D.G. Sets for SVs - DC UPS Owner’s has identified and shall maintain designated stores at Ramanmandi and Bahadurgarh. All free issue material (other than line pipe) shall be issued to the contractor from nearest designated stores as under: S No. 1 2 3

Designated Stores Ramanmandi Ramanmandi Bahadurgarh

Area coverage limit for free issue materials Ramanmandi to Bathinda Ramanmandi(Pumping St.) to SV-04 (near Barwala) SV-04 (near Barwala) to Bahadurgarh (Receipt St.)

NOTE: Sectionalizing valve (SV) and Diesel Generator sets for SV02 to SV 06 will be issued from Bahadurgarh stores. 5.1.3

Conditions for Owner Supplied Material

5.1.3.1 The Contractor shall be responsible for taking over of all the material and subsequent handling, hauling, transportation to the actual work site(s)/fabrication yard(s) and storage & safe keeping of the all materials. 5.1.3.2 The Contractor shall inspect all Owner supplied free issue materials at the time of taking over from the Owner and defects noticed, if any, shall be brought to the notice Doc. No. : 0435-JH0902-00-PL-0004 Rev. B

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of Owner/Owner representative and jointly recorded. Once the material has been taken over by the Contractor, all the responsibility for safe keeping of the materials shall rest with the Contractor. 5.1.3.3 Every month the Contractor shall submit to the Owner an account for the material issued to the Contractor in the Performa prescribed by Engineer-in-Charge. 5.1.3.4 On completion of the works Contractor shall submit a “Material Appropriation Statement” for all materials supplied by the Owner as free issue materials. 5.1.3.5 The scrap allowances shall be permissible as per the provision of contract document. The percentage allowance shall be accounted on the basis of actual consumption as incorporated in the work. 5.1.3.6 All unused and scraps material shall be the property of the Owner and shall be returned by Contractor to Owner at Owner’s designated storage point(s) including transportation of the same from Contractor’s stock yard(s)/worksite(s)/work shop(s) to the Owner’s designated storage point(s). Contractor shall be responsible for the proper measurements of the unused/scrap materials to be returned to the Owner. 5.1.3.7 Owner also have surplus coated pipeline material (X-Stock) stored at its various terminal site of Mundra-Delhi pipeline listed elsewhere in tender. Contractor shall be responsible to inspect and identify usable pipeline lengths in the presence of owner representative. Contractor shall take over all the identified pipe lengths good for the service and shall takeup subsequent repairs, handling, hauling, transportation to the actual work site(s)/fabrication yard(s), storage & safe keeping of the all materials. Contractor shall use these pipes on priority from Bahadurgarh end, however, these pipes will not be used at any crossing location. 5.2

Materials to be supplied by Contractor The procurement and supply, in sequence and at the appropriate time & place, including inspection & expediting of all materials, consumables and any additional materials required for completion of the work as defined in this tender document except the materials specifically listed under para 5.1 above as Owner supplied freeissue material, shall be entirely the Contractor's responsibility. The item rates quoted for the execution of the work shall be inclusive of supply of all these materials. All materials supplied by the Contractor shall be strictly in accordance with the requirements of relevant applicable Owner Material Specifications enclosed with the tender document. All equipment, materials, components etc. to be permanently installed as pipeline system shall be new and specifically purchased for this job from Owner approved vendors, duly inspected by Owner approved third party inspection agency (Only manufacturer’s certificates shall not be adequate). Contractor shall submit all details /drawings etc. to Owner for review and approval before placement of order. As a minimum, such materials to be supplied by the Contractor shall include, but not limited to, the following:

a)

All pipeline materials of all sizes including pipes, fittings, flanges, cap, spectacle blinds, etc, required for permanent installation in the system

b)

All valves (gate, globe, check, ball, plug etc.) of size 4” and below as per specification and data sheet, required for permanent installation in the system

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c)

All stud bolts & nuts ( including the ones required for dual plate check valves) , jack screws, all type of gaskets (metallic spiral wound gaskets) in required quantities to be used for permanent installation into the system for all sizes and ratings of flanges and flanged valves, equipment etc.

d)

Long radius Hot Induction bends (R = 6D) of all angles and wall thickness (fabricated from Owner supplied free issue mother pipes). Tentative required length for each bend and bend respective chainage, refer document no. 0435-JH0902-00-PL-MTO0202, 0435-JH0902-00-PL-MTO-0203 however this documents only for reference contractor shall carry out actual bend angle and required length as per actual site condition. Transportation including handling and loading of line pipe from Owner’s designated dump site/ storage yard to Contractor’s yard/fabricator’s works, unloading, for manufacturing bends and return of surplus pipe back to Owner’s storage yard with pipe identification marking shall be in contractor’s scope. Contractor shall optimize use of pipe for fabrication of bends based on actual length of pipe received. Wastage of pipe shall be contractor’s account. The bends shall be manufactured at the works approved manufacturers by the Owner. The quantities required for bends shall include fabrication and pre qualification testing of bends.

e)

Insulating joints of all sizes & rating as per relevant data sheets and specifications.

f)

Flow tees of all sizes as per data sheets as per relevant data sheets and specifications.

g)

All casing pipes, casing insulators and end seals including materials for vent and drain and carbon steel pipes for optical fiber cable (OFC) conduits in required quantities. Size of casing pipe for carrier pipe and carbon steel conduit for OFC shall be as follows: i. ii. iii.

24” (610 mm) O.D., 7.9 mm WT, API 5 L Gr. B/ IS 3589, LSAW/HSAW, – for 18” NB (457.0mm O.D.) carrier pipe at rail/road crossings. 16” (406.4mm) O.D., 6.4mm WT, API 5 L Gr. B/IS 3589, LSAW/HSAW –for 10” (273.1mm) OD, carrier pipe at rail/road crossings. 6” dia., Heavy IS 1239- casing pipe for OFC.

Width for each crossing for Spread 1 and 2 with respective chainage, refer document no. 0435-JH0902-00-PL-LST-1020. Length of OFC casing shall be taken as same as that for the pipeline casing. The details given in doc, 0435-JH0902-00-PL-LST-1020 are the indicative. Exact chainage, crossing type, method are to be verified by the Contractor at site and execute as the instruction of Engineer In-Charge. h)

All Materials for Field joint coating, corrosion coating of HI bends and repairs of damaged corrosion coating of line pipes.

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i)

All materials required for civil, structural and general civil works including structural steel, cement, sand, reinforcement, etc. for facilities at Dispatch Terminal, SV Stations, and Receipt Terminal including all types of equipment and material required for excavation/ construction of pits for equipment and instrument installations.

j)

All materials for all types of markers including painting conforming spec. 0435JH0902-00-PI-SPC-0003, cement, sand, reinforcements, structural steel, etc.

k)

All types of coating and painting materials including primer and paints required for above ground pipeline facilities as per specification 0435-JH0902-00-PI-SPC-0003 For above ground refer Option-1 table and for Underground combination of P03 + F04 = 350+150 = minimum 500 micron thk. For piping/ valves

l)

All materials required for continuous concrete coating/ Set of Concrete Boxes / Geotextile Bags of Pipe Sack make or equivalent system / including concrete coating of field weld joints for providing negative buoyancy wherever required.

m)

All steel materials such as structural steel, reinforcement steel, shims, wedges, packing plates, pipes, nuts & bolts, washers, U-bolts, anchor bolts, clamps, clips, pipe saddles/shoes etc. as required for the fabrication of structural supports and supports basements/foundations, platforms etc. Pipes supplied by Owner shall not be used for fabrication of supports and support saddles etc.

n)

All materials, equipments along with necessary piping and instrumentation connection, consumables, pigs and manpower required for providing assistance / support for commissioning of the system.

o)

All materials i.e. fittings, flanges, valves, blind flange etc. required for isolation and nitrogen purging for pipe section(s).

p)

All equipment and consumables for welding such as welding electrodes, oxygen, acetylene, inert gases, all types of electrodes, filler wire, solder wire, brazing rods, flux etc. for welding/ cutting and soldering purpose.

q)

All temporary materials required for filling, pressurizing and dewatering in connection with hydrostatic testing including pipes, flanges, blind flanges, fittings, temporary gaskets, nuts, bolts, clamps, strainers etc required for fabrication of test headers and all consumables.

r)

All equipment and consumables required for all types of test and NDT (such as radiography, UT, magnetic particle examination, dye penetration testing, etc.) including radiographic film, X-ray/gamma ray machines as per relevant specification, developing equipment and consumables, etc.

s)

All equipment and consumables required for hydrostatic testing like pumps, pressure and temperature gauges, test water and corrosion inhibitors for test water for hydrostatic testing and water for idle time preservation if required.

t)

All pigs required for cleaning, gauging, filling, de-watering, pre-commissioning and commissioning of the pipeline.

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u)

All materials and equipments related to blasting of rock for excavating trench or grading of ROU, pipeline and pipe laying/installation and other works.

v)

All materials required for sand/soft soil or any other material containing no gravels, rock or lump of hard soil padding around pipeline and OFC cable at no extra cost to owner, including slope breakers, select backfill of approved quality, bank stabilization of water crossings wherever required.

w)

Cohesion less soil like sand in required quantity for backfilling of trench along pipeline route.

x)

All materials required for repair/restoration of pavements, roads, bunds, walls, other structures that are affected/damaged by Contractor's construction activities. Materials shall be equivalent/superior to those used for original construction of the facility.

y)

All materials and consumables required for hook-up.

z)

Materials for making sand ridges (sand, polyethylene sheets etc.) for pipe stacking at dump sites/stock yard/contractor storage yard.

aa)

All material required for concreting and grouting works etc

bb)

All type of safety tools, tackles, devices, safety appliances, gas detectors, fire screens, apparatus, equipment, etc. including ladders and scaffolding etc. complete as required.

cc)

Supply and Installation of PVDF sheet above pipeline where the pipeline crossing and running under the electrical wire network

dd)

Supply and installation of PVDF sheet above pipeline where pipeline crossing under beneath of existing pipeline

ee)

Supply, Painting and installation of CS Casing pipe where ever required at crossing as per alignment sheet details and painting specification

ff)

Any other material not specifically listed herein, but required for the successful completion of the work. The item rates quoted for the execution of the WORK shall be inclusive of supply of all materials mentioned above unless specifically covered otherwise under Schedule of Rates. The quantities indicated in Schedule of Rates under Contractor’s Scope of Supply are approximate. Contractor shall carry out MTO of all materials required based on AFC General Arrangement drawings, alignment sheets and firm up the actual requirement of materials. All escalations/ extra materials procured by Contractor for contingencies shall be Contractor’s property and no payments shall be made for such materials. Payment shall be made for actual materials installed by the Contractor as a part of permanent installation

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6.0

LIST OF ATTACHMENTS Refer Document No. 0435-JH0902-00-PL-LST-0103 of the Tender Document for List of Attachments for Pipeline Construction Tender

7.0 SCOPE OF WORK FOR SERVICES FOR LAND ACQUISITION FOR SV/CP STATIONS (Optional Scope to be takenup on specific confirmation from Owner) 7.1 The contractor shall provide the services for acquiring land for SV/CP-04 location falling on the Ramanmandi-Bahadurgarh pipeline. Land admeasuring approximately 60m X 40m per station is to be permanently acquired for setting up the station with allied facilities. 7.2 The Contractor’s scope of job includes, but is not limited to, the following: a

Assist identification of plot in close vicinity of Ch. 122.246 Km of Pipeline along the pipeline route and acceptance by HPCL.

b

Collection of revenue records, establishing correctness of ownership by search/ revenue records, nil encumbrances etc.

c

Acquiring the land in the name of HPCL.

d

Expediting subsequent formalities including signing of agreements or sale deed if any, to facilitate possession of land by HPCL.

e

Making payment to land owners.

f

Obtaining all required approvals/ no objection certificates from concerned authorities like village panchayats or municipalities etc. under whose jurisdiction each plot of land falls, for constructing and setting up the SV/CP Station -04.

g

Obtaining approvals from concerned road authority for laying of approach road to SV-04 station from the nearest road.

h

Registering the land in HPCL’s name

i

Entry of HPCL’s name in original Jamabandi on the acquired plot no. and obtaining copy of the same in support.

j

After taking possession of the land party to prepare layout plan of station showing outside roads etc.

7.3 HPCL’s scope in above context shall be limited to: i)

Payment of statutory fees like registration fees, stamp duty etc.( if any)

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HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) JOB SPECIFIC REQUIREMENTS – PIPELINE LAYING AND ASSOCIATED WORKS


JOB SPECIFIC REQUIREMENTS – PIPELINE LAYING AND ASSOCIATED WORKS 0435-JH0902-00-PL-SOW-0005 19 Sept, 09


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SYNOPSIS



DESCRIPTION

PREPARED BY

CHECKED BY

APPROVED BY

A

Issued for IDC

D. Memnathan

S. Ishwad

N. Agarwal

B

Issued for Review

D. Hemnathan

S. Ishwad

N. Agarwal

C

Issued for Tender

D. Hemnathan

S. Ishwad

N. Agarwal

Doc. No. : 0435-JH0902-00-SOW-0005 Rev. B

DATE

CLIENT APPROVAL

27 August 09

N/A

05 Sept. 09

19 Sept. 09

Page 2 of 14

DATE


CONTENTS 1.0 INTRODUCTION...........................................................................................................3 2.0 JOB SPECIFIC REQUIREMENTS................................................................................3 3.0 AS-BUILT DOCUMENTS............................................................................................14 4.0 DOCUMENTS TO BE SUBMITTED AT THE TIME OF BIDDING..............................15 5.0 GENERAL...................................................................................................................15

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1.0

INTRODUCTION This document covers the additional guidelines/ requirements for the pipeline construction activities. This specification shall be read in conjunction with Scope of Work for pipeline laying and associated works (document no. 0435-JH0902-00-PLSOW-0004).

2.0 2.1

JOB SPECIFIC REQUIREMENTS General Owner is getting the engineering carried out for the complete pipeline including the facilities that are to be installed at Despatch Terminal, SV Stations and Receipt Terminals. Approved for Construction (AFC) drawings shall be made available to the successful Bidder by Owner. It is the responsibility of the Contractor to carry out complete installation works as per the followings. a) Piping and Instrumentation Diagram (P&ID’s) and line schedule. b) Approved for construction Piping General Arrangement Drawings (GADs). c) Approved for construction Alignment sheets/crossing drawings. d) Piping Material Specifications. e) Specifications, Piping support standards/drawings and support index. f) Any other drawings/sketches prepared by Owner and/or by the Contractor and approved by the Owner.

2.2

Vendor Drawings of Owner Supplied Materials Owner shall furnish Vendor Drawings of all equipment / materials, as required, that are being supplied as free issue to Contractor, at an appropriate time during design and detailed engineering, in case Contractor requires the same for his work execution.

2.3

Pipeline Route

2.3.1

Route Description Owner has finalized the entire pipeline route. The proposed 18”NB pipeline alignment originates from GGSREP dispatch terminal at Ramanmandi, Punjab and runs in the south-east direction and terminates at Bahadurgarh receipt station in Haryana. In addition, the 10” NB pipeline also originates from GGSREP dispatch terminal at Ramanmandi, Punjab and runs in the north direction and terminates at Bathinda receipt station in Punjab. Pipeline crosses various Ghaggar river, National Highways (NH), State Highways (SH), Express highways, other roads, railways, water crossings such as drains/ nalas /canals (lined and unlined) & streams en-route. In addition, the pipeline route is also indicated in route maps and alignment sheets for all the spreads. Contractor is advised to make site visits to familiarize themselves

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with all the salient features of terrain and available infrastructure along the pipeline route. Contractor shall be deemed to have considered all constraints and eventualities on account of site conditions along pipeline route while formulating his bid. Contractor shall not be eligible for any compensation in terms of cost and/or time, on account of site conditions along pipeline route varying to any extent from whatever is described in the tender document and the drawings furnished along with the tender document. 2.3.2

Pipeline Route Survey Survey data along entire pipeline route such as route maps, alignment sheets including plan and ground profile details are enclosed along with the tender document. It shall be the Contractor’s responsibility to verify the pipeline routes. Where in Contractor’s opinion the survey and investigation data is not found to be sufficient in detail, it shall be the responsibility of the Contractor to arrange and provide such additional data/information at no additional cost to Owner. Contractor shall also perform any additional topographic surveys and geo-technical surveys that may be required during execution of the project for local detours or at any other locations without any extra cost to the Owner. Contractor shall be deemed to have considered such eventualities while formulating his bid.

2.3.3

Soil Investigation and Soil Resistivity Survey Soil investigation (visual classification/ stratification) and resistivity survey data along the pipeline route is enclosed with the tender document for reference purposes only. It shall be Contractor's responsibility to verify the data and satisfy himself with regard to accuracy and utility of this data. Contractor shall not be entitled for any compensation in terms of time or cost in case of any variation in actual site conditions from the data furnished in the tender document. It shall be Bidder's responsibility to familiarize himself with sub-soil conditions along the pipeline route at the proposed alignment, and workout the lengths of pipeline to be laid in different subsoil conditions including the quantum of rock excavation that would be necessary. Rates for pipeline construction as quoted shall be inclusive of all rock excavation. No extra compensation shall be payable to Contractor for any rock excavation whatsoever. NOTE : Contractor shall carry out soil investigation and topographical survey for the SV stations. Cost of the same shall be included in the quoted rates.

2.3.4

Alignment Sheets and Associated Drawings Preliminary Alignment Sheets, Station approach drawings, equipment layouts and typical piping GADs for associated facilities are included in the Tender document. These drawings are indicative only and are furnished to enable the Bidder to estimate the quantum of work and to quote a firm price for the work. Final alignment sheets and piping GA drawings, etc. shall be prepared by contractor. Contractor shall carry out all the works in accordance with the ‘AFC’ drawings.

2.4

R.O.U.

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For pipeline construction purposes, in general 18.0 meter ROU shall be made available to Contractor by the Owner. However, in certain restricted areas such as reserved forest areas, private holdings, congested and plantation areas etc, ROU may be restricted to a width of 10.0 meter or less. Contractor shall carry out construction work within the width as made available to him with no extra time and cost implication to the Owner. It shall be Contractor's responsibility to make arrangement for any additional land required for laying in restricted areas / HDD crossings/ other crossings areas for fabrication, construction, storage and all other work areas. 2.5

Line Pipe and Coating Owner shall supply line pipe bare and externally corrosion coated with 3-layer sideextruded polyethylene coating. Contractor shall receive and take over the pipes at the designated places of issue progressively from the coating Contractor in the presence of Owner representative. At the time of 'taking over', Contractor shall perform inspection of pipes and pipe coating and record all defects noticed in the presence of Owner's representative. Contractor shall takeover the entire quantity of bare and coated line pipe from Coating contractor at dump site(s). Return of surplus line pipe material to Owner’s designated storage yard is in Contractor’s scope including loading, transportation, unloading, and handling, stacking of pipes at storage yard and getting the pipes inspected by Owner’s representative at storage yard. Contractor shall repair all defects recorded at the time of 'taking-over' of pipes and will be compensated as per rates set forth in the Schedule of Rates. However, rebuffing for dents in bevels less than 1mm in depth shall be carried out by Contractor ahead of welding in the field at no extra cost to Owner. Repair of PE coated pipes Any repairs to 3LPE coating attributable to Owner shall be carried out by Contractor using Contractor supplied PE repair patch compatible with parent coating system. Method of repair of pipe corrosion coating shall be as per specification enclosed with the tender document. The coating repair procedure for application shall be submitted to Owner for approval prior to start of construction. Repair of PE coated pipes in field shall be carried out as follows in accordance with specification enclosed in the bid. a. 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 2.0mm and an area not exceeding 20 cm2 shall be rebuild by heat shrink patch only and without exposing to bare metal. b. 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. c. Defects exceeding the above and in number not exceeding 2 per pipe and linear length not exceeding 500mm shall be repaired using heat shrinkable sleeves of HTLP 80 or equivalent.

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2.6

Storage of material

2.6.1

All materials shall be preserved against deterioration and corrosion due to poor or improper storage while under the custody of the Contractor.

2.6.2

All materials shall be duly protected by the Contractor at his own cost with the appropriate preservatives like primer, lacquer coating, grease etc. and shall be covered with suitable material to prevent them from direct exposure to sun, rain, wind and dust.

2.6.3

Pipes shall be stacked according to the API RP 5L1/API RP 5LW with identification marks and stacks shall be arranged on sleepers/sand pads at least 300 mm above ground.

2.6.4

The Contractor shall check that valves, fittings, specials etc. are not subjected to corrosion from hydrostatic test water remaining in the packing. Any such condition when detected should be brought to the notice of Engineer-in-Charge and remedial measures taken as directed.

2.6.5

All machined surfaces shall be properly greased and should be maintained and protected from damages.

2.6.6

Openings of equipment, machinery, valves etc. shall be kept blocked/covered with blinds to prevent entry of foreign matter.

2.6.7

As far as possible materials shall be transported to the site of erection only just prior to the actual erection and shall not be left lying around indefinitely on ground but kept on packing/sleepers etc. to maintain the minimum distance from the ground as specified and/or as per directions of Engineer-in-Charge.

2.7

Pipe allocation at dumpsites In case pipes meant for two or more spreads are being supplied from one dumpsite, the Contractor shall coordinate while take over of pipes and Coating contractor maintaining the dumpsite shall allocate the pipes as per the directions of Engineer-incharge.

2.8

Pipeline Burial Pipeline burial depth shall be appropriate for the route, surface use of land, terrain features and external loads imposed. The entire pipeline between scraper traps shall be buried with a minimum cover of 1.2 meter except in areas likely to have an increased risk of impact damage or third party interference where pipeline shall be buried with a minimum depth of cover as given below: S.No. a) b) c) d)

LOCATION MINIMUM COVER (m) Rocky terrain 1.0 Minor water crossing/canal/ nala 1.5 Drainage, ditches at roads crossings 1.5 Uncased/cased road crossings/Station 1.2 approach

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e) f)

Cased railway crossings River Crossings (Below scour level)

g)

Marshy land/Creek area

1.8 2.5 (For normal soil) 1.5 (For rocky strata 2.0

The minimum cover may further be increased based on the safety and risk assessment. Where ever the pipeline runs within 15m from habitable dwelling unit additional cover of 300 mm shall be provided. 2.9

Long Radius (R=6D) Bends Long radius bends of all angles supplied by the Contractor shall be fabricated from Owner supplied free issue line pipe as per specifications given in document no 0435JH0902-00-PL-SPC-0014. Transportation including handling and loading of line pipe from Owner’s designated dump site/storage yard to Contractor’s yard/Fabricator’s works, unloading, for manufacturing of bends and return of surplus pipe back to Owner’s storage yard with pipe identification marking shall be in Contractor’s scope. Contractor shall optimize use of pipes for fabrication of bends based on actual length of pipes received. Wastage of pipes shall be to Contractor’s account. The quantities required for bends shall include fabrication and pre-qualification testing of bends.

2.10

Priorities Owner may, at its sole option, assign priority of construction to any part of total pipeline length. Contractor shall comply with such priority of execution without any Cost and time implication to the Owner.

2.11

Pipeline through Seismic Areas Pipeline route is passing through the seismic zone. Owner has carried out seismic analysis for pipeline and following recommendation is made: Location of Fault Taragwali Fault Jandali Khurd fault Bad Chhapar Fault Kherwali fault

Chainage 10.920 86.671 167.201 201.267

Type of Fault Major Minor Minor Minor

In case the dug out soil of the trench at fault locations indicated below, is of cohesive in nature, the same soil shall be replaced by loosely compacted cohesion less soil like sand for the one km. stretch of pipeline on the either side of these fault line locations in case of major fault and 500mtr on either side of the minor fault zone. The sand padding shall be of at least 300mm thick all around the pipe. 2.12

Pipeline Construction in reserved forest areas/hill areas. Where the pipeline route passes through forest areas, Contractor shall clear only the minimum width required for laying the pipeline as per Owner’s approved procedure. Number of trees/ plants to be felled shall be kept to a minimum.

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Considering the nature of terrain in this area, the ROU may have a provision of drain, as required, essentially to avoid wash out during monsoons. This will minimize the erosion of the ROU during regular monsoons. In addition the sides of ROU may be stabilized using rock-pitching, as required. Slope breakers, soil stabilization mat and select back fill may be provided, as required, to arrest soil erosion in the ROU. Cross slopes i.e. slopes transverse to pipeline alignment are present at some places of the pipeline route in the hilly areas. Contractor shall construct retention wall to avoid soil erosion/washout during monsoons wherever required, as per the instruction of the Engineer-in-Charge. 2.13

River Crossings Pipeline shall be installed across the Ghaggar river (At approx. Ch. 51.275 km) The river crossing drawings for bid purpose for the above river is enclosed with tender document. Details of survey/investigations carried out by the Owner and data collected are enclosed with the tender document for information/ reference. The minimum requirements regarding limits of crossing, scour profile, pipeline details, cover requirements, bank protection etc. are indicated in the drawings for understanding of the scope of work involved. Preliminary crossing profile drawing with the limit of crossing are enclosed with the tender document for reference purpose. HDD is to be done for this river crossing. Contractor shall design the HDD crossings including the preparation of AFC crossings drawings. All available survey details are being enclosed with tender document. Contractor shall carry out all additional geo technical investigations required for HDD. Contractor shall also submit scour depth along with design calculation as per specification for Owner’s approval. All works shall be carried out as per approved document/drawings only.

2.13.1 Coating on pipes for Crossings Crossings installed by open cut method shall be provided with concrete coating of thickness as shown on relevant drawings. Coated pipe surface shall be roughened prior to application of concrete coating. Concrete coating shall conform to spec. 0435-JH0902-00-PL-SPC-0013 enclosed with the bid document. 2.14

Environmental Restrictions The following measures shall be adopted during pipeline construction in order to minimize the impact of pipeline construction activities on the environment.

2.14.1 Contractor shall take due care to minimize the damage to trees. The number of trees felled shall be minimum. Contractor shall exercise maximum care not to damage the crop outside the ROU. The compensation of damage of crop outside ROU, if any, shall be to Contractor’s account. The contractor should plant a minimum of 10 trees for every tree cut along the pipeline route in consultation with local DFO(s) and Owner representative. 2.14.2 During ROU clearance, the vegetation shall be cut off at ground level leaving the Doc. No. : 0435-JH0902-00-SOW-0005 Rev. B

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roots intact to the extent possible. Only stumps and roots directly over the trench shall be removed for pipeline installation. 2.14.3 Intake and discharge of water required/used for line flushing and testing should not cause unacceptable environmental disturbance. During dewatering process, proper drainage arrangement shall be made to discharge the hydro-test water to avoid flooding of the near by area. Hydro-test water shall be discharged after necessary treatment as per the statutory stipulations. 2.14.4 The contractor shall plan that all the water crossings (river/streams) shall be installed during dry seasons to avoid disturbance of breeding seasons and soil erosion. 2.14.5 In addition to above, relevant requirements of Haryana Pollution Control Board & Punjab Pollution Control Board (as applicable) shall be complied with. Copy of the documents shall be made available to the successful bidder. 2.15

Tie-in with Pipeline The final tie-in between each spread shall be carried out as per instruction of Engineer-in-Charge after completion of pipeline works.

2.16

Leak Detection Contractor shall submit a detailed procedure for leak detection during hydrotest. Such method of detection shall consume minimum possible time to complete the hydro-test activity within contractual completion schedules. This procedure needs approval of the Engineer-in-charge. All works for locating leak/burst (occurred during hydrostatic testing) as defined in the specification shall be payable as per relevant items of schedule of rates.

2.17

Contractor’s responsibilities Appraisal and taking cognizance of site-conditions, pipeline route, Central and State Government rules and regulations/ bye-laws, applicable Indian Standards and Codes, authorities having jurisdiction over the work site(s), environmental and pollution concerns including conditions/ stipulations laid down by the concerned authorities etc. The Contractor is deemed to have recognized any restrictive features and constraints of the site(s), pipeline route and /or specific requirements of the work and made due allowance for it in the work to be performed by him. Furnishing and mobilizing at site(s) of all construction equipment, manpower, tools and tackles, construction sections, fully equipped and fully manned with other required support facilities etc.

2.18

Statutory Permissions Owner shall arrange in principle approval from statutory Authorities for various crossings / Govt. land etc. The responsibility of the Owner ends with providing in principle approvals. Further responsibility for obtaining approvals/ clearances / work permits for laying the pipeline and completing the work as per approval obtained to the entire satisfaction of the concerned Authorities lies with the contractor. The

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conditions mentioned in the in principle approvals from statutory Authorities already obtained by the Owner are enclosed with this document. All such requirements shall be shall be binding on the contractor. In case of conflict between requirements stipulated by statutory authorities and those specified in applicable standards, specifications, scope of work, drawings etc. forming part of this tender, the more stringent requirements shall be complied with. 2.19

Hydrostatic Testing & Preservation

2.19.1 Pipeline: Hydrostatic testing of mainline shall exclude valves at terminals and facilities that are to be installed as a part of the scraper stations. Temporary test headers shall be provided and the mainline shall be hydrostatically tested between the temporary test headers only. The pipeline shall be hydrostatically tested to the minimum test pressure 1.25 times of design pressure for all the sections. The highest point of the test section shall be subjected to the minimum test pressure specified above. The maximum test pressure shall not be higher than the one resulting in a hoop stress corresponding to 95% of SMYS of pipe material based on the minimum wall thickness in the test section. 2.19.2 Corrosion Inhibitor a.

One of the following vendors shall be used for corrosion inhibitor for hydortesting- Chem Treat India Pvt. Ltd., New Mumbai. - Rencal Chemical, New Mumbai. - Ion Exchange India Ltd., Hyderabad. - ONDEO-NALCO, Kolkata. - Navdeep Chemicals, Mumbai - Dorf ketal Chemicals, Mumbai

b.

Contractor shall analyze quality and quantity of corrosion inhibitor required for the period of preservation to be adopted. Contractor shall carryout testing of water sample to determine the doses for inhibitor and provide relevant test reports of water sample and detailed calculation to owner for approval. The inhibitor shall be tested in Owner recommended labs before dispatch to site

2.19.3 Preservation a.

The lines can be preserved by completely filling with the hydro-tested water containing inhibitor as per clause no in 2.19.2. b. The water shall not be drained after hydrotesting. Or

b.

After hydrotesting, the line pipe shall be drained and all online permanent facilities, SV’s etc. shall be installed and subsequently the pipeline sections shall be refilled with corrosion inhibited water with required doses.

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2.19.4 Subsequent to separate hydro-testing of pipeline and associated facilities, tie-in /hook-up shall be carried out by the Contractor. Pipes/pre-fabricated assembly used for such tie-in shall be pre-tested to a test pressure specified for the pipeline. The Contractor at no extra cost shall provide all materials required for the fabrication of the test headers to Owner. After successful completion of hydrostatic testing, the Contractor shall de-water the pipeline as per the directions of Engineer-in-charge. 2.19.5 Terminal Facilities Piping facilities between the insulating joint and the hook-up point/battery limit and all above ground facilities installed by the Contractor shall be hydrostatically tested to a test pressure equivalent to 1.25 times the design pressure indicated in line schedule document and corresponding design pressure for mainline in accordance with "Standard Specification For Inspection, Flushing and Testing of Piping System" enclosed with the tender document. All valves in the piping network being hydro tested shall be kept in the crack open position. Holding time shall be six hours. 2.20

Direction of construction For all the pipeline sections, the direction of construction shall be considered along the direction of flow i.e. from Ramanmandi towards Bhatinda / Bahadurgarh unless specified otherwise.

2.21

Canal Crossings

2.21.1 Pipeline shall be installed by HDD method for following crossings: 1) Adjoining Canals at Ch.93.656 and Ch.93.683 KM (ROW 110 MTR) 2) Adjoining Canals at Ch.210.683 and Ch.210.729 KM (ROW 112 MTR) Contractor shall design the HDD crossings including the preparation of AFC crossings drawings. All available survey details are being enclosed with tender document. Contractor shall carry out all geo technical investigations required for HDD. Contractor shall also submit scour depth along with design calculation as per specification for Owner’s approval. All works shall be carried out as per approved document/drawings only. 2.21.2 All lined canals having width more than 5m shall be installed through boring method only. All other unlined canals crossings shall be installed through open cut in consultation with concerned authorities. No damage should be caused to any irrigation sources, while laying the pipeline through canal crossings. The banks of the /Canal should be brought to the original condition. Stabilisation of banks shall be carried out as per requirements of concerned authorities. 2.22

SH, NH & Railways Crossings. All SH, NH and Railways crossings , the pipeline shall be installed through cased crossings in consultation with concerned authorities. The area/ boring pit shall be restored to original condition as per requirement of concerned authorities.

Doc. No. : 0435-JH0902-00-SOW-0005 Rev. B

Page 12 of 14


2.23

Pre-commissioning and Commissioning assistance

2.23.1 Pipeline Contractor shall be responsible for pre-commissioning of the pipeline spread(s) being installed by him. The above shall include P&ID checks (with respect to requirement of design/operation/safety and interlocks of latest revision of P&IDs), flushing, tightness test, de-watering, swabbing, as required as per Document no 0435-JH0902-00-PL-SPC-0010. Contractor shall make available the power required for functional testing of actuated sectionalizing valves during pre-commissioning without any extra cost to the Owner. 2.24

Commissioning Owner shall carry out overall commissioning of the entire pipeline system. However, all assistance/support including supply of manpower, temporary equipment, tools and tackles, pigs etc. for commissioning shall be provided by Contractors for individual section as per Document no 0435-JH0902-00-PL-SPC-0010.

3.0

AS-BUILT DOCUMENTS

3.1

Contractor shall prepare all documents as per the requirements indicated in Specification for Documentation for Pipeline Construction No. 0435-JH0902-00-PLSPC-00259 enclosed with the tender document. In addition to details required as per Specification No. 0435-JH0902-00-PL-SPC-0025, the as–built pipeline drawings shall show top of the pipe level and coordinates of each turning point. The co-ordinates shall be recorded using DGPS of adequate carousel (+/-) 1 metre. The co-ordinates shall be indicated in UTM grid. The drawings shall also show final graded ground profile. In addition to the hard copy, three copies of final documents shall also be submitted in electronic media i.e. CD ROM diskettes. Software’s used for the presentation of these documents shall be as follows: Type of document Software a) Reports MS Office (Word / Excel) b) Drawings AutoCAD Release 14/2000

3.2

For the purpose of preparation of as-built drawings, Contractor shall update the "Approved For Construction" (AFC) drawings approved by the Owner. Contractor shall be provided electronic file of all ‘AFC’ drawings/ alignment sheets. Contractor shall update the all drawings approved by the Owner. As-built drawings shall be prepared on AutoCAD Rel. 14/ 2000.

4.0

DOCUMENTS TO BE SUBMITTED AT THE TIME OF BIDDING No technical documents are required to be submitted at the time of bidding; bidder is advised to comply with all the requirements of bid document without any deviations. Owner reserves the right to reject any bid with deviations without making any

Doc. No. : 0435-JH0902-00-SOW-0005 Rev. B

Page 13 of 14


reference to bidder. 5.0

GENERAL

5.1

In case of conflict between the requirements given in this document and the requirements of other specifications enclosed with the tender document, the requirements specified in Scope document shall govern.

5.2

Should there be conflict, discrepancy, inconsistency or dispute between the various documents, they shall be referred in the order of priority as given below: a)

Scope Document for pipeline laying works & associated works, document no. 0435-JH0902-00-PL-SOW-0004 and Job specific requirements for pipeline laying works, document no. 0435-JH0902-00-PL-SOW-0005.

b)

Schedule of rates

c)

P&ID's/Line schedule

d)

AFC drawings

e)

Job specifications/standard specifications

f)

Data sheets

g)

Job standards

h)

Standards

i)

Drawings/sketch

j)

Specifications

k)

Other documents not covered under Cl. 5.2 a) thru’ k) above

Doc. No. : 0435-JH0902-00-SOW-0005 Rev. B

Page 14 of 14

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) SPECIFICATION FOR PIPING MATERIAL


SPECIFICATION FOR PIPING MATERIAL 0435-JH0902-00-PI-SPC-0001 20 August 09


DOCUMENT NO.: 0435-JH0902-00-PE-SPC-0001 Rev. D

Page 1 of 42


SYNOPSIS



DESCRIPTION

PREPARED BY

CHECKED BY

A

Issued for IDC

B

CD/NME

JC/SV

Issued for Review

CD/NME

JC/SV

AK

C

Issued for Tender

CD/NME

JC/SV

J. Wallace

D

Revised and Issued for Design

D. Hemnathan

S. Ishwad

KMN PILLAI


APPROVED BY

DATE

13 May 09

CLIENT APPROVAL N/A

18 May 09 15 June 09 20 August 09

Page 2 of 42

DATE


TABLE OF CONTENTS 1.0

Introduction ................................................................................................................... 4

General 4 Definitions And Abbreviations .....................................................................................................5 2.0

General Requirements .................................................................................................. 9

3.0

Technical Requirements ............................................................................................... 9

4.1

General ............................................................................................................................9

4.2

Piping .............................................................................................................................10

4.3

Pipe Fittings ...................................................................................................................12

4.4

Flanges And Flanged Joints ...........................................................................................13

4.5

Valves ............................................................................................................................14

4.0

Certification ................................................................................................................. 20

4.6

Type A Certificate...........................................................................................................20

4.7

Type B Certificate...........................................................................................................20

4.8

Type C Certificate...........................................................................................................20

4.9

Certification Guidelines...................................................................................................20

5.0

Numbering System...................................................................................................... 21

4.10

Line Numbering System .................................................................................................21

4.11

Manual Valve Numbering System...................................................................................21

6.0

Piping Class And Service Summary .......................................................................... 21

APPENDIX A – PIPING MATERIAL SPECIFICATIONS…………………………………………. 13 APPENDIX B – BRANCH CONNECTIONS…………………………………………………………46


Page 3 of 42


1.0

INTRODUCTION

General The scope of this document is to provide the minimum requirements for pipe, piping components and valves which are to be used in process piping system the EPCM phase of the Guru Gobind Singh Refinery Products Evacuation Project (GGSRPEP). It follows the intent of ASME B31.4 and ASME B31.3 for onshore facility piping. As a part of Product Evacuation Project, Hindustan Petroleum Corporation Limited (HPCL) proposes to lay the following initial and future cross-country multiproduct pipelines and facilities: Initial Installation (for Phase-1) •

Multi product pipeline from GGSR, Raman Mandi to HPCL’s existing Depot at Bathinda (approximately 29.6 km); with a provision for future extension of the pipeline from Bathinda to Sangrur (approximately 86 km).

•

Multi product pipeline from GGSR, Raman Mandi to HPCL’s existing Depot at Bahadurgarh (approximately 243 km).

•

Necessary sectionalising valve (SV) facilities at various locations along the pipeline route.

•

Two dedicated pumping facilities located at Raman Mandi to transfer, different products down the pipelines on a batching sequence basis, to the storage tank facilities at Bathinda and Bahardurgarh with tie-ins for future installation of pumps to meet forecasted throughput as stated in following sections.

•

Necessary utilities at Raman Mandi to support, operate, monitor and maintain the facilities and pipelines either by installation of new utility system or by extension of existing terminal facilities as stated in following sections. Future Installation (Phase-2 operation)

•

Future additional multi-product transfer to Sangrur will be met through extension of 29.6 km Raman Mandi to Bathinda pipeline by approximately 86 km from Bathinda to Sangrur. To achieve this, one additional train of pump (one booster and one mainline pump) will be installed at Raman Mandi.

•

Increased capacity of multi-product transfer from Raman Mandi to Bahadurgarh is achieved by installation of pipeline inline booster pumping station on the Raman Mandi and Bahardurgarh pipeline.

•

Future utilities (new / extension) for future facilities at pumping station, boosting station and at all three (3) terminals.


Page 4 of 42


Definitions and Abbreviations ABS

Acrylonitrile Butadiene Styrene

BB

Bolted Bonnet

BW

Butt Weld

CA

Corrosion Allowance

CAF

Compressed Asbestos Fibre

CE

Carbon Equivalent

CS

Carbon Steel

ENP

Electroless Nickel Plating

EFW

Electric Fusion Welding

FF

Flat Face

HAZ

Heat Affected Zone

Hv

Vickers Hardness

HPCL (Company)

Hindustan Petroleum Corporation Limited

HRC

Rockwell Hardness C

NDE

Non-destructive Examination

NPS

Nominal Pipe Size

OS&Y

Outside Screw and Yoke

P&IDs

Piping and Instrumentation Diagrams

PN

Nominal Pressure (in kg/cm2g)

PRE

Pitting Resistance Equivalent

PTFE

Polytetrafluoroethylene (fluoroplastic)

RF

Raised Face

RTJ

Ring Type Joint

SAW

Submerged Arc Welding

Sch

Pipe Schedule (wall thickness)

SS

Stainless Steel

WT

Wall Thickness

WP

WorleyParsons

XS

Extra Strong (pipe schedule)

XXS

Double Extra Strong (pipe schedule)


Page 5 of 42


REFERENCE DOCUMENTS Code for Pressure Piping Piping shall comply with the latest editions of ASME B31.4 and ASME B31.3 and other codes and standards as referred herein. Code and Standards The requirements of the latest editions of the following Codes and Standards shall be complied with unless specifically noted otherwise within this Specification. American Society of Mechanical Engineers ASME V ASME VIII ASME IX ASME B1.20.1 ASME B1.2 ASME B16.5 ASME B16.9 ASME B16.10 ASME B16.11 ASME B16.20 ASME B16.21 ASME B16.25 ASME B16.34 ASME B16.36 ASME B16.47 ASME B18.2.2 ASME B31.3 ASME B31.4 ASME B36.10M ASME B36.19M

Boiler and Pressure Vessel Code - Section V - Non Destructive Examination Boiler and Pressure Vessel Code - Section VIII Div. 1 and Div. 2 - Rules for Construction of Pressure Vessels Boiler and Pressure Vessel Code - Section IX - Welding and Brazing Qualifications Pipe Threads (Except Dry seal) Gauges and Gauging for Unified Inch Screw Threads Pipe Flanges and Flanged Fittings Factory-Made Wrought Steel Butt Welding Fittings Face to Face and End to End Dimensions of Valves Forged Steel Fittings, Socket Welding and Threaded Metallic Gaskets for Pipe Flanges — Ring Joint, Spiral Wound and Jacketed Non Metallic Flat Gaskets for Pipe Flanges Butt Welding Ends Valves - Flanged, Threaded and Welding End Steel Orifice Flanges, Class 300, 600, 900, 1500 and 2500 Large Diameter Steel Flanges Square and Hex Nuts Process Piping Pipeline Transportation Systems for Liquid Hydrocarbons, and Other Liquid Welded and Seamless Wrought Steel Pipe Stainless Steel Pipe

American Society for Testing and Materials ASTM A105 ASTM A106 ASTM A182 ASTM A193

Carbon Steel Forgings for Piping Applications Seamless Carbon Steel Pipe for High Temperature Service Forged or Rolled Alloy Steel Pipe Flanges, Forged Fittings and Valves and Parts for High Temperature Service Alloy Steel and Stainless Steel Bolting Materials for High


Page 6 of 42


ASTM A194 ASTM A216 ASTM A234 ASTM A240 ASTM A262 ASTM A269 ASTM A312 ASTM A358 ASTM A370 ASTM A403 ASTM A435 ASTM A450 ASTM A519 ASTM A530 ASTM A672 ASTM A694 ASTM A700 ASTM A790 ASTM A815 ASTM A860 ASTM B608 ASTM B633 ASTM B766 ASTM D1418 ASTM D2996 ASTM E165 ASTM G48

Temperature Service. Carbon and Alloy Steel Nuts for Bolts for High Pressure and High Temperature Service Steel Castings, Carbon, Suitable for Fusion Welding, for High Temperature Service Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures. Heat-Resisting Chromium and Chromium-Nickel Stainless Steel Plate, Sheet and Strip for Pressure Vessels Detecting Susceptibility to lntergranular Attack in Austenitic Stainless Steels Seamless and Welded Austenitic Stainless Steel Tubing for General Service Seamless and Welded Austenitic Stainless Steel Pipes Electric Fusion -Welded Austenitic Chromium - Nickel Alloy Steel Pipe for High-Temperature Service Test Methods and Definitions for Mechanical Testing of Steel Products Wrought Austenitic Stainless Steel Piping Fittings Straight-Beam Ultrasonic Examination of Steel Plates General Requirements for Carbon, Ferritic Alloy, and Austenitic Alloy Steel Tubes Seamless Carbon and Alloy Steel Mechanical Tubing General Requirements for Specialized Carbon and Alloy Steel Pipe Electric-Fusion- Welded Steel Pipe for High Pressure Service at Moderate Temperatures Carbon and Alloy Steel Forgings for Pipe Flanges, Fittings, Valves and Parts for High Pressure Transmission Service Packaging, Marking, and Loading Methods for Steel Products for Domestic Shipment Seamless and Welded Ferritic / Austenitic Stainless Steel Pipe Wrought Ferritic, Ferritic/Austenitic, and Martensitic Stainless Steel Piping Fittings Wrought High-Strength Low Alloy Steel Butt Welding Fittings Welded Copper Alloy Pipe Electrodeposited Coatings of Zinc on Iron and Steel Electrodeposited Coatings of Cadmium Standard Practice for Rubber and Rubber LatticesNomenclature Pipe Filament-Wound “Fibreglass” (Glass-Fibre-Reinforced Thermosetting-Resin) Pipe Test Method for Liquid Penetrant Examination Test Method for Pitting and Crevice Corrosion Resistance of Stainless Steel and Related Alloys by the Use of Ferric Chloride Solution


Page 7 of 42


British Standards Institute BS 6755 BS 6755 Part 1 BS 6755 Part 2

Testing of Valves Production Pressure Testing Requirements Fire Type-Testing Requirements

American Petroleum Institute API 5 L API SPEC 6D API 6FA API 6FB API 15LR API STD 594 API STD 598 API STD 607

Line Pipe Pipeline Valves Fire Test for Valves (Trunnion Ball Valves) Fire Test for End Connections Low Pressure Fibreglass Line Pipe And Fittings Wafer Type Check Valves Valve Inspection and Testing Fire Test of Soft Seated Quarter Turn Valves

Manufacturer’s Standardization Society MSS SP 53 MSS SP 55 MSS SP 75

Quality Standard for Steel Castings and Forgings for Valves. Flanges and Fittings and Other Piping Components – Magnetic Particle Examination Method Quality Standard for Steel Castings for Valves, Flanges, Fittings, and Other Piping Components - Visual Method for Evaluation of Surface Irregularities High Test Wrought Butt Welding Fittings

European Standards EN10 204

Inspection Documents for The Delivery of Metallic Products

Oil Industry Safety Directorate OISD-STD-130

Inspection of Piping Systems

Project Specification The following General Specification shall be used in conjunction with this specification where applicable: 0435-JH0902-00-PI-BOD-0001 0435-JH0902-00-PI-SPC-0002 0435-JH0902-00-PI-SPC-0004 0435-JH0902-00-PI-SPC-0005 0435-JH0902-00-GEN-BOD-0001 0435-JH0902-00-ME-REP-0001

Basic of Design Piping Specification for Valve Welding Spec, for Fab, or Piping Specification for Piping Fabrication Basis of Design (Process/ Pipeline) Corrosion Assessment and Material Selection Study report


Page 8 of 42


2.0

GENERAL REQUIREMENTS •

All piping materials selected under this Specification shall be in compliance with the project Specification.

•

Material selections shall comply with the maximum pressure and temperature limitation as specified in the Piping Standard Sheets provided as part of this Specification. The piping drawings will designate jurisdictional limits of applicable piping standards.

•

Substitution of equivalent materials is subject to approval of the WP/HPCL. All requests for substitution shall be accompanied with sufficient data, drawings and descriptive details to permit evaluation by the WP/HPCL.

•

Cast iron, ductile or malleable iron, aluminum, plastic or copper-bearing alloys shall not be used in hydrocarbon service.

•

Piping design pressure is based on flange maximum-allowable working pressure, unless otherwise noted in the Piping Standard Sheets or Job Specification.

•

When required, impact testing shall comply with applicable standards and material specifications.

•

All gaskets shall be asbestos free.

•

Contractor shall develop detail buying description for all components required for the project. All such buying description shall be subjected to WP/HPCL review and approval.

3.0

TECHNICAL REQUIREMENTS

4.1

General •

All piping component wall thicknesses specified in the individual Piping Standard Data Sheets are calculated in accordance with ASME B31.3 or B31.4 as specified and are based on continuous long-term internal design pressure, design temperature, specified corrosion/erosion allowance, the manufacturing minus/under tolerance and the threading allowance as applicable. All piping subject to any additional loading such as short term upset conditions, occasional loads, external pressure, thermal loading, live loads, marine motions etc shall be individually assessed to ensure full compliance with ASME B31.3, B31.4

•

Pipe dimensions shall be in accordance with ASME B36.10M for carbon steel and for stainless steel with wall thicknesses in excess of Sch 80S. For stainless steel with wall thicknesses up to and including Sch 80S, dimensions shall be in accordance with ASME B36.19M.

•

All materials shall be new, clean and free from rust, pits and obvious defects.


Page 9 of 42


4.2

•

Pipe, valves and fittings in sizes 1 1/4", 2 1/2", 3 1/2" and 5" shall not be used. Where equipment is normally provided by a supplier with connections in any of the above sizes, connections will be made with suitable swages or reducers to pipe of approved size.

•

Materials shall conform to impact test requirements specified in ASME B31.3, for the combination of minimum design metal temperature (MDMT) and reference thicknesses specified.

•

Galvanized piping requiring welding or threading shall be galvanized after fabrication. Electro less-nickel plating may be substituted for galvanizing on certain fittings with WP approval. Galvanized piping shall comply with the requirements of ASTM A53.

•

Deviations from the Piping Standard Sheet may occur due to non-availability or design conditions. These deviations are permissible if they are of an equal or higher standard than the individual Piping Standard requirements, and written approval is given by COMPANY. Piping components not specified on the individual Piping Standard Sheet, shall be treated as specialty piping (SP) items and shall have a specific data sheet for each of the design type, rating and size I dimensions.

•

All piping materials except for bolts I nuts and gaskets shall be supplied with material certificates conforming to European Standard EN 10 204, Type 3.1B, or COMPANY approved Inspection Certificate. Bolts I nuts and gaskets shall be supplied with material certificates conforming to European Standard EN10 204, Type 2.2 and 2.1 respectively, or WP approved Inspection Certificate. Piping

4.2.1 General All pipe shall be specified with the nominal size and schedule number as per ASME B36.10M unless specified otherwise on the individual Piping Standard Sheet. For non-schedule pipe wall thickness when specified is the minimum wall thickness permitted within allowable manufacturing tolerance. The pipe wall thickness may be supplied thicker than specified only after written approval has been given by WP/HPCL. Corrosion allowance is as per the relevant Piping Standard Sheet. Pipes shall be supplied with beveled end. Beveling shall be in accordance with ASME B16.25. Where plain end pipes are specified, as for small bore pipes for socket welded piping, the pipes shall be supplied with square cut ends. Pipe shall preferably be supplied in double random lengths. Each length of pipe shall be subject to a hydrostatic test in accordance with the relevant code. Single random lengths will be accepted where specified in the Job Specification or for small diameter pipes or where double random lengths are unavailable. Each length of pipe shall be marked legibly by “low stress die-stamping” or by “engraving” or by “stenciling”. Stencil marking shall utilize water insoluble ink; DOCUMENT NO.: 0435-JH0902-00-PE-SPC-0001 Rev. D

Page 10 of 42


the ink shall not contain any harmful metal or metal salts such as zinc, lead or copper which cause corrosive attack on heating. Stainless steel piping shall be supplied marked permanently over the entire length. The marking details shall be as per material specifications and shall include nominal pipe size (NPS), charge or heat number and the manufacturer’s unique symbol. Beveled end pipes shall be supplied with ends protected to avoid transport damages. Pipes shall be shipped with end protectors to protect beveled ends. Also, pipes shall be supplied preserved and protected as per the requirements of ASTM A700.

4.2.2 Carbon Steel Pipe Carbon steel pipe shall have a maximum carbon content of 0.23% by ladle analysis or 0.25% by product analysis. Maximum carbon equivalent (CE) shall be 0.43% by ladle analysis or 0.45% by product analysis according to the formula:

CE = C + (

Mn (Cr + Mo + V ) ( Ni + Cu ) )+ + 6 5 15

Where Cr, Mo, V and Cu are not shown on the material certificates, the carbon equivalent shall be 0.38% by ladle analysis or 0.40% by check analysis, as calculated in accordance with the formula:

CE = C + (

Mn ) 6

Length will be as specified on the Job Specifications.

4.2.3 Low Temperature Carbon Steel Pipe The pipe material shall have maximum carbon content of 0.23% except where ASTM Specification is more restrictive, the manganese content may be increased to 1.30% max. The carbon equivalent (CE) shall be 0.45% max. Impact testing shall be carried out as per ASTM A370 at -50°F. Impact values shall meet the requirements specified in ASME B31.3. 4.2.4 Austenitic Stainless Steel Pipe Pipe materials shall be in accordance with ASTM A312 TP316 or ASTM A358 TP316, if specified. All pipes shall be supplied in the de-scaled, pickled, passivated and solution heat treated condition. Repair by welding is not permitted. Material shall be capable of successfully passing an intergranular. For pipes made by automatic welding process, the entire length of the weld shall be examined 100% by an eddy current test in accordance with ASTM A450 or by


Page 11 of 42


radiography in accordance with the requirements of ASME Section VIII, Div 1 Para UW-51. A weld joint factor of 1.00 shall be guaranteed. 4.3

Pipe Fittings •

Carbon steel fittings shall meet the requirements of ASTM A234 and A105N, as applicable. Carbon steel forgings shall be supplied with a maximum carbon content of 0.25% and CE of 0.45% by product analysis. Fittings manufactured from pipe shall comply with requirements specified for pipe.

•

Carbon steel and alloy steel piping fittings for ‘low temperature service’ shall conform to ASTM A420 or ASTM A350 LF2.

•

Where austenitic stainless steel fittings are specified, they shall conform to ASTM A182 or A403 and the same material requirements specified for austenitic stainless steel pipe.

•

Duplex Stainless Steel fittings shall be supplied as per ASTM A815 and the same material requirements specified for duplex stainless steel pipe.

•

Dimensions of metallic butt weld fittings shall be in accordance with ASME B1 6.9, with socket weld and threaded fittings to ASME B16.11. All 90° butt weld elbows shall be long radius (1.5D) unless space limitations dictate otherwise & COMPANY approval is given.

•

For fittings made of carbon steel, the beveled surface of the welding end shall be subjected to wet magnetic particle examination in accordance with practice E709. Personnel performing the examination shall be qualified in accordance with ASNTTC-1A.

•

For fittings made of wrought austenitic stainless steel, preferably, all the surfaces shall be liquid penetrate tested in accordance with Practice E 165. Personnel performing the examination shall be qualified in accordance with ASNT-TC-1A.

•

Repair by welding of wrought fittings shall not be allowed, without WP approval.

•

Welding components used for joining unequal wall thickness and/or yield strength materials shall be beveled in accordance with ASME B16.25 the properties of the welding material shall correspond to the higher strength material.

•

Threaded and socket-weld fittings: Threaded and socket-welded fittings shall comply with ASME B16.11. Bushings, street elbows and close nipples may be used only with permission of the WP. Threaded half couplings are prohibited. Thread shall be per ASME B1.20.1 tapered. Thread sealant shall be Teflon tape.

•

Fittings shall be marked and shipped in crates, grouped according to pressure/class rating where possible.

•

Pipe fittings, other than non-metallic shall be supplied with wall thickness and nominal sizes that meet the requirements of ASME B36.10M, B36.19M, B16.9, B16.11 and where allowed, B16.28.


Page 12 of 42


4.4

Flanges and Flanged Joints • • •

• • •

• •

Weld-neck flanges and socket-weld flanges shall be provided with bore to match the attached pipe. All flanges in butt weld (BW) piping shall be weld-neck (WN) unless specific requirements dictate otherwise. Flange dimensions shall be in accordance with ASME B16.5. Non metallic flanges shall generally meet the bolting dimensions of the above standards and be suitably face finished to mate with ASME B16.5 flanges. However, the flange thickness & hub dimensions of the nonmetallic flanges may vary depending on the material used Flanges 26-in and larger shall be per MSS SP-44 or ASME B16.47 series A. Repair by welding is not permitted. Flanges shall be packed and shipped in such a way as to prevent damage of machined parts. All machined or threaded parts shall be protected in accordance with ASTM A700. Suitable protection shield or cover shall be provided on the gasket contact surface. Galvanized flanges shall be packed in accordance with ASTM A53. Carbon steel forgings shall be supplied with a maximum carbon content of 0.25% and CE of 0.45% by product analysis. All flange faces other than for non-metallic and CuNi materials shall be “smooth” and shall meet the following minimum criteria: a. Roughness = 125 to 250 µinRa; (3.2 to 6.3 µmRa). b. Continuous spiral groove or concentric serrated. c. Non-Metallic, Copper and CuNi shall be stock finish.

• •

•

•

Orifice flanges sizes 2", 3" and 4" shall have bolt-hole diameters 1/16 in. smaller than that indicated in ASME B16.5 (custody transfer metering applications only). Jack screws, 180° apart, shall be provided, one on each flange, for all orifice assemblies. Carbon steel flange bolting shall be stud bolting with material conforming to the Piping Standard Sheets and threaded full length. Reduced shank stud bolts shall not be used. Nuts shall be as specified on the Piping Standard Sheets. Carbon steel bolting shall be cadmium plated as specified in the Piping Standard Sheets. Stud bolts of 1" diameter and less shall be UNC with those 1-1/8” diameters and larger being of the UN8 series per ASME B1.1. Stud bolts 1-5/8" diameter and larger are to be increased in length by a minimum of one nut thickness to allow the use of hydraulic bolt tensioning equipment. Nuts shall be Hexagon Heavy Series to ASME B18.2.2 and oversized to accommodate the stud bolt coating system as appropriate. Thread sealant shall be teflon paste. Flat face flanges, unless specified on the Piping Standard Sheets, shall not be used without specific WP/HPCL approval. Full-face gaskets shall be used with flatface flanges.


Page 13 of 42


• •

• • • •

All flanged joints shall be installed with a single gasket between contact faces. Spiral wound gaskets shall be used for all metallic RF joints. Spiral wound gaskets shall be as per the following: a.

0.175" nominal thickness.

b.

316 SS windings.

c.

Flexile super filler or equal.

d.

Centering ring 0.125" thick, CS Black Epoxy Coated for CS piping and SS for SS Piping.

e.

Design to API 601.

Gaskets for Fiber glass Reinforced Piping (FRP) systems shall be as specified in the Piping Standard Sheets. Ring type joint gaskets shall be oval or octagonal in section and shall conform to ASME B1 6.20 or to API 6A (as applicable). Rubber gaskets (0.125" thick, maximum hardness 60 shore Durometer) conforming to ASME B16.21 shall be used for potable water systems. Insulating gasket as shown below will be used when bolting dissimilar metal flanges. Insulating set is comprised of one phenolic resin central gasket with neoprene coating on faces, one phenolic sleeve per bolt, two phenolic washers per bolt and two steel washers per bolt, packed in an individual box. When bolting copper nickel, stainless steel or duplex stainless steel flanges together, similar sleeves and washers, less phenolic resin gasket, shall be utilized in conjunction with specified stud bolts and gaskets.

Note: - Cut insulating sleeve length 1/4” shorter than dimension A. 4.5

Valves 4.5.1 General


Page 14 of 42


• Valve selection shall be in accordance with the relevant Piping Standard and the associated Valve Code Sheet. • Valves shall be supplied in accordance with HPCL/WP’s Approved Manufacturers List. Valve manufacturer’s numbers illustrate an approved type. An equivalent substitute may be made with HPCL/WP’s approval. • Valves size 2" and over which are described as Outside Screw and Yoke (OS&Y) with rising stem and non-rising hand wheel shall be provided with stem protectors and visual position indicators. • Valves provided with integral by-passes shall confirm to the same Piping Specification as the principal valve. The bypass valve shall be a globe or choke type. The manufacturer of the principal valve shall furnish and install the bypass complete with valve. • Impact type hand wheels shall be provided as required in the Job Specification. Impact hand wheels shall not be used on cast-iron valves or on valves with cast-iron wheels. • Chain wheel operators when required by Job Specification and shall be adequate for the pressure and temperature with chain guides. Chain operated valves, size 10-in and larger, shall be provided with an impact hammer. Hammer-blow operators shall not be provided for cast-iron valves or valves with cast-iron wheels. • Valves shall be supplied with gear operators as indicated in the Valve data Sheets included in Appendix 2 of this Specification. • Valves heavier than 500 lb shall be provided with lifting points. The design of such lifting points shall be approved by the WP/HPCL. • Valves shall be bi-directional unless valve construction specifically renders this requirement impractical – e.g. Globe, Ball and Needle valves. For unidirectional valves, an indicator showing flow direction shall be engraved or cast/forged into the valve body. • Vent and drain valves shall comply with the Job Specification and shall be adequate for the pressure and temperature limitation indicated in the relevant Valve data Sheet included in Appendix 2 of this Specification. • Valve position indicators shall be designed so as to prevent incorrect orientation on valve assembly. • Quarter turn valve handles shall be lever lock type if specified in the purchase requisition or data sheet. • Gearbox operators shall be sized to provide an output torque of at least 150% of the maximum required valve operating torque. Gearbox ratios shall be 60:1 maximum for valves 8" and smaller and 120:1 maximum for valves 10" and larger. Maximum operating force required to operate the valve shall DOCUMENT NO.: 0435-JH0902-00-PE-SPC-0001 Rev. D

Page 15 of 42


be with in 70 lbf. Where indicated in the Job Specification, gear operators are to be supplied and shall be the manufacturer’s standard heavy duty models selected to provide the valve torque requirements. Gearboxes shall be fitted with position indicators, have self-locking mechanisms, and be fully sealed and protected to suit a very corrosive marine environment. • Bonnet gaskets may be to the manufacturer’s standard, provided that the standard is equal to, or better than, that of associated flange gaskets. • Valve bolting shall comply with the following: a.

Carbon and Alloy Steel Valves: ASTM A193-B7 ASTM A194-2H

(With Cadmium Plating to ASTM B766 Cl.8 Type II or Zinc Plating to ASTM B633) b.

Stainless Steel Valves: ASTM A193 B8 I B8M ASTM A194 8M

c.

Bronze Valves: Manufacturer’s Standard

Bolting specified above is for external bolting only. Internal bolting requirements are subject to intended fluid service requirements. • Where specified, welding end valves shall be supplied with pup pieces having a minimum length of 16". • Studded end valves are not allowed. Where space limitation requires installation of such valves, permission shall be obtained from the WP. • Valves flange pressure class rating shall be in accordance with ASME B16.5. • Valves shall be tested as per API 6D or as specified in the Job Specification. The hydrostatic shell test pressure shall be 1.5 times the rated ASME Class design pressure. Hydrostatic seat test pressure shall be the operating design pressure. Hydrostatic seat test for bi-directional valves shall be carried out in both directions. Allowable leakage rates shall be as per Job Specification. • Hydrostatic test fluid shall have a chlorine content of less than 200ppm for carbon steel valves and less than 50ppm for stainless steel valves. • NDT of the valves shall be carried out as specified in the Job Specification. • Material certificate per EN 10204 Type 3.1B or COMPANY approved certificate shall be provided for all the pressure containing parts of the valves.


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• All valves shall be shipped in the closed position except ball valves, which shall be shipped in the open position. • Valve ends and stuffing box shall be covered with close fitting protectors (e.g. plastic caps) to protect the machined parts and prevent ingress of dirt and moisture. • All valves shall be marked in accordance with MSS SP-25.

4.5.2 Ball Valve • All ball valves in hydrocarbon service shall be certified “fire-safe” in accordance with API STD 607 or BS6755 Part 2. Test certification shall be provided by the valve manufacturer to verify the valve performance. • Vents or drains are not required for floating ball valves. • For trunnion mounted ball valves, vent and drain connection shall be provided as per MSS SP 45. • Ball valves shall be reduced bore unless specifically stated otherwise, with valve bodies of either 1 or 2 piece construction. • All ball valves over 2" shall incorporate anti-static feature ensuring electrical continuity between ball, stem and body. For ball valves 2" and smaller electrical continuity is required between valve stem and body. Use of conductive stem seal is not permitted as the sole means of achieving the anti-static function. • Ball valves shall be fitted with blow-out proof stems and have the body split outside the plane of the stem protrusion. Trunnion mounted balls shall have body cavity relief. Stem seal covers shall be bolted. Valve stems shall be designed so that the stem “weak point” is outside of the valve body.

4.5.3 Globe Valves • Pressure/temperature ratings and valve design shall meet ASME B16.34 requirements. • The minimum requirement for valve trim for carbon steel valve bodies is 13% chrome. • Unless specified otherwise, straight plug designs only are acceptable.

4.5.4

Check Valves • Flow direction of the valve shall be clearly marked on the valve body.


Page 17 of 42


• For swing check valves, the disk shall be secured in the closed or open position to prevent damage during transport and handling.

4.5.5 Gate Valves • Gate Valves shall be solid wedge types with solid disc or flexible wedge disc. Split wedge gates are not permitted. • For Gate valve sizes 3" and smaller, where operating torque is not a concern, solid wedge discs shall be used. • For gate valve sizes 4" and larger, higher operating torques and possibilities of sticking of gate due to differential temperatures shall be considered. Accordingly, flexible wedge ‘H’ type discs shall be used. • Where corrosion or erosion of seat material is possible due to entrapped fluid between the ‘H’ type disc and the seat, simple flexible wedge discs shall be used. • Wedge shall be made from one solid piece of material (monoblock construction).

4.5.6 Inspection and Testing Pressure testing Each valve shall be pressure tested in accordance with the requirements of API 6D and API 598. The maximum chloride content of the water for hydrotesting of Stainless Steel valves shall be 30ppm. Non-destructive testing Inspection of valve components shall be in accordance with the following: a) 150#, 300# INSPECTION

APPLICABLE AREAS

PERCENTAGE OF TESTING Carbon Steel

Stainless Steel

NonFerrous

Visual

All Materials and Welds

100

100

100

Radiography

Castings – Critical Areas

100

100

100

Welds

100

100

100

Weld Repairs

100

100

100

Forgings

100

100

100

Castings

100

100

100

100 for

100 for

100 for

Magnetic Particle / Dye Penetrant

Welds DOCUMENT NO.: 0435-JH0902-00-PE-SPC-0001 Rev. D

Page 18 of 42


INSPECTION

b)

APPLICABLE AREAS

Weld Overlays 600#, 900#

INSPECTION

APPLICABLE AREAS

PERCENTAGE OF TESTING Carbon Steel DP/10 for MP

Stainless Steel DP/10 for MP

NonFerrous DP/10 for MP

100

100

100

PERCENTAGE OF TESTING Carbon Steel

Stainless Steel

NonFerrous

Visual

All Materials and Welds

100

100

100

Radiography

Castings – Critical Areas

100

100

10

Welds and Weld Repairs

100

100

100

Forgings

100

100

100

Castings

100

100

100

Welds and Weld Overlays

100

100

100

Magnetic Particle / Dye Penetrant

NDE of pipe and fittings shall be in accordance with the nominated specification and any supplementary requirements specified. Radiography The radiographic technique employed shall be in accordance with the recommendation of ASME V Article 2 for forgings and ASME V Article 3 for castings. Acceptance criteria shall be as specified in ASME B16.34 Annex B with the additional requirements that no cracks or crack like defects are acceptable. Magnetic particle inspection The magnetic particle inspections shall be applied using the detailed requirements, methods, procedures and qualifications specified in ASME V Article 7. The wet particle technique using background paint shall be adopted and the magnetising technique shall be appropriate to the component being inspected. Acceptance criteria shall be as described in ASME VIII, Division 1 and Appendix 7. In Addition linear defects shall be limited to a maximum of 3 mm. Liquid penetrant examination The liquid penetrant examination shall be applied using the detailed requirements, methods, procedures and qualifications specified in ASME V Article 6. Acceptance criteria shall be as specified for magnetic particle inspection. DOCUMENT NO.: 0435-JH0902-00-PE-SPC-0001 Rev. D

Page 19 of 42


Ultrasonic examination The ultrasonic examination shall be applied using the detailed requirements, methods, procedures and qualifications specified in ASME V Article 5. Acceptance criteria shall be as specified in ASME B16.34 Annex E. Weld repairs to valves Weld repair to valves are not allowed. Others Tests and certification as required by OISD-STD-130 4.0

CERTIFICATION

Contractor / Manufacturer shall provide certification to verify that the materials of construction meet the requirements of the material specifications. Certificates to EN 10204 incorporating requirements for documentation and marking are designated as Type A, Type B and Type C. Conformance with EN 10204 is required and clarified as follows: 4.6

Type A Certificate

Reports/Certificates to EN 10204 2.2, EN 10204 2.3 or equivalent. Material welded to pressure containing components shall be certified to the same degree as the pressure containing component. 4.7

Type B Certificate

Works Certificate to EN 10204 3.1B or equivalent. 4.8

Type C Certificate

Certificate to EN 10204 3.1C or equivalent 4.9

Certification Guidelines

The Vendor shall ensure that appropriate certification, showing mill heat or batch markings, is received for all furnished materials. Materials furnished without documentation are unacceptable. All certificates shall contain the following information: a)

Name of manufacturer.

b)

Purchase order number and date.

c)

Manufacturer’s order number.

d)

Identification number of certificate and its date of issue.

e)

Material specification.

f)

Dimensions.


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g)

Material charge number, batch number or heat-lot number.

h)

Mechanical properties recorded from test results.

i)

Chemical composition recorded from chemical analyses.

j)

NDT methods and results, where applicable.

k)

Heat treatment procedures and records, where applicable.

l)

For sour service materials, certificate of compliance to NACE MR 0175 / ISO 15156

4.9.1

Type A Certificate Gasket

4.9.2

All gaskets and ring type joints (where required)

Type B Certificate Piping/Fittings and Flanges All piping and associated fittings other than for type C Certificate. Fasteners

4.9.3

All studs and nuts for flanges

Type C Certificate All piping within the main transportation system (i.e. pipeline and fittings)

5.0

NUMBERING SYSTEM

4.10

Line Numbering System Line numbering shall be in accordance with the document no. 0435-JH0902-00-PIBOD-0001 Basic of Design Piping, section 5.

4.11

Manual Valve Numbering System Manual valve numbering shall be in accordance with the document no. 0435JH0902-00-PI-SPC-0002 Specification for Valve, Appendix A.

6.0

PIPING CLASS AND SERVICE SUMMARY

Piping Class

Service

Piping Code

Material

Design Pressure (bar)

Design Temp. (°C)

ASME Flange Rating

A1

Process

A106 Gr.B

18.6

Utility

IS 1239

10.0

A5

Corr, Inhibitor/ Foam Concentrate

A312 TP316

18.0

0°C to 65°C 0°C to 50°C 0°C to 65°C

150 RF

A1U

ASME B31.3 ASME B31.3 ASME B31.3


150 RF/FF 150 RF

Corrosion Allowanc e (mm.) 1.0 2.0 Nil

Page 21 of 42


B1

Process

B2

Process

C1

Process

C2

Process

D1

Process

ASME B31.3 ASME B31.4 ASME B31.3 ASME B31.4 ASME B31.3

A106 Gr.B

48.6

API 5L, PSL 2 A106 Gr.B

48.6

API 5L, PSL 2 A106 Gr.B

97.6


97.6

146

0°C to 65°C 0°C to 65°C 0°C to 65°C 0°C to 65°C 0°C to 65°C

300 RF

1.0

300 RF

1.0

600 RF

1.0

600 RF

1.0

900 RTJ

1.0

Page 22 of 42


APPENDIX A PIPING MATERIAL SPECIFICATIONS


Page 23 of 42


PIPING SERVICE CLASS INDEX – TABLE A PIPING CLASS

RATING

BASIC MATERIAL

CORROSION ALLOWANCE

SERVICE

A1

150#

CS

1.0 mm

Hydrocarbon Multi Product (HSD, MS, SKO, ATF, NAFTA), Pressure relief, Open/Closed drain, Vent, Raw water, Utility water, Nitrogen.

A1G

150#

CS-GALV

1.5mm

Instrument air, Potable water, Service air

A5

150#

SS 316

0mm

Chemical Injection / Foam Concentrate

B1

300#

CS

1.0mm

Hydrocarbon Multi Product (HSD, MS, SKO, ATF, NAFTA), Pressure relief, Open/Closed drain, Vent.

C1

600#

CS

1.0mm


D1

900#

CS

1.0 mm


A1U

150#

CS

2.0mm

Fire water / Water Sprinkler / Foam water

B2

300#

CS

1.0mm


C2

600#

CS

1.0mm



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PIPING MATERIAL SPECIFICATION

CLASS A1 SERVICE

REFER TO TABLE A

RATING

ANSI 150 #

Pressure (Barg) 19.6 19.2 SERVICE LIMITS 0 Temperature C 0- 38 50 ITEMS

BALL VALVE (NOTE 1, 4,5)

GATE VALVE (NOTE 1, 4,5)

GLOBE VALVE (NOTE 1, 4)

NPS SIZES RATING /SCH FROM TO

MATERIAL

2”

30”

150

RF

800

SW

BODY/BONNET – ASTM A105N / ASTM A216 WCB,TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / API602

150

RF

BODY/BONNET – ASTM A105N / ASTM A216 WCB, TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / API600.

800

SW

1/2” 1 1/2” 2”

24”

1/2” 1 1/2”

½”

1 ½”

800

SW

BUTTERFLY VALVE (NOTE 4)

3”

24”

150

RF

800 150

SW RF

150

RF

STUDS/ NUTS

100% PER B31.3 REQUIREMENTS

RF SW

PLUG VALVE

GASKET

C.S. – GROUP 1.1

RADIOGRAPHY STRESS RELIEF

150 800

RF

FLANGES

PIPING MATERIAL

1 ½” 1 ½”

150

FITTINGS (NOTE 2)

1.0 mm

½” ½”

24”

PIPE

15.8 150

ENDS

2”

CHECK VALVE (NOTE 4)

17.7 100

CORROSION ALLOWANCE

1/2” 1 1/2” 2” 24” 2”

30”

1/2” 1 1/2” SCH. 80 2” 6” SCH. 40 8” 12” SCH. 20 14” 24” SCH. 10 26” 30” SCH. 10 1/2” 1 1/2” 3000 2” 6” SCH. 40 8” 12” SCH. 20 14” 30” SCH. 10 1/2” 1 ½” 150 2”

30”

150

PE BE BE BE SW BW BW BW SWRF WNRF

BODY/BONNET – A105N / ASTM A216 WCB, TRIM - AISI316 SEALS PTFE. DIMENSIONS / DESIGN AS PER B 16.10, / BS 5351, API 6D. FLOATING BALL UP TO 6”. TRUNINON BALL FOR SIZES 8” & ABOVE

BODY/BONNET – ASTM A105N / ASTM A216 WCB,TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / BS5352 BODY/BONNET – ASTM A105N / ASTM A216 WCB,TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / BS1873 BODY – ASTM A105, TRIM – AISI 316, TO BS 5353 / MANUFACTURING STANDARD (NOTE 4) DUEL PLATE WAFER TYPE; BODY A 216 WCB, TRIM 13% Cr. TO API 609 LIFT CHECK TYPE, BODY – A105N, TRIM 13% Cr TO BS 5352 SWING TYPE, BODY A216 WCB, TRIM 13% Cr TO BS 1868 DUAL PLATE WAFER LUG TYPE, BODY A 216 WCB, TRIM 13% Cr TO API 594 C.S. Seamless ASTM A 106 Gr. B TO ASME B36.10 C.S. Seamless ASTM A 106 Gr. B TO ASME B36.10 C.S. Seamless ASTM A 106 Gr. B TO ASME B36.10 C.S. API 5L Gr. B LSAW (PSL 2) / A 106 Gr. B (Seamless)TO ASME B36.10 ASTM A105N, FORGED C.S. AS PER ANSI B16.11 ASTM A234 Gr. WPB Seamless AS PER ANSI B16.9 ASTM A105N PER ANSI B16.5 ASTM A105N PER ANSI B16.5, SCH TO MATCH PIPE

4.5mm THK, SPIRAL WOUND, SS316+GRAFITE WITH SOFT STEEL CENTERING RING TO ASME B16.20 STUD BOLTS, ALLOY STEEL, ASTM A193 Gr.B7/194 Gr.2H FULL LENGTH THREAD WITH TWO HEXAGONAL NUTS AS PER ANSI B 18.2.1/18.2.2 (Cadmium Plated) ½”

30”

150

NOTE 1: FOR HANDWHEEL AND GEAR AND GEAR WITH MOTORIZED OPERATION REFER TO SPEC 0435-JH0902-00-PI-SPC-0002 NOTE 2: FOR BRANCHING TABLE REFER APPENDIX B. NOTE 3: FOR PIPE SIZES /FITTINGS 12” AND ABOVE, THE THICKNESS SHALL BE CALCULATED BASED ON ACTUAL DESIGN PRESSURE / TEMPERATURE PER LINE LIST NOTE 4: FOR VALVE DESIGNATION REFER TO VALVE DESIGNATION TABLE – 1 FOR 150#. NOTE 5: SPECIFIC VALVES ARE MOTOR OPERATED, REFER REVELENT P & ID


Page 25 of 42



CLASS A1G SERVICE

REFER TO TABLE A

RATING

ANSI 150 #

Pressure (Barg) 19.6 19.2 SERVICE LIMITS Temperature 0C 0-38 50

GATE VALVE (NOTE 1,3)

½” 2”

1 1/2” 6”

800 150

SCRD RF

1/2” 1 1/2”

800

SCRD

150

RF

800

SCRD

150

RF

800 150

SCRD RF

2”

6”

GLOBE VALVE (NOTE 1,3)

1/2” 1 1/2”

CHECK VALVE (NOTE 1,3)

1/2” 1 1/2” 2” 6”

FLANGES GASKET STUDS/ NUTS NOTE 1: NOTE 2: NOTE 3: NOTE 4:

2”

6”

½” 2” 3”

1 ½” 2” 6”

SCH 80 SCH 40 SCH 40

PE PE BE

½” 3”

2” 6”

800 SCH 40

SCRD BW

1.5 mm

PIPING MATERIAL

C.S.(GALV) – GROUP 1.1


NIL PER B31.3 REQUIREMENTS

MATERIAL

FROM TO

BALL VALVE (NOTE 1,3)

FITTINGS (NOTE 2)

15.8 150

NPS SIZES RATING/ ENDS SCH

ITEMS

PIPE

17.7 100

CORROSION ALLOWANCE

BODY/BONNET – ASTM A216 WCB / A105 , TRIM - AISI316 SEALS PTFE. DIMENSIONS AS PER BS 5351, API 6D BODY/BONNET – ASTM A105 / ASTM A216 WCB,TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / API602 BODY/BONNET – ASTM A105 / ASTM A216 WCB,TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / BS 5352 OR API600, BODY/BONNET – ASTM A105 / ASTM A216 WCB,TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / BS5352 BODY/BONNET – ASTM A105 / ASTM A216 WCB,TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / BS1873 LIFT CHECK TYPE, BODY – A 105, TRIM 13% Cr, TO BS 5352 SWING TYPE, BODY A216 WCB, TRIM 13% Cr, TO BS 1868 C.S Seamless ASTM A 106 Gr. B (GALVANISED) TO ASME B36.10 C.S Seamless ASTM A 106 Gr. B (GALVANISED) TO ASME B36.10 CS Seamless ASTM A 106 Gr. B TO ASME B36.10 ASTM A105, FORGED C.S. AS PER ANSI B16.11 (GALVANISED) ASTM A234 Gr. WPB Seamless AS PER ANSI B16.9

SCRD, ASTM A105 PER ANSI B16.5 (GALVANISED) RF 3” 6” 150 SORF ASTM A105 PER ANSI B16.5, SCH TO MATCH PIPE ½” 6” 150 3 mm THK, CNAF TO ASME B16.21 STUD BOLTS, ALLOY STEEL, ASTM A193 Gr.B7M /194 Gr.2HM FULL LENGTH THREAD WITH TWO HEXAGONAL NUTS WITH WASHER AS PER ANSI B 18.2.1/18.2.2

1/2”

2”

150

FOR HANDWHEEL AND GEAR OPERATION REFER TO SPEC. 0435-JH0902-00-PI-SPC-0002 FOR BRANCHING TABLE REFER APPENDIX B. FOR VALVE DESIGNATION REFER TO VALVE DESIGNATION TABLE –1 FOR 150#.

FOR SIZES 3” AND ABOVE, HOT DIP GALVANISING OF FLANGED PIPE SPOOLS SHALL BE DONE AFTER FABRICATION.


Page 26 of 42



CLASS A1U SERVICE

REFER TO TABLE A

RATING

ANSI 150 #

Pressure (Barg) SERVICE LIMITS Temperature 0C

BALL VALVE (NOTE 1,3)

GATE VALVE (NOTE 1,3)

½” 2”

1 1/2” 18”

800 150

SCRD RF/FF

1/2” 1 1/2”

800

SCRD

150

RF/FF

800

SCRD

150

RF/FF

800 150

SCRD RF/FF

HVY HVY HVY HVY 800 SCH 40

PE PE BE BE SCRD BW

2”

18”


1/2” 1 1/2”


1/2” 1 1/2” 2” 18”

FITTINGS (NOTE 2)

2”

½” 2” 3” 12” ½” 3”

GASKET STUDS/ NUTS NOTE 1: NOTE 2: NOTE 3: NOTE 4:

15.8 150

6”

1 ½” 2” 12” 18” 2” 18”

2.0 mm

PIPING MATERIAL

C.S. – GROUP 1.1


NIL PER B31.3 REQUIREMENTS

MATERIAL BODY/BONNET – ASTM A216 WCB / A105 , TRIM - AISI316 SEALS PTFE. DIMENSIONS AS PER BS 5351, API 6D BODY/BONNET – ASTM A216 WCB,TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / API602 BODY/BONNET – ASTM A216 WCB,TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / BS 5352 OR API600, BODY/BONNET – ASTM A216 WCB,TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / BS5352 BODY/BONNET – ASTM A216 WCB,TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / BS1873 LIFT CHECK TYPE, BODY – A 105, TRIM 13% Cr, TO BS 5352 SWING TYPE, BODY A216 WCB, TRIM 13% Cr, TO BS 1868 C.S ERW, IS 1239 Black Pipe C.S ERW, IS 1239 Black Pipe C.S ERW, IS 1239 Black Pipe C.S ERW, IS 3589 Black Pipe ASTM A105, FORGED C.S. AS PER ANSI B16.11 ASTM A234 Gr. WPB Seamless AS PER ANSI B16.9

SCRD, ASTM A105 PER ANSI B16.5 RF/FF SORF/ ASTM A105 PER ANSI B16.5, SCH TO MATCH PIPE 3” 6” 150 FF ½” 6” 150 3 mm THK, CNAF TO ASME B16.21 STUD BOLTS, ALLOY STEEL, ASTM A193 Gr.B7M /194 Gr.2HM FULL LENGTH THREAD WITH TWO HEXAGONAL NUTS WITH WASHER AS PER ANSI B 18.2.1/18.2.2

1/2” FLANGES

17.7 100

NPS SIZES RATING/ ENDS SCH FROM TO

ITEMS

PIPE

19.6 19.2 0-38 50

CORROSION ALLOWANCE

2”

150

FOR HANDWHEEL AND GEAR OPERATION REFER TO SPEC. 0435-JH0902-00-PI-SPC-0002 FOR BRANCHING TABLE REFER APPENDIX B. FOR VALVE DESIGNATION REFER TO VALVE DESIGNATION TABLE –1 FOR 150#.


Page 27 of 42


CLASS A5


SERVICE RATING

REFER TABLE A ANSI 150 # Pressure (Barg) 19 18.3 15.7 SERVICE LIMITS Temperature 0C 0-38 50 100 NPS SIZES RATING/ ITEMS ENDS SCH FROM TO 1 /2” 1 1/2” 150 RF BALL VALVE 1 /2” 1 1/2” 800 SW (NOTE 1) 2” 24” 150 RF GATE VALVE (NOTE 1)

GLOBE VALVE (NOTE 1) PLUG VALVE

CHECK VALVE (NOTE –1)

PIPE

FITTINGS (NOTE 2) FLANGES GASKET STUDS/ NUTS

14.2 150

CORROSION ALLOWANCE PIPING MATERIAL RADIOGRAPHY STRESS RELIEF

0 mm SS 316 – GROUP – 2.1. RANDOM PER B31.3 REQUIREMENTS

MATERIAL

BODY/BONNET– ASTM A182 F316/ A351 CF8M, TRIM AISI316 SEALS PTFE. DIMENSIONS AS PER BS 5351 FLOATING BALL UP TO 6” AND TRUNIONON BALL FOR 8” AND ABOVE. BODY/BONNET – ASTM A182 F316/ A351 CF8M, TRIM AISI316. 1/2” 1 1/2” 800 SW DIMENSIONS / DESIGN AS PER B 16.10 / API602 BODY/BONNET – ASTM A182 F316/ A351 CF8M, TRIM AISI316. 2” 24” 150 RF DIMENSIONS AND DESIGN AS PER B 16.10 / API600 BODY/BONNET, ASTM A182 F316 / A351 CF8M, TRIM AISI316 1/2” 1 1/2” 800 SW DIMENSIONS AND DESIGN AS PER B 16.10 / BS 5352 BODY/BONNET, ASTM A182 F316 / A351 CF8M, TRIM AISI316 2” 6” 150 RF DIMENSIONS AND DESIGN AS PER B 16.10 / BS1873 BODY ASTM A182 F304, TRIM AISI 316, TO BS 5352 / MFR. STD. ½” 1 ½” 800 SCRD (NOTE 1) LIFT CHECK TYPE, BODY – A182 F316, TRIM AISI 316 ½” 1 1/2” 800 SW TO BS 5352 LIFT CHECK TYPE, BODY – A182 F316, TRIM AISI 316 ½” 1 1/2” 150 RF TO BS 5352 2” 24” 150 RF SWING TYPE, BODY A351 CF8, TRIM AISI 316 TO BS 1868 DUAL WAFER LUG TYPE, BODY A351 CF8, TRIM AISI 316 2” 24” 150 RF TO API 594 ½” 1 ½” SCH 80S PE S.S SEAMLESS ASTM A312 TP 316 TO ASME B36.19 (NOTE 4) 2” SCH 40S BE S.S SEAMLESS/EFW ASTM A 312 TP 316 TO ASME B36.19 3” 24” SCH 10S BE S.S EFW ASTM A 358 - 316 TO ASME B36.19 1/2” 1 1/2” 3000 SW ASTM A182 F316, FORGED SS AS PER ANSI B16.11 2” SCH 40S BW ASTM A403 WP 316 Seamless / Welded PER ANSI B16.9 4” 24” SCH 10S BW ASTM A403 WP 316 WX Welded PER ANSI B16.9 (NOTE 3) 1/2” 1 ½” 150 SWRF ASTM A182 F 316 PER ANSI B16.5 2” 24” 150 SORF ASTM A182 F 316 PER ANSI B16.5 SCH TO MATCH PIPE 4.5mm THK, SPIRAL WOUND, SS316+GRAFITE WITH SOFT ½” 24” 150 STEEL CENTERING RING TO ASME B16.20 STUD BOLTS, ALLOY STEEL, ASTM A193 Gr.B8M /194 Gr.8MA FULL LENGTH THREAD WITH TWO HEXAGONAL NUTS WITH WASHER AS PER ANSI B 18.2.1/18.2.2

NOTE 1: FOR VALVE DESIGNATION REFER TO VALVE DESIGNATION TABLE – 2 FOR 150#. NOTE 2: FOR BRANCHING TABLE REFER APPENDIX B. NOTE 3: FOR PIPE SIZES / FITTINGS 12” AND ABOVE, THE THICKNESS SHALL BE VERIFIED BASED ON ACTUAL DESIGN PRESSURE / TEMPERATURE PER LINE LIST. NOTE 4: SCHEDULES 5S AND 10S WALL THICKNESSES DO NOT PERMIT THREADING IN ACCORDANCE WITH ANSI/ASME B1.20.1


Page 28 of 42


VALVE DESIGNATION TABLE –1 FOR 150# PIPING CLASS – A1, A1G, A1U PRIMARY SERVICE RATING: VALVES:

ANSI 150 #

TEMPERATURE LIMITS:

-29°C TO 204°C

Refer To Valve Specifications 0435-JH0902-00-PI-SPC-0002 for details of the following Valve Designations.

SIZE (NPS)

GATE

GLOBE

BALL

GA-C804 / GA-C100

GL-C804 / GL-C100

BA-C804F / BA-C100 F

CH-C814

GA-C803

GL-C803

BA-C803F

CH-C813

2”

GA-C110F

GL-C100

BA-C100F / BAC110FX

CH-C100

PL-C100

3”

GA-C110F

GL-C100

BA-C100F / BAC110FX

CH-C100

PL-C100

4”

GA-C110F

GL-C100

BA-C100F / BAC110FX

CH-C100

PL-C100

6”

GA-C110F

GL-C100

BA-C100F / BAC110FX

CH-C130

PL-C100

8”

GA-C110FG

GL-C100G

BA-C110FG / BAC110-FX

CH-C130

PL-C100G

10” – 16”

GA-C110FG

GL-C100G


CH-C130

PL-C100G

18” TO 24”

GA-C110FG

USE GATE


CH-C130

1/2” TO 1 1/2” S.W / RF 1/2” TO 11/2” SCRD.


CHECK

BUTTERFLY

PLUG

PL-C803

Page 29 of 42


VALVE DESIGNATION TABLE –2 FOR 150# PIPING CLASS – A5 PRIMARY SERVICE RATING: VALVES:

ANSI 150 #

TEMPERATURE LIMITS:

-29°C TO 204°C

Refer To Valve Specifications 0435-JH0902-00-PI-SPC-0002 for details of the following Valve Designations.

SIZE (NPS) 1/2” TO 1 1/2” S.W / RF 1/2” TO 1 1/2” SCRD.

GATE

GLOBE

BALL

CHECK

BUTTERFLY

PLUG

BA-S804 / BA-S100

BA-S803F

2” 3” 4” 6” 8” 10” 12” TO 24”


Page 30 of 42



CLASS B1 SERVICE

REFER TO TABLE A

RATING

ANSI 300 # Pressure (Barg) 51.1 50.1 46.6 45.1 SERVICE LIMITS Temperature 0C 0- 38 50 100 150 ITEMS

BALL VALVE (NOTE 1,4,5)

GATE VALVE (NOTE 1,4,5)


NPS SIZES RATING FROM TO / SCH 1/2” 1 1/2” 1/2” 1 1/2” 2”

24”

1/2” 1 1/2” 2”

24”

1/2” 1 1/2”

ENDS

300 800

RF SW

300

RF

800

SW

300

RF

800

SW

2”

6”

300

RF

PLUG VALVE

½”

1 ½”

800

SW

BUTTER FLY VALVE (NOTE 4)

8”

24”

300

RF

800 300

SW RF

300

RF


1/2” 1 1/2” 2” 24” 2”

24”

FLANGES

1/2” 1 1/2” SCH 80 2” 10” SCH 40 12” 24” SCH 40 1/2” 1 ½” 3000 2” 10” SCH 40 12” 24” SCH 40 1/2” 1 ½” 300 2” 24” 300

GASKETS

1/2”

PIPE

FITTINGS (NOTE 2)

STUDS NUTS

PE BE BE SW BW BW SWRF WNRF

CORROSION ALLOWANCE

1.0mm

PIPING MATERIAL RADIOGRAPHY STRESS RELEIF

C.S. –GROUP 1.1 100 % PER B31.3 REQUIREMENTS

MATERIAL BODY/BONNET – A105N / ASTM A216 WCB, TRIM - AISI316 SEALS PTFE. DIMENSIONS / DESIGN AS PER B 16.10, / BS 5351, API 6D. FLOATING BALL UP TO 4”. TRUNINON BALL FOR SIZES 6” & ABOVE BODY/BONNET – ASTM A105N / ASTM A216 WCB,TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / API602 BODY/BONNET – ASTM A105N / ASTM A216 WCB, TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / API600. BODY/BONNET – ASTM A105N / ASTM A216 WCB,TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / BS5352 BODY/BONNET – ASTM A105N / ASTM A216 WCB,TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / BS1873 BODY ASTM A105N, TRIM AISI 316, TO BS 5353 / MFR. STD. (NOTE 4) DUEL PLATE WAFER TYPE, BODY A 216 WCB, TRIM 13% Cr, TO API 609 LIFT CHECK TYPE, BODY – A105N, TRIM 13% Cr, TO BS 5352 SWING TYPE, BODY ASTM A216 WCB, TRIM 13% Cr, TO BS 1868 DUAL PLATE WAFER LUG TYPE, BODY ASTMA A216 WCB, TRIM 13% Cr, TO API 594 C.S Seamless ASTM A 106 Gr. B TO ASME B36.10 C.S Seamless ASTM A 106 Gr. B TO ASME B36.10 CS WELDED API 5L Gr. B LSAW /A 106 Gr. B TO ASME B36.10 A-105 Seamless, ASME B16.11 A-234 Gr. WPB Seamless, ASME B16.9 A-105N PER ASME B16.5 A-105N PER ASME B16.5, SCH TO MATCH PIPE

4.5mm THK, SPIRAL WOUND, SS316+GRAFITE WITH SOFT STEEL CENTERING RING TO ASME B16.20 STUD BOLTS, ALLOY STEEL, ASTM A193 Gr.B7 /194 Gr.2H FULL LENGTH THREAD WITH TWO HEXAGONAL NUTS AS PER ANSI B 18.2.1/18.2.2 (Cadmium Plated) 24”

300

NOTE 1: FOR HANDWHEEL AND GEAR AND GEAR WITH MOTORIZED OPERATION REFER TO SPEC 0435-JH0902-00-PI-SPC-0002 NOTE 2: FOR BRANCHING TABLE REFER APPENDIX B. NOTE 3: FOR PIPE SIZES /FITTINGS 12” AND ABOVE, THE THICKNESS SHALL BE CALCULATED BASED ON ACTUAL DESIGN PRESSURE / TEMPERATURE PER LINE LIST NOTE 4: FOR VALVE DESIGNATION REFER TO VALVE DESIGNATION TABLE –3 FOR 300# NOTE 5: SPECIFIC VALVES ARE MOTOR OPERATED, REFER REVELENT P & ID


Page 31 of 42


VALVE DESIGNATION TABLE –3 FOR 300# PIPING CLASS B1

PRIMARY SERVICE RATING: VALVES:

ANSI 300 #

TEMPERATURE LIMITS:

-29°C TO 204°C

Refer To Valve Specifications 0435-JH0902-00-PI-SPC-0002 for Details of the following Valve Designations.

SIZE (NPS)

GATE

GLOBE

BALL

GA-C804 / GA–C300

GL-C804 / GL-310

BA-C804 / BA-C300

CH-C814

1/2” TO 1 1/2” SCRD

GA-C803

GL-C803

BA-C803

CH-C813

2”

GA-C310F

GL-C300

BA-C300F / BA C310FX

CH-C300

3”

GA-C310F

GL-C300


CH-C300

4”

-

-


CH-C300

6”

-

-

BA-C310F/ BAC310-FX

CH-C330

8”

-

-


CH-C330

10”

-

-


CH-C330

12” TO 24”

-

-


CH-C330

1/2” TO 1 1/2” S.W / RF


CHECK

BUTTERFLY

PLUG

Page 32 of 42



CLASS C1 SERVICE

REFER TO TABLE A

CORROSION ALLOWANCE

1.0mm

RATING

ANSI 600 #

PIPING MATERIAL

C.S. – GROUP 1.1

Pressure (Brag)

SERVICE LIMITS

Temperature 0C

NPS SIZES

102 0-38

100 50

93 100

RATING / SCH

ENDS

600

RF

24”

600

RF

1/2”

1 1/2”

1500

SW

2”

24”

600

RF

1/2”

1 1/2”

1500

SW

2”

6”

600

RF

PLUG VALVE

½”

1 ½”

1500

SW

BUTTER FLY VALVE (NOTE 4)

8”

24”

600

RF

1/2” 2”

1 1/2” 24”

1500 600

SW RF

2”

246”

600

RF

1/2” 2” 12” 1/2” 2” 12” 1/2” 2”

1 1/2” 10” 24” 1 1/2” 10” 24” 1 ½” 24”

SCH 80 SCH 80 SCH 80 6000 SCH 80 SCH 80 600 600

PE BE BE SW BW BW SWRF WNRF

ITEMS





PIPE

FITTINGS (NOTE 2)

FLANGES

GASKET STUDS NUTS

FROM 1/2”

TO 1 1/2”

2”

90 150



MATERIAL BODY/BONNET – A105N / ASTM A216 WCB, TRIM - AISI316 SEALS PTFE. DIMENSIONS / DESIGN AS PER B 16.10, / BS 5351, API 6D. FLOATING BALL UP TO 4”. TRUNINON BALL FOR SIZES 6” & ABOVE BODY/BONNET – ASTM A105N / ASTM A216 WCB,TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / API602 BODY/BONNET – ASTM A105N / ASTM A216 WCB,TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / API600. BODY/BONNET – ASTM A105N / ASTM A216 WCB,TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / BS5352 BODY/BONNET – ASTM A105N / ASTM A216 WCB,TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / BS1873 BODY ASTM A105N, TRIM AISI 316, TO BS 5353 / MFR. STD. (NOTE 4) DUEL PLATE WAFER TYPE, BODY A 216 WCB, TRIM 13% Cr, TO API 609 LIFT CHECK TYPE, BODY– A105N, TRIM 13% Cr TO BS 5352 SWING TYPE, BODY 216 WCB, TRIM 13% Cr, TO BS 1868 DUAL PLATE WAFER TYPE, BODY A 216 WCB, TRIM 13% Cr, TO API 594 C.S. SEAMLESS ASTM A 106 GR.B TO ASME B36.10 C.S. SEAMLESS ASTM A 106 GR.B TO ASME B36.10 CS WELDED API 5L GR.B LAW/ A 106 GR.B TO ASME B36.10 ASTM A105 Seamless PER ASME B16.11 A-234 Gr. WPB Seamless PER ASME B16.9 A-234 Gr. WPB Seamless PER ASME B16.9 ASTM A105N PER ASME B16.5 ASTM A105N PER ASME B16.5, SCH TO MATCH PIPE

4.5 mm THK, SPIRAL WOUND, SS316+GRAFITE WITH SOFT STEEL CENTERING RING TO ASME B16.20 STUD BOLTS, ALLOY STEEL, ASTM A193 Gr.B7 /194 Gr.2H FULL LENGTH THREAD WITH TWO HEXAGONAL NUTS WITH WASHER AS PER ANSI B 18.2.1/18.2.2 (Cadmium Plated) 1/2”

24”

600

-

NOTE 1: FOR HANDWHEEL AND GEAR AND GEAR WITH MOTORIZED OPERATION REFER TO 0435-JH0902-00-PI-SPC-0002 NOTE 2: FOR BRANCHING TABLE REFER APPENDIX B. NOTE 3: FOR PIPE SIZES /FITTINGS 12” AND ABOVE, THE THICKNESS SHALL BE CALCULATED BASED ON ACTUAL DESIGN PRESSURE / TEMPERATURE PER LINE LIST NOTE 4: FOR VALVE DESIGNATION REFER TO VALVE DESIGNATION TABLE - 4 FOR 600#. NOTE 5: SPECIFIC VALVES ARE MOTOR OPERATED, REFER REVELENT P & ID


Page 33 of 42


VALVE DESIGNATION TABLE - 4 FOR 600# PIPING CLASS C1

PRIMARY SERVICE RATING:

TEMPERATURE LIMITS:

ANSI 600 #

-29°C TO 204°C

VALVES: Refer To Valve Specifications 0435-JH0902-00-PI-SPC-0002 for details of the following Valve Designations. SIZE (NPS)

GATE

GLOBE

BALL

-

-

BA-C804F / BA-C600

-

-

-

2”

-

-

BA-C600F BAC610FX

CH-C600

-

3”

-

-

BA-C600F BAC610FX

CH-C600

-

4”

-

-

BA-C610F BAC610FX

CH-C600

-

6”

-

-

BA-C610FG/ BAC610-FX

CH-C600 / CH-C630

-

8”

-

-


CH-C630

10”

-

-


CH-C630

12” TO 24”

-

-


CH-C630

1/2” TO 1 1/2” S.W / RF 1/2” TO 1 1/2”

CHECK CH-C814

-

BUTTERFLY

PLUG

-

-

SCRD.


Page 34 of 42



CLASS D1 SERVICE

REFER TOTABLE A

RATING SERVICE LIMITS ITEMS


ANSI 900 # Pressure (Barg)

153

0

Temperature C

150

0- 38

NPS SIZES

RATING / SCH

FROM ½”

TO 1 ½”

2”

24”

900

½”

1½”

3000

2”

24”

900

½”

1½”

3000

2”

6”

900

½”

1 ½”

3000

½”

1½”

3000

2”

24”

900

2”

24”

900

½” 2” 4”

1½” 3” 10”

SCH 160 SCH 160 SCH 120

12”

24”

NOTE 3

1/2” 2” 4” 12” ½” 2”

1 1/2” 3” 10” 24” 1 ½” 24”

6000 SCH 160 SCH 120 NOTE 3 900 900

900



PLUG ALVE


PIPE

FITTINGS (NOTE 2)

FLANGES

GASKET STUDS NUTS

139

50

CORROSION ALLOWANCE

1.0mm

PIPING MATERIAL

C.S. – GROUP 1.1

135

RADIOGRAPHY

100%

150

STRESS RELIEF

PER B31.3 REQUIREMENTS

100

ENDS

MATERIAL

BODY/BONNET – A105N / ASTM A216 WCB, TRIM AISI316.SEALS PTFE. DIMENSIONS / DESIGN AS PER B 16.10, / BS 5351, API 6D. FLOATING BALL UP TO 11/2”. RF TRUNINON BALL FOR SIZES 2” & ABOVE BODY/BONNET – ASTM A105N / ASTM A216 WCB,TRIM SW – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / API602 BODY/BONNET – ASTM A105N / ASTM A216 WCB, TRIM RF – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / API600. BODY/BONNET – ASTM A105N / ASTM A216 WCB,TRIM SW – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / BS5352 BODY/BONNET – ASTM A105N / ASTM A216 WCB,TRIM RF – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / BS1873 BODY ASTM A105N, TRIM AISI 316 TO BS 5353 / SW MFR.STD. (NOTE 4) SW LIFT CHECK TYPE, BODY – A105, 13% Cr, TO BS 5352 SWING TYPE, BODY A216 WCB, TRIM 13% Cr, TO RF BS1868 DUAL PLATE WAFER LUG TYPE, BODY A 216 WCB, RF TRIM 13% Cr, TO API 594 PE C.S SEAMLESS ASTM A 106 GR. B TO ASME B36.10 BE C.S SEAMLESS ASTM A 106 GR. B TO ASME B36.10 BE C.S SEAMLESS ASTM A 106 GR. B TO ASME B36.10 C.S API 5L GR. B, LSAW / A 106 GR. B SEAMLESS TO BE ASME B36.10 SW ASTM A105N Seamless PER ASME B16.11 BW A-234 Gr. WPB Seamless PER ASME B16. 9 BW A-234 Gr. WPB Seamless PER ASME B16. 9 BW A-234 Gr. WPB Seamless PER ASME B16. 9 SWRF/RTJ ASTM A105N PER ASME B16.5 WNRF/RTJ ASTM A105N PER ASME B16.5, SCH TO MATCH PIPE RF

RTJ TYPE, Octagonal Ring Joint, Soft Iron TO ASME B16.20- 90 HB max. Hot Dip Galvanized STUD BOLTS, ALLOY STEEL, ASTM A193 Gr.B7 /194 Gr.2H FULL LENGTH THREAD WITH TWO HEXAGONAL NUTS AS PER ANSI B 18.2.1/18.2.2 (Cadmium Plated) 1/2”

24”

900

-

NOTE 1: FOR HANDWHEEL AND GEAR AND GEAR WITH MOTORIZED OPERATION REFER TO 0435-JH0902-00-PI-SPC-0002 NOTE 2: FOR BRANCHING TABLE REFER APPENDIX B.


Page 35 of 42

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) SPECIFICATION FOR PIPING MATERIAL NOTE 3: FOR PIPE SIZES /FITTINGS 12” AND ABOVE, THE THICKNESS SHALL BE CALCULATED BASED ON ACTUAL DESIGN PRESSURE / TEMPERATURE PER LINE LIST NOTE 4: FOR VALVE DESIGNATION REFER TO VALVE DESIGNATION TABLE - 5 FOR 900#. NOTE 5: SPECIFIC VALVES ARE MOTOR OPERATED, REFER REVELENT P & ID

VALVE DESIGNATION TABLE – 5 FOR 900# PIPING CLASS D1

PRIMARY SERVICE RATING:

TEMPERATURE LIMITS:

ANSI 900 #

-29°C TO 204°C

VALVES: Refer To Valve Specifications 0435-JH0902-00-PI-SPC-0002 for details of the following Valve Designations. SIZE (NPS)

GATE

GLOBE

BALL

CHECK

BAC1504F / BA-C900F

CH-C1514

BAC1503F

CH-C1513

2”

BA-C910F / BAC910FX

CH-C900

3”

BA-C910F / BAC910FX

CH-C900

1/2” TO 1 1/2” SW / RF 1/2” TO 1 1/2” SCRD.

4”

-

-

BA-C910F / BAC910FX

CH-C900

6”

-

-

BA-C910FG / BAC910FX

CH-C930

8”

-

-


CH-C930

10”

-

-


CH-C930

12” TO 24”

-

-


CH-C930


PLUG

Page 36 of 42


PIPELINE MATERIAL SPECIFICATION

CLASS B2 SERVICE

REFER TO TABLE A

RATING

ANSI 300 # Pressure (Barg) 51.1 50.1 46.6 45.1 SERVICE LIMITS Temperature 0C 0- 38 50 100 150 ITEMS

NPS SIZES RATING FROM TO / SCH

ENDS

1/2” 1 1/2” PIPELINE BALL 1/2” 1 1/2” VALVE (NOTE 1,4,5,6) 2” 22”

300 800

RF SW

300

RF

1/2” 1 1/2”

800

SW


2”

22”

300

RF

FLANGES

½” 1/2” 2” 12” 1/2” 2” 12” 1/2” 2”

1 ½” 1 1/2” 10” 22” 1 ½” 10” 22” 1 ½” 22”

800 SCH 80 SCH 40 SCH 40 3000 SCH 40 SCH 40 300 300

SW PE BE BE SW BW BW SWRF WNRF

GASKETS

1/2”

PLUG VALVE PIPE

FITTINGS (NOTE 2)

STUDS NUTS

CORROSION ALLOWANCE

1.0mm

PIPING MATERIAL RADIOGRAPHY STRESS RELEIF

C.S. –GROUP 1.1 100 % PER B31.4 REQUIREMENTS

MATERIAL BODY/BONNET – A105N / ASTM A216 WCB, TRIM - AISI316 SEALS PTFE. DIMENSIONS / DESIGN AS PER B 16.10, / BS 5351, API 6D. FLOATING BALL UP TO 4”. TRUNINON BALL FOR SIZES 6” & ABOVE BODY/BONNET – ASTM A105N / ASTM A216 WCB,TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / API602 BODY/BONNET – ASTM A105N / ASTM A216 WCB, TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / API600. BODY ASTM A105N, TRIM AISI 316, TO BS 5352 / API 599 C.S Seamless ASTM A 106 Gr. B TO ASME B36.10 C.S Seamless ASTM A 106 Gr. B TO ASME B36.10 CS WELDED API 5L Gr. B LSAW /A 106 Gr. B TO ASME B36.10 A-105N Seamless, ASME B16.11 A-234 Gr. WPB Seamless, ASME B16.9 / MSS SP 75 A-105N AS PER ASME B16.5 A-105N AS PER ASME B16.5, SCH TO MATCH PIPE

4.5mm THK, SPIRAL WOUND, SS316+GRAFITE WITH SOFT STEEL CENTERING RING TO ASME B16.20 STUD BOLTS, ALLOY STEEL, ASTM A193 Gr.B7 /194 Gr.2H FULL LENGTH THREAD WITH TWO HEXAGONAL NUTS AS PER ANSI B 18.2.1/18.2.2 (Cadmium Plated) 22”

300

NOTE 1: FOR HANDWHEEL AND GEAR AND GEAR WITH MOTORIZED OPERATION REFER TO SPEC 0435-JH0902-00-PI-SPC-0002 NOTE 2: FOR BRANCHING TABLE REFER APPENDIX B. NOTE 3: FOR PIPE SIZES /FITTINGS 12” AND ABOVE, THE THICKNESS SHALL BE CALCULATED BASED ON ACTUAL DESIGN PRESSURE / TEMPERATURE PER LINE LIST NOTE 4: FOR VALVE DESIGNATION REFER TO VALVE DESIGNATION TABLE –3 FOR 300# NOTE 5: SPECIFIC VALVES ARE MOTOR OPERATED, REFER REVELENT P & ID NOTE 6: PIPELINE BALL VALVE REFER SPECIFICATION 0435-JH0902-00-PL-SPC-0022


Page 37 of 42


PIPELINE MATERIAL SPECIFICATION

CLASS C2 SERVICE

REFER TO TABLE A

RATING

ANSI 600 #

SERVICE LIMITS

Pressure (Brag) 102

Temperature 0C

ITEMS

BALL VALVE (NOTE 1,4,5,6)

GATE VALVE (NOTE 1,4,5) PLUG VALVE PIPE

FITTINGS (NOTE 2)

FLANGES

GASKET STUDS NUTS

NPS SIZES

0-38

100 50

93 100

RATING / SCH

ENDS

600

RF

FROM 1/2”

TO 1 1/2”

2”

22”

600

RF

1/2”

1 1/2”

1500

SW

2”

24”

600

RF

½” 1/2” 2”

1 ½” 1 1/2” 10”

1500 SCH 80 SCH 80

SW PE BE

12”

22”

SCH 80

BE

1/2” 2” 12” 1/2” 2”

1 1/2” 10” 22” 1 ½” 22”

6000 SCH 80 SCH 80 600 600

SW BW BW SWRF WNRF

90 150

CORROSION ALLOWANCE

1.0mm

PIPING MATERIAL

C.S. – GROUP 1.1



MATERIAL BODY/BONNET – A105N / ASTM A216 WCB, TRIM - AISI316 SEALS PTFE. DIMENSIONS / DESIGN AS PER B 16.10, / BS 5351, API 6D. FLOATING BALL UP TO 4”. TRUNINON BALL FOR SIZES 6” & ABOVE BODY/BONNET – ASTM A105N / ASTM A216 WCB,TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / API602 BODY/BONNET – ASTM A105N / ASTM A216 WCB, TRIM – 13% Cr, DIMENSIONS / DESIGN AS PER B 16.10 / API600. BODY ASTM A105N, TRIM AISI 316, TO BS 5353 / API 599 C.S. SEAMLESS ASTM A 106 GR.B TO ASME B36.10 C.S. SEAMLESS ASTM A 106 GR.B TO ASME B36.10 CS WELDED API 5L GR.B LSAW/ A 106 GR.B TO ASME B36.10 ASTM A105N Seamless PER ASME B16.11 A-234 Gr. WPB Seamless PER ASME B16.9 / MSS SP 75 A-234 Gr. WPB Seamless PER ASME B16.9 / MSS SP 75 ASTM A105N PER ASME B16.5 ASTM A105N PER ASME B16.5, SCH TO MATCH PIPE

4.5 mm THK, SPIRAL WOUND, SS316+GRAFITE WITH SOFT STEEL CENTERING RING TO ASME B16.20 STUD BOLTS, ALLOY STEEL, ASTM A193 Gr.B7 /194 Gr.2H FULL LENGTH THREAD WITH TWO HEXAGONAL NUTS WITH WASHER AS PER ANSI B 18.2.1/18.2.2 (Cadmium Plated) 1/2”

22”

600

-

NOTE 1: FOR HANDWHEEL AND GEAR AND GEAR WITH MOTORIZED OPERATION REFER TO 0435-JH0902-00-PI-SPC-0002 NOTE 2: FOR BRANCHING TABLE REFER APPENDIX B. NOTE 3: FOR PIPE SIZES /FITTINGS 12” AND ABOVE, THE THICKNESS SHALL BE CALCULATED BASED ON ACTUAL DESIGN PRESSURE / TEMPERATURE PER LINE LIST NOTE 4: FOR VALVE DESIGNATION REFER TO VALVE DESIGNATION TABLE - 4 FOR 600#. NOTE 5: SPECIFIC VALVES ARE MOTOR OPERATED, REFER REVELENT P & ID NOTE 6: PIPELINE BALL VALVE REFER SPECIFICATION 0435-JH0902-00-PL-SPC-0022


Page 38 of 42


APPENDIX B BRANCH CONNECTIONS


Page 39 of 42

DOCUMENT NO : 0435-JH0902-00-PE-SPC-0001

REV. : 0

PAGE 40 of 42

BRANCH CONNECTION TABLE FOR A1, A1G, A1U, B1, B2 BRANCH inches

3/4

3/4

SWT

1

1 1/2

2

3

4

6

8

10

12

14

16

18

20

24

26

28

30

32

H

1

SWT

SWT

E

1 1/2

SWT

SWT

SWT

A

2

SW

SW

SWT

BWT

D

3

SW

SW

SW

BWT

BWT

E

4

SW

SW

SW

BWT

BWT

BWT

R

6

SW

SW

SW

W

BWT

BWT

BWT

8

SW

SW

SW

W

W

BWT

BWT

BWT

10

SW

SW

SW

W

W

BWT

BWT

BWT

BWT

12

SW

SW

SW

W

W

W

BWT

BWT

BWT

BWT

14

SW

SW

SW

W

W

W

BWT

BWT

BWT

BWT

BWT

16

SW

SW

SW

W

W

W

W

W

BWT

BWT

BWT

BWT

18

SW

SW

SW

W

W

W

W

W

BWT

BWT

BWT

BWT

BWT

20

SW

SW

SW

W

W

W

W

W

BWT

BWT

BWT

P

BWT

BWT

24

SW

SW

SW

W

W

W

W

W

BWT

P

P

P

P

BWT

BWT

26

SW

SW

SW

W

W

W

W

W

W

P

P

P

P

P

BWT

BWT

28

SW

SW

SW

W

W

W

W

W

W

P

P

P

P

P

P

BWT

BWT

30

SW

SW

SW

W

W

W

W

W

W

P

P

P

P

P

P

P

BWT

BWT

32

SW

SW

SW

W

W

W

W

W

W

P

P

P

P

P

P

P

P

BWT

BWT

36

SW

SW

SW

W

W

W

W

W

W

P

P

P

P

P

P

P

P

P

P

36

Notes: BWT SWT W SW P

DOCUMENT NO.: 0435-JH0902-00-PE-SPC-0001 Rev.0

-

Butt Weld Tee Equal and Reducing Socket Weld Tee Equal and Reducing Weldolet Sockolet Reinforcing Pad (Pad thickness to be verified by Contractor)

a)

Weldolets and tees, when used for branch connections, shall meet the rating requirements of the applicable Piping Material Specification.

b)

All branch connections shall be designed and reinforced so that the branch line connection is equal to the pressure and temperature rating of the header.

c)

Any deviation from the connection type shown in the above table or branch connections for larger piping sizes shall be approved in writing by WP/HPCL.

BWT

Page 40 of 42


REV. : 0

PAGE 41 of 42

BRANCH CONNECTION TABLE FOR C1, C2 BRANCH inches

3/4

1/2

SWT

1

1 1/2

2

3

4

6

8

10

12

14

16

18

20

24

3/4

SWT

H

1

SWT

SWT

E

1 1/2

SWT

SWT

SWT

A

2

SW

SWT

SWT

BWT

D

3

SW

SW

W

BWT

BWT

E

4

SW

SW

W

BWT

BWT

BWT

R

6

SW

SW

W

W

BWT

BWT

BWT

8

SW

SW

W

W

W

BWT

BWT

BWT

10

SW

SW

W

W

W

BWT

BWT

BWT

BWT

12

SW

SW

W

W

W

W

BWT

BWT

BWT

BWT

14

SW

SW

W

W

W

W

BWT

BWT

BWT

BWT

BWT

16

SW

SW

W

W

W

W

BWT

BWT

BWT

BWT

BWT

BWT

18

SW

SW

W

W

W

W

W

BWT

BWT

BWT

BWT

BWT

BWT

20

SW

SW

W

W

W

W

W

BWT

BWT

BWT

BWT

BWT

BWT

BWT

22

SW

SW

W

W

W

W

W

BWT

BWT

BWT

BWT

BWT

BWT

BWT

BWT

24

SW

SW

W

W

W

W

W

BWT

BWT

BWT

BWT

BWT

BWT

BWT

BWT

26

28

30

32

36



-

Butt Weld Tee Equal and Reducing Socket Weld Tee Equal and Reducing Weldolet Sockolet Reinforcing Pad (Pad thickness to be verified by EPCC Contractor)

a)


b)


c)


Page 41 of 42


REV. : 0

PAGE 42 of 42

BRANCH CONNECTION TABLE FOR D1 BRANCH inches

3/4

1

1 1/2

2

3

4

6

8

10

12

14

16

18

3/4

BWT

H

1

BWT

BWT

E

1 1/2

BWT

BWT

BWT

A

2

W

W

BWT

BWT

D

3

W

W

W

BWT

BWT

E

4

W

W

W

BWT

BWT

BWT

R

6

W

W

W

W

BWT

BWT

BWT

8

W

W

W

W

W

BWT

BWT

BWT

10

W

W

W

W

W

BWT

BWT

BWT

BWT

12

W

W

W

W

W

W

BWT

BWT

BWT

BWT

14

W

W

W

W

W

W

BWT

BWT

BWT

BWT

BWT

16

W

W

W

W

W

W

W

BWT

BWT

BWT

BWT

BWT

18

W

W

W

W

W

W

W

W

P

P

P

P

BWT

20

W

W

W

W

W

W

W

W

P

P

P

P

P

20

24

26

28

30

32

36



-

Butt Weld Tee Equal and Reducing Socket Weld Tee Equal and Reducing Weldolet Sockolet Reinforcing Pad (Pad thickness to be verified by Contractor)

a)


b)


c)


BWT

Page 42 of 42

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDED (HSAW) LINE PIPE


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

0435-JH0902-00-PL-SPC-0002 17 June 09


DOC. No.: 435-JH0902-00-PL-SPC-0002 Rev. 0

Page 1 of 37


SYNOPSIS



DESCRIPTION

0

Issued for Purchase

PREPARED BY

CHECKED BY

APPROVED BY

S. Ishwad

R. Singhi

J. Wallace


DATE

17 June 09

CLIENT APPROVAL N/A

Page 2 of 34

DATE


CONTENTS 1 2 5 6 7 9 10 11 12 14 (new)

Scope References Process of manufacture and material Material requirements Dimensions, weights, lengths, defects, and end finishes Inspection and testing Marking Coating and protection Documents Inspection of field tests & warranty

Appendix – B Appendix – C Appendix – F

Repair of defects by welding (normative) Repair welding procedure (normative) Supplementary requirements (normative)

SR 5 SR 6 SR 19

Fracture toughness testing (charpy v-notch) for pipes of size 4 ½ or larger Drop weight tear testing on welded pipe of size 20 or larger, grade x52 or higher. Additional fracture toughness requirements (transverse charpy v-notch) for psl 2 pipe

Appendix –H Appendix – I Annexure –1 (new)

Purchaser inspection (normative) Marking instructions for api licensees (normative) First day production tests

Figure 6.2.6.1 Figure 6.2.6.2 Figure 7.8.3 Figure 9.8.5.2

Metallographic specimen extraction plan Locations for hardness measurement Procedure for measurement of out of line weld bead Reference standard for ut of helical weld seam


Page 3 of 34


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. In addition to this, stringent requirements / provisions / amendments of the latest 44th edition, October 2007 shall also apply. 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. In addition manufacturer shall comply with all the latest stringent requirements / provisions / amendments made in API 5L, 44th edition, October 2007.

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 18 through 48 (both sizes included)

2

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 ASTM E 92 : ASTM E 112 : BS BS 5996

:

Test Method for Vickers Hardness of Metallic Materials. Standard Test Methods for Determining Average Grain Size.

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


Page 4 of 34


5

Process of Manufacture and Material 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

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)

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.

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

Material Requirements

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


Page 5 of 34


Element C Mn Si S P Al Nb V Ti Cr Mo Cu Ni N B

Product Analysis (percent) 0.16 max. 1.50 max. (For Grade B to X52) 1.60 max. (For Grade X56 to X70) 0.15 min. 0.45 max. 0.015 max. 0.02 max. 0.07 max. 0.05 max. 0.08 max. 0.04 max. (For Grade B to X60) 0.06 max. (For Grade X65 to X70) 0.20 max. 0.10 max. 0.35 max. 0.20 max. 0.012 max. 0.0005 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 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:


Page 6 of 34


CE (Pcm) CE (IIW)

≤ ≤

0.20 0.40

6.2

MECHANICAL PROPERTIES

6.2.1

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 5L Grade

Permissible in excess of SMYS, psi (MPa)

Up to and including X46 X52 to X65 X70

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. 6.2.5

Fracture Toughness Tests

6.2.5.2 Charpy Impact Tests for PSL 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


Page 7 of 34


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 (New) 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 Vickers hardness tests shall be carried out on each specimen taken for metallographic (New) 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 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 retest shall be in accordance with para 9.12.2 of API Spec. 5L. 6.2.7 (New)

Residual Stress Test 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 test 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. 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)


Page 8 of 34


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 C t E R F -

Residual Stress, kPa (psi) Increase in circumference, mm (in) Specified wall thickness, mm (in) Young’s Modulus of Elasticity, 2 x 108 kPa, (29 x 106 psi) Pipe Radius, mm (0.5 * Specified outside diameter), mm (in) 0.1154 in SI units, (0.425 in conventional units)

6.2.7.5 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 pipe 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. 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 Spec 5L Table 7 stands modified accordingly. Size 18 ≥ 20 and ≤ 36 > 36

Tolerance ± 3 mm + 3 mm, - 0.25% of specified OD ± 3 mm.

Pipe Ends Diameter tolerances for the pipe ends indicated in API Spec 5L Table 8 shall be applicable on the inside diameter.


Page 9 of 34


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 ≤ 36 > 36

: :

Tolerance 0.5% of OD ≤ 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). 7.3

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 12.0 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


Page 10 of 34


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 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 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


Page 11 of 34


Any hard spot having a minimum dimension greater than 2 in. (50.8 mm) in any direction and a 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 defects on the skelp shall be as per para 9.8.5.4 of this specification.

7.8.12

Undercuts b.

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 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 (New)

Peaking 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

General Pipes shall be furnished with plain ends.

7.9.3

Plain Ends


Page 12 of 34


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 (New)

Bevel Protectors 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.

9

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 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

TESTING OF MECHANICAL PROPERTIES

9.3.1

Tensile Tests

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 :


Page 13 of 34


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- I 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 d

= =

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

The results of the test shall meet the minimum requirements of the skelp with regard to yield, tensile and elongation. 9.3.5

Fracture Toughness Tests

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 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.


Page 14 of 34


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.

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).

9.5

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 be 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-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: (i)

For UT


Page 15 of 34


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)

9.8.3

For all other NDT methods 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 shall be performed after hydrotesting. Skelp Inspection The longitudinal edges of the skelp shall be 100% ultrasonically inspected over a 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 nonavailability 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 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


Page 16 of 34


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 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


Page 17 of 34


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. 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. b. c.

At the beginning of each operating shift (12 hours maximum). At least once during each operating shift (12 hours maximum). 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. 2. 3. 4.

No individual imperfection of length less than 20 mm shall be considered for population density assessment. Maximum length of imperfection in any direction shall not exceed 30 mm. Maximum area of individual imperfection shall not exceed 500 mm2. 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 Skelp


Page 18 of 34


(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.

2. 3.

4.

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.) Maximum area of any individual discontinuity shall not exceed 1000 mm2. 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. 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

Residual Magnetism Measurement Requirements e.

9.9

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 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 API Spec 5L para 9.9 (c) or (d).

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


Page 19 of 34


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.

9.12.7

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

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

12.2

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 (New)

PRODUCTION REPORT 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


Page 20 of 34


-

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, 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 (New)

LINE PIPE TRACEABILITY DATA 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 (New)

Inspection of Field Tests & Warranty 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.


Page 21 of 34


APPENDIX B REPAIR OF DEFECTS BY WELDING (NORMATIVE) B.1.2

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-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. b. c. d. e. f.

B.3.4 (New)

No repair of weld seam is permissible after hydrostatic testing. No repair of weld seam is permissible at pipe ends up to a length of 300 mm. Cumulative length of weld seam repairs on one pipe length shall not exceed 10% of the length of pipe. Repair welding shall be executed only after specific approval by Purchaser Representative for each repair. No repair of a repaired weld is permitted. The repair weld shall be performed with a minimum of two passes.

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.


Page 22 of 34


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 For all pipes where fracture toughness test is specified, Charpy V-Notch impact test as specified (New) shall be included in the Repair Welding Procedure Qualification. C.2.2.6 Hardness test as specified in para 6.2.6.2 of this specification shall be included in the procedure (New) qualification. The location of the hardness measurements is to be indicated taking into account the new HAZ of the repaired area.


Page 23 of 34


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-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 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:

SR6

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.

Drop Weight Tear Testing (DWTT) on Welded Pipe

SR 6.1 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. 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.


Page 24 of 34


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 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) 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 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.


Page 25 of 34


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.


Page 26 of 34


APPENDIX- I MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE) I.1

General

I.1.1

Marking shall also include Purchase Order number, item number, pipe number, heat number and weight.

I.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.

I.3

Sequence of Marking

I.3.4

Specified Dimensions: Actual pipe weight in kg shall also be marked.

I.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.

I.5

Length Actual length shall be marked in metres.

I.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 nonavailability 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.


Page 27 of 34


ANNEXURE - I (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 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.


Page 28 of 34


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 face 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: 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, + 20º 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)

e.

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.

In addition, all the tests and inspections required to be conducted as per this specification shall be conducted on all the pipes selected for testing during first day production test.


Page 29 of 34


HELICAL WELD

FIGURE : 6.2.6.1 METALLOGRAPHIC SPECIMEN EXTRACTION PLAN


Page 30 of 34


FIGURE : 6.2.6.2 LOCATIONS FOR HARDNESS MEASUREMENT


Page 31 of 34


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


Page 32 of 34


WELD SEAM (SHOWN STRAIGTH FOR CLARITY)

FIGURE : 9.8.5.2 REFERENCE STANDARD FOR UT OF HELICAL WELD SEAM

1,2 3,4 5 6 7 8 9

-

Longitudinal inside notch at weld seam edge Longitudinal outside notch at weld seam edge Transverse inside notch at weld seam edge Transverse outside notch at weld seam edge Longitudinal inside notch at weld seam centre Longitudinal outside notch at weld seam centre 1.6 mm dia. through thickness hole.


Page 33 of 34


Abbreviations: ASTM API ID HSAW HAZ NDT NPS OD WT

American Society for Testing and Materials American Petroleum Institute Inside Diameter Helical Seam Submerged Arc Welded Heat Affected Zone Non Destructive Testing Nominal Pipe Size Outside Diameter, Specified Wall Thickness, Specified


Page 34 of 34

Hindustan Petroleum Corporation Ltd. (A Government of India Enterprise)

GGSR Product Evacuation Project

Specification for 3 Layer Polyethylene (PE) External Coating of Line Pipes

Document No.:0435-JH-0902-PL-SPC-0001

1

12.05.2009

Client Comments incorporated and Reissued for ITB

SI

MD

AK

0

06.04.2009

Issued for Bids

MD

SI

AK

Rev.

Date

Purpose

Prepared

Checked

Approved

by

By

by

No.

Page 1 of 35

Document No. : 0435-JH0902-PL-SPC-0001 Rev. 1

CONTENTS

1.0

SCOPE ............................................................................................................................................ 3

2.0

REFERENCE DOCUMENTS........................................................................................................... 3

3.0

PLANT SCALE AND INSTALLATION............................................................................................ 5

4.0

MATERIALS .................................................................................................................................... 6

5.0

FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING........................................... 7

6.0

MEASUREMENT AND LOGGING ................................................................................................ 11

7.0

COATING PROCEDURE AND QUALIFICATION ........................................................................ 11

8.0

PIPE SURFACE PREPARATION ................................................................................................. 18

9.0

COATING APPLICATION ............................................................................................................. 21

10.0

INSPECTION AND TESTING........................................................................................................ 24

11.0

HANDLING, TRANSPORTATION AND STORAGE..................................................................... 30

12.0

REPAIR OF COATING .................................................................................................................. 32

13.0

MARKING ...................................................................................................................................... 33

14.0

QUALITY ASSURANCE................................................................................................................ 34

APPENDIX- I............................................................................................................................................... 35 LIST OF ACCEPTABLE COMBINATION OF COATING MATERIALS .................................................... 35

Page 2 of 35


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, Latest Edition, `External 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. i.

ASTM D-149

:

Standard Test Methods of Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Materials at Commercial Frequencies.

ii.

ASTM D-257

:

Standard Test Methods for D-C Resistance or Conductance of Insulating Materials.

iii.

ASTM D-543

:

Standard Method of Test for Resistance of Plastics to Chemical Reagents.

iv.

ASTM D-570

:

Standard Method of test for Water Absorption of Plastics.

v.

ASTM D-638

:

Standard Method of Test for Tensile Properties of Plastics.

vi.

ASTM D-792

:

Standard Test Method for Density and Specific Gravity (Relative Density) of Plastics by Displacement.

vii.

ASTM D-1238

:

Test Method for Flow Rates of Thermoplastics by Extrusion.

viii.

ASTM D-1525

:

Test Method for Vicat Softening Temperature of Plastics.

ix.

ASTM D-1603

:

Test Method for Carbon Black in Olefin Plastics.

Page 3 of 35


x.

ASTM D-1693

:

Test Method for Environmental Stress Cracking of Ethylene Plastics.

xi.

ASTM D-2240

:

Test Method for Rubber Property – Durometer Hardness.

xii.

ASTM D-3895

:

Test Method for Oxidative-Induction Time of Polyolefins by Differential Scanning Calorimetry.

xiii.

ASTM G-42

:

Tentative Methods for Cathodic Disbounding of Pipeline coatings subjected to Elevated or Cyclic Temperatures.

xiv.

API RP 5L1

:

Recommended Practice Transportation of Linepipe.

xv.

API RP 5LW

:

Transportation of Line Pipe on Barges and Marine Vessels.

xvi.

DIN EN 10204

:

Metallic Products Documents.

xvii.

DIN 53735

:

Testing of Plastics: Determination of Melt Index of Thermoplastics.

xviii.

IEC 454 – 2

:

Specification for Pressure-Sensitive Tapes for Electrical Purposes.

xix.

ISO 8501-1

:

Preparation of Steel Substrates before Application of Paints and Related Products – Visual Assessment of Surface Cleanliness: Part 1 – Representative Photographs of the Change of Appearance imparted to Steel when Blast Cleaned with different Abrasives.

xx.

ISO 8502 – 3

:

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).

xxi.

ISO 9002

:

xxii.

ISO 11124

:

Quality Systems: Model for Quality Assurance in Production, Installation and Servicing. Preparation of Steel Substrates before Application of Paints and Related Products.

xxiii.

API 5L

:

–

Types

for

of

Railroad

Inspection

Adhesive

Specification for Line Pipe

Page 4 of 35


xxiv.

ASME B31.8

:

Gas Transmission Systems.

and

Distribution

xxv.

ASME B31.4

:

Pipeline Transportation Systems Hydrocarbons and Other Liquids.

xxvi.

CSA Z245.20-02

:

External Fusion Bond Epoxy Coating for Steel Pipe.

for

Piping

Liquid

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 and 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 nonstop work execution owing to prohibitive adverse weather conditions and install requisite equipment and plant in roofed and adequately weather protected areas.

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. 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.

3.6

Page 5 of 35


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 topcoat. 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 Infra-red 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 certificates. 1.

2.

3.

Epoxy Powder: i.

Gel Time

ii.

Cure time

iii.

Moisture content

iv.

Thermal Characteristics (Tg1, Tg2 , H) ∆

Adhesive: i.

Specific Gravity

ii.

Melt Flow Rate

iii.

Vicat Softening Point

Polyethylene: i.

Melt Flow Rate

Page 6 of 35


ii.

Specific Gravity

iii.


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: i.

Name of the Manufacturer

ii.

Type of Material

iii.

Batch Number

iv.

Place and Date of Manufacture

v.

Shelf Life/Expiry Date (if applicable)

vi.

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.

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 (+)65°C 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 impairing its serviceability and properties specified.

5.2

The top coat polyethylene used shall be a black readymade compound, fully stabilized against influence of ultraviolet radiation (i.e. sunlight), oxygen in air and heat (due to

Page 7 of 35


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 Z245.20-02. 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:

5.2.3

Sr. No.

Properties

Unit

Requirement

Test Method

i.

Melt Flow Rate (190°C / 2.16 kg)

g/10 minutes

1.0 min.

ASTM D 1238

ii.


°C

100 min.

ASTM D 1525

iii.

Specific Gravity

-

0.926 min.

ASTM D 792

Requirement

Test Method

17 min.

ASTM D 638

0.25 min.

ASTM D 1238 or

Properties of Polyethylene Compound Sr. No.

Properties

i.

Tensile Strength @ + 25°C

ii.

Melt Flow Rate (190°C / 2.16 kg)

Unit N/mm

2

g/10 mintues

DIN 53735 iii.

Specific Gravity @ + 25°C

-

0.926 min. (MDPE) 0.924 min. (HDPE)

ASTM D 792

Page 8 of 35


Sr. No.

Unit

Requirement

Test Method

Shore D

50 min.

ASTM D 2240

%

0.05 max.

ASTM D 570

Ohm-cm

1015 min.

ASTM D 257

Volts/ mm

30,000 min.

ASTM D 149

iv.

Hardness + 25°C

v.

Water Absorption, 24 hours, @ + 25°C

vi.

Volume Resistivity @ + 25°C

vii.

Dielectric withstand, 1000 Volt/ sec rise @ + 25°C

viii.


°C

110 min.

ASTM D 1525

ix.

Elongation

%

600 min.

ASTM D 638

x.

Oxidative Induction Time in Oxygen at 200°C, Aluminium pan, no screen

Minutes

10

ASTM D3895

Hours

300

ASTM D 1693

xi.

xii.

5.3.3

Properties

Environment Stress Crack Resistance (ESCR) (for F50) •

Medium Density, Condition “C”.

•

High Density, Condition “B”.

Carbon Black Content

300 %

2 min.

ASTM D 1603

Requirement

Test Method

Properties of Coating System Sr. No.

Properties

Unit

i.

Bond Strength (using Type 2 Test Assembly i.e. Dynamometer)

Kg/cm

ii.

•

@ 20 +/- 5°C

•

@ 65 +/- 5°C

Impact Strength

DIN 30670

8.0 min. 5.0 min. Joules per

7 min

DIN 30670 Page 9 of 35


Sr. No.

Properties (Min. of 30 impacts on body along the length. No breakdown allowed when tested at 25 kV)

iii.

Indentation Hardness •

@ 23 +/- 2°C

•

@ 70 +/- 2°C

iv.

Elongation at Failure

v.

Coating Resistivity (*)

vi.

vii.

Requirement

mm

Test Method

DIN 30670 0.2 max. 0.3 max.

%

300 min.

DIN 30670

Ohm – m2

108 min.

DIN 30670

Heat Ageing (*)

-

Melt Flow Rate shall not deviate by more than 35% of original value

DIN 30670

Light Ageing (*)

-

Melt Flow Rate shall not deviate by more than 35% of original value

DIN 30670

viii. Cathodic Disbondment

ix.

Unit mm of coating thickness

•

@ + 65°C after 30 days

•

@ + 65°C after 48 hrs

mm radius of disbondment (**)

ASTM G42 15 max. 7 max.

Degree of Cure of Epoxy •

Percentage Cure, ∆ H

•

∆ Tg

%

95

°C

+3 / -2

CSA Z 245.20-98(***)

Page 10 of 35


(*)

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 G 42.

(***)

Temperature to which the test specimens are to be heated during cyclic heating shall however be as per the recommendations of epoxy powder manufacturer.

5.4

The acceptable combinations of coating material shall be as per Annexure-I.

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: i.

Details of plant(s), location(s), layout, capacity and production rate(s).

ii.

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.

iii.

Details of process control and inspection equipment required for the coating process such as temperature control, thickness control, holiday testers, etc.

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iv.

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.

v.

Plant Organisation Chart and availability of manpower including coating specialist.

vi.

Details of utilities/ facilities such as water, power, fuel, access roads and communication etc.

After COMPANY has given approval, 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: i.

Pipe inspection at the time of bare pipe receipt.

ii.

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.

iii.

Pipe heating, temperatures and control prior to epoxy application.

iv.

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).

v.

Application of FBE powder, adhesive and polyethylene, including characteristics, temperature, line speed, application window, curing time, etc.

vi.

Quenching and cooling, including time and temperature.

vii.

Quality Assurance System, Quality Plan, Inspection and Test Plan and reporting formats, including instrument and equipment types, makes and uses, etc

viii.

Detailed method of repair of coating defects duly classified depending upon nature and magnitude of defects and repair thereof including coating stripping technique

ix.

Details of instrument and equipment calibration methods including relevant

Page 12 of 35


standards and examples of calibration certificates. x.

Complete details and inventory of laboratory and equipment for procedure qualification and regular production

xi.

Pipe handling and stock piling procedures

xii.

Sample of recording and reporting formats, including laboratory reports, certificates and requirement as per clause 6.0 of this specification.

xiii.

Complete details of test certificates for raw materials including test methods and standards used.

xiv.

Test certificates from PE compound manufacturer for tests for thermal aging, coating resistivity and aging under exposure to light. These test certificates shall not be older than three years.

xv.

Health, Safety and Environment Plans.

xvi.

Storage details of coating materials and chemicals.

xvii.

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 the COMPANY has given approval. 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 25 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 10 (ten) test pipes shall be selected by COMPANY Representative for coating procedure approval tests and shall be subjected to procedure qualification testing as described hereinafter. COMPANY Representative shall witness all tests. Out of 10 (ten) test pipes, 1 (one) pipe partly coated with epoxy and partly coated with both epoxy and adhesive layers shall be included. Remaining 9 (nine) test pipes shall have all three layers.

Page 13 of 35


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 fluidised 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 the 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 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 shot to grit 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 on the abrasive blast cleaned pipe surface.

7.4.4

Coating Application The COMPANY Representative will check the correctness of each coating application operation, values of the main parameters of each operation, pre-heating 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.

Page 14 of 35


7.5

Qualification of Applied Coating

7.5.1

Tests on pipe coated partly with epoxy and partly with epoxy & adhesive layers i.

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.

ii.

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.

iii.

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.

iv.

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.

v.

vi.

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.245.20-02, 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.

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.245,20-02, Table 4.

Page 15 of 35


vii.

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.245,20-02, Table 4.

7.5.2

Tests on pipes coated with all three layers i.

Bond Strength Ten 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 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.

ii.

Impact Strength: Three test pipes shall be selected for impact strength test and the test shall meet the specified requirements.

iii.

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.

iv.

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.

v.

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.

vi.

Holiday Inspection All the pipes shall be subject to holiday inspection. The test voltage shall be as specified in para 10.4. (b).

Page 16 of 35


vii.

Coating Thickness Measurement All pipes shall be subject to coating thickness measurements. Acceptance criteria shall be as per para 10.3.

viii.

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. a.

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. Silicon coated sulphite paper shall be placed between the epoxy layer and adhesive layer immediately after epoxy application, to ensure physical separation of epoxy & adhesive as well as to prevent contamination of epoxy with adhesive layer, at a location from where the epoxy samples are to be removed for the test. 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: i.

ii. iii.

Surface cleanliness, surface roughness measurements and dust control immediately after second abrasive blast cleaning and salt test immediately after deionised water wash. pH of pipe surface before and after phosphoric acid wash. 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 ten (10) test pipes shall be removed and

Page 17 of 35


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 deemed 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 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.

Page 18 of 35


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. 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. 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 ISO-11124

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 short/grit into the pipe.

8.6

All pipes shall be tested for salt contamination after blast cleaning unit. One test shall be carried out on each pipe. The acceptance criteria shall be 2 g/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. Any pipe having salt contamination exceeding 2 g/cm2 shall be either reblasted or deionised water washed and then rechecked for salt contamination. In case salt level less than 2 g/cm2 is consistently achieved, the frequency of salt contamination testing may be relaxed to at least one pipe per hour at the sole discretion of the COMPANY Representative. µ

µ

µ

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 cleaned pipe shall conform to near white metal finish to Sa 2 1/2 of ISO 8501-1. Surface of pipe after abrasive blast cleaning shall have an anchor pattern of 50 to 80 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 21/2), 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. Tape used for assessment of degree of dust shall comply IEC 454-2. Pressure shall be exerted on the applied tape using a 4 kg roller, prior to peeling-off to assess the degree of dust.

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.

Page 19 of 35


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 that have damages repaired by grinding and have ground areas more than 50mm in diameter shall be reblasted. 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.

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 defect 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.

Page 20 of 35


8.13

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 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. 8.14

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.

Page 21 of 35


9.1.3

External surface of the pipe shall be heated to about 190 °C or 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, thermocouples etc. The recording method shall allow to correlate each linepipe. 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 minimised 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.

Page 22 of 35


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)

10” (273.1 mm)

2.0

2.7

18” (457.0 mm)

2.2

2.9

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) b)

Satisfactory qualification of the reclaimed system during PQT stage 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 fluidised bed, epoxy spray system and epoxy recycling system shall be at least (–) 40°C and this shall be 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 able capable of raising an alarm / activate audio system (hooter) in the event of change

Page 23 of 35


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.

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 120 mm (+) 20 / (-) 0 mm from pipe ends. 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

INSPECTION AND TESTING

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

Page 24 of 35


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, disbanded 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. 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 focussed at the middle of the pipe at one end while inspection is carried out visually from other end.

10.3

Coating Thickness i.

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.

ii.

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.

iii.

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.

Page 25 of 35


10.4

10.5

Holiday Detection i.

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.

ii.

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.

iii.

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.

iv.

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.

v.

Holidays, which are lesser in size than those mentioned in (d) above, shall be repaired in accordance with a approved procedure and shall be at Contractor’s expense.

Bond Strength Test i.

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.

ii.

The frequency of test for cut back portions shall be one pipe in every ten (10) pipes coated and for middle of pipe shall be one pipe in every fifty (50) 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.

iii.

In case the test fails to comply 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

Page 26 of 35


Contractor’s expense. iv.

10.6

10.7

10.8

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 (20) instead of every ten pipes, at the sole discretion of the COMPANY Representative.

Impact Strength i.

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.

ii.

Minimum thirty (30) impacts located equidistant along the length of coated pipe shall be performed.

iii.

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.

iv.

In case of test failure, retesting and disposal of coated pipe shall be as per para 10.5 (c) above.

Indentation Hardness i.

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 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.

ii.


Air Entrapment Test i.

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.

ii.

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

Page 27 of 35


the coating to a 45° angle and view with a microscope. Similar examination shall be done in the coating cut back area. iii. iv.

v. 10.9

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. 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. In case of test failure, retesting and disposal of coated pipe shall be as per para 10.5 (c) above.

Degree of Cure i.

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. Silicon coated sulphite paper shall be placed between the epoxy layer and adhesive layer immediately after epoxy application, to ensure physical separation of epoxy & adhesive as well as to prevent contamination of epoxy with adhesive layer, at a location from where the epoxy samples are to be removed for the test. 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 the specified requirements. ∆

∆

ii.

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

iii.

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 i.

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 30° / 150°. 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.

ii.

Frequency of this test shall be three per shift, one each at the start of shift, middle of shift and end of shift. The test shall be carried out at the cut back

Page 28 of 35


portion on the pipe from which the Degree of Cure test has been carried out as per para 10.9 above. iii.


10.11 Cathodic Disbondment Test i.

48 hours CD test shall be conducted as per clause 5.3.3 (h) of this specification.

ii.

The frequency of this test shall be twice in every week or two test representing each batch of epoxy powder used, whichever is more frequent.

iii.

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 reserves 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 despatch 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 contractors 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.

Page 29 of 35


Under no circumstances any action or omission of the COMPANY's Representative shall relieve the CONTRACTOR of his responsibility for material and quality of coating produced. No pipes shall be transported from the coating plant unless authorised by COMPANY in writing.

11.0

HANDLING, TRANSPORTATION AND STORAGE

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 rebevelled 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 be 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 rows of pipes remain free from any surface water. The

Page 30 of 35


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. 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. 2 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. The inspector of the coating contractor shall clear every lorry before loading the pipes and proper records of the same shall be maintained.

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.

Page 31 of 35


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 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 pipe 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 cm2 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.

Page 32 of 35


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 140 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 120 mm.

Not withstanding the above, if any 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 : •

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 shall indicate, but not limited to the following information: i.

Pipe number, Heat number

ii.

Diameter & Wall thickness

Page 33 of 35


iii.

Coated pipe number

iv.

Colour band

v.

Any other information considered relevant by COMPANY.

vi.

Pipe Manufacturer Name

vii.

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 organisation 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. The CONTRACTOR shall have established a Quality Assurance Group within its organisation that shall be responsible for reviewing the Quality System and ensuring that it is implemented.

14.2

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 organisation.

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.

Page 34 of 35


APPENDIX- I LIST OF ACCEPTABLE COMBINATION OF COATING MATERIALS The following combinations of coating materials are considered acceptable. In case any of the combinations listed below are offered, details regarding properties of the offered materials need not be furnished with bid. However, In the event of award of contract, CONTRACTOR shall furnish the combination(s) proposed and re-confirmation of compatibility of the proposed combination (s) from the raw materials Manufacturers. EPOXY POWDER (MANUFACTURER)

ADHESIVE (MANUFACTURER)

PE COMPOUND (MANUFACTURER)

CORRO-COAT EP-F 2001 (JOTUN)

FUSABOND 158D (DUPONT)

SCLAIR 35 BP HDPE

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 2001 (JOTUN) or SCOTCHKOTE 226N (3M)

ME0420 (BOREALIS)

HE 3450 (BOREALIS)

(NOVACOR)

Although the above combinations would be acceptable to COMPANY, the responsibility of suitability for application, performance and compliance to the coating system requirements shall unconditionally lie with the CONTRACTOR. CONTRACTOR shall ensure that adhesive as well as polyethylene is manufactured by the same Manufacturer.

Page 35 of 35


HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) SPECIFICATION FOR TRANSPORTATION AND HANDLING OF STEEL LINE PIPE


SPECIFICATION FOR TRANSPORTATION AND HANDLING OF STEEL LINE PIPE 0435-JH0902-00-PL-SPC-0005 7th July 09


Doc No: 0435-JH0902-00-PL-SPC-0005 Rev. B

Page 1 of 7


SYNOPSIS



DESCRIPTION

PREPARED BY

CHECKED BY

APPROVED BY

A

Issued for IDC

D. Hemnathan

S. Ishwad

J. Wallace

B

Issued for Review

D. Hemnathan

S. Ishwad

J. Wallace


DATE

07 July 09

CLIENT APPROVAL

DATE

N/A

07 July 09

Page 2 of 7



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

2.0

CODES, REGULATIONS AND STANDARDS ................................................................ 4

3.0

GENERAL....................................................................................................................... 5

4.0

RAIL TRANSPORTATION.............................................................................................. 5

5.0

TRUCK TRANSPORTATION.......................................................................................... 6

6.0

MARINE TRANSPORTATION ............................................. Error! Bookmark not defined.

7.0

INSPECTION .................................................................................................................. 7

8.0

SAFETY .......................................................................................................................... 7


Page 3 of 7


1.0

SCOPE This specification covers the minimum requirements for transportation and handling of steel line pipe by Truck, Railroad or Marine Vessel.

2.0

CODES, REGULATIONS AND STANDARDS

2.1

Vendor shall meet or exceed the requirements of the latest edition of the following codes, regulations and standards, except as superseded herein. In cases where more than one code, regulation or standard apply to the same condition, the most stringent shall be followed. In the event of a conflict between this specification and other specifications or correspondence, the OWNER shall be consulted and a ruling, in writing, shall be obtained before any work is started. •

•

American Petroleum Institute (API) -

API RP 5L1

Recommended Practice for Railroad Transportation and Truckload of Line Pipe

-

DEP 31.40.30.31 GEN

Technical Specification for External Polyethylene Coating for Line Pipe

DIN STANDARD -

• 2.2

2.3

DIN 30 670

Polyethylene Coatings for Steel Pipe

All Laws and Regulations of Authorities having jurisdiction over transportation of goods in all locations between the point of loading and the destination.

The following General Specifications shall be used in conjunction with this specification where applicable: •

0435-JH0902-00-PL-SPC-02/03/04 Specification for Linepipe

•

0435-JH0902-PL-SPC-0001

Specification for polyethylene Coating for

•

0435-JH0902-00-PL-SPC-0006

Specification for Pipeline Construction

Some requirements in this specification may be modified by specific requirements in the Purchase Specification. In case of conflict, the specific requirements supersede this specification.


Page 4 of 7


2.4

Any deviation from this specification must be approved, in writing, by OWNER. Such written approval must be obtained prior to the commencement of any work which would constitute such a deviation.

3.0

GENERAL

3.1

Transportation and handling of line pipe to this specification shall meet the requirements of API RP 5L1 as applicable, as well as the requirements of this specification which exceed the requirements of API RP 5L1.

3.2

Pipe shall be transported, handled and stored in a manner such that corrosion and mechanical damage, to either pipe and coating are prevented until the pipe has been delivered to designated stockpile area.

3.3

Any additional requirements to be applied to a particular purchase shall be included on specification sheets accompanying the Purchase inquiry. This specification sheet shall then be deemed as part of the project specification.

4.0

RAIL TRANSPORTATION

4.1

Transportation and handling of line pipe by railroad to this specification shall comply with the requirements of API RP 5L1 and with the laws and regulations of authorities having jurisdiction over transportation of goods in all locations between the point of loading and the destination.

4.2

Pipe shall be stacked in a nested manner such that the weld seams of the pipes are kept free from contact with other pipes or blocking.

4.3

Loading of pipes of different outside diameter in one stack shall be avoided.

4.4

If pipes of the same outside diameter but different wall thickness or steel grade are loaded in one stack, pipe with the higher steel grade shall be loaded under lower steel grade, or heavier wall thickness shall be loaded under lighter wall thickness. For loads of mixed steel grade and wall thickness, the product of steel grade and wall thickness shall be used to determine stacking order.

4.5

Joints shorter than the average joint length shall be loaded on top, and in any case shall not be loaded in bottom tiers.

4.6

Permitted stacking height on rail cars depends on pipe outside diameter, wall thickness, steel grade, coating, blocking, bearing strips and intended route, and shall be evaluated separately with the outside diameter, wall thickness and steel grade of each individual pipe.


Page 5 of 7


4.7

When transporting exterior coated pipe, rubber padding shall be used to separate each joint from contact with adjacent joints and with the surface of the rail car. Reasonable care shall be used in handling to ensure that the pipe reaches its destination with coating intact and undamaged.

4.8

Details of handling/loading procedures for each size or type of pipe shall be provided in writing to OWNER for approval, prior to commencement of loading operations. OWNER’s review and/or approval of Vendor’s procedures does not relieve the Vendor of any responsibility for complying with all of the requirements of this specification.

5.0

TRUCK TRANSPORTATION

5.1

Transportation of line pipe by truck to this specification shall comply with the laws and regulations of authorities having the jurisdiction over transportation of goods in all jurisdictions between the point of loading and location of destination. Loading and handling procedures shall comply with the requirements of API RP 5L1 for loading and handling for rail transportation where applicable.

5.2

Pipe shall be stacked in a nested manner such that the weld seams of the pipes are kept free from contact with other pipes or blocking.

5.3

Loading of pipes of different outside diameter in one stack shall be avoided.

5.4

If pipes of same outside diameter but different wall thickness or steel grade are loaded in one stack, the pipe with the higher steel grade shall be loaded under lower steel grade, or heavier wall thickness shall be loaded under lighter wall thickness. For loads of mixed grade and wall thickness, the product of steel grade and wall thickness shall be used to determine stacking order.

5.5

Joints shorter than the average joint length shall be loaded on top, and in any case shall not be loaded in bottom tiers.

5.6

Permitted stacking height on flat beds depends on pipe outside diameter, wall thickness, steel grade, coating, blocking, bearing strips and intended route, and shall be evaluated separately with the outside diameter, wall thickness and steel grade of each individual pipe.

5.7

Trucks shall be provided with fenders/mud flaps to prevent stones and gravel from impacting the pipe.

5.8

When transporting exterior coated pipe, rubber padding shall be used to separate each joint from contact with adjacent joints and with the surface of the flat bed. Reasonable care shall be used in handling to ensure that the pipe reaches its destination with coating intact and undamaged.


Page 6 of 7


5.9

Details of handling/loading procedures for each size or type of pipe shall be provided in writing to OWNER for approval, prior to commencement of loading operations. OWNER’s review and/or approval of Vendor’s procedures does not relieve the Vendor of any responsibility for complying with all of the requirements of this specification.

6.0

INSPECTION Vendor shall give OWNER a minimum of ten (10) working days written notice, prior to commencement of any loading/unloading operations. OWNER reserves the right to inspect at any time, without advance notice, at point of loading, or at any point in transit, any loading/unloading or transportation operation.

7.0

SAFETY Vendor shall comply with local Occupational Health and Safety laws and regulations and with local laws and regulations governing transportation of goods by railroad, truck or water as applicable.


Page 7 of 7

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) SPECIFICATION FOR PIPELINE CONSTRUCTION


SPECIFICATION FOR PIPELINE CONSTRUCTION 0435-JH0902-00-PL-SPC-0006 07 July 09


Doc No.: 0435-JH0902-00-PL-SPC-0006 Rev. 0

Page 1 of 34


SYNOPSIS



DESCRIPTION

PREPARED BY

CHECKED BY

APPROVED BY

A

Issued for IDC

D. Hemnathan

S. Ishwad

J. Wallace

B

Issued for Review

D. Hemnathan

S. Ishwad

J. Wallace

0

Issued for Tendering

D. Hemnathan

S. Ishwad

J. Wallace


DATE

05 July 09

CLIENT APPROVAL N/A

07 July 09

24 Sept 09

Page 2 of 34

DATE



SCOPE............................................................................................................................ 5

2.0

CODES, REGULATIONS, STANDARDS........................................................................ 5

3.0

GENERAL....................................................................................................................... 6

4.0

CONSTRUCTION ........................................................................................................... 6

4.1

Fences .............................................................................................................................6

4.2

Clearing............................................................................................................................7

4.3

Grading ............................................................................................................................8

4.4

Unloading, Hauling, Stringing, and Storing .......................................................................9

4.5

Trenching .......................................................................................................................10

4.6

Bending and Laying........................................................................................................13

4.7

Welding ..........................................................................................................................15

4.8

Testing Welders .............................................................................................................18

4.9

Pigging ...........................................................................................................................19

4.10

Coating...........................................................................................................................20

4.11

Testing for Holidays........................................................................................................20

4.12

Protection of Coated Pipe...............................................................................................20

4.13

Lowering-In ....................................................................................................................21

4.14

Backfill............................................................................................................................22

4.15

Clean-Up and Fence Repair ...........................................................................................23

4.16

Testing ...........................................................................................................................24

4.17

Highway and Railway Crossings ....................................................................................26

4.18

Waterway Crossings.......................................................................................................27

4.19

Rock Trench ...................................................................................................................28

4.20

Earth Padding.................................................................................................................29

4.21

Rock Shield ....................................................................................................................29

4.22

Rock Riprap ...................................................................................................................29

4.23

Concrete.........................................................................................................................29

4.24

River Weights .................................................................................................................30


Page 3 of 34


4.25

Electrolysis Test Leads...................................................................................................30

4.26

Valve Installations ..........................................................................................................31

4.27

Painting ..........................................................................................................................31

4.28

Crossing of Major Rivers ................................................................................................31

4.29

Riprap ............................................................................................................................33

4.30

Pups...............................................................................................................................33

5.0

SAFETY ........................................................................................................................ 33


Page 4 of 34


1.0

SCOPE This specification provides the requirements that shall be followed for the construction of pipelines. The rules and regulations of agencies having jurisdiction over pipelines in the location of installation shall be considered a part of this specification.

2.0

CODES, REGULATIONS, STANDARDS

2.1

CONTRACTOR shall meet or exceed the requirements of the latest edition of the following codes, regulations and standards, except as superseded herein. In cases where more than one code, regulation, or standard apply to the same condition, the most stringent shall be followed. In the event of a conflict between this specification and other specifications or correspondence, the OWNER shall be consulted and a ruling, in writing, shall be obtained before any work is started.

2.2

2.3

•

ASME B31.4

Pipeline Transportation System for Liquid Hydrocarbons and other Liquids

•

API RP 5L1

Recommended Practice for Railroad Transportation of Line Pipe

•

API 1104

Welding of Pipelines and Related Facilities

•

API RP 1102

Recommended Practice for Liquid Petroleum Pipelines Crossing Railroads and Highways

•

OISD 141

Transportation of Hydrocarbon Pipeline system

•

OISD 138

Inspection of Cross Country Pipeline

•

Regulations, Codes and Statutes of Authority having jurisdiction in location of pipeline installation.


0435-JH0902-00-PL-SPC-0012

Specification for Field Joint Coating (Heat Shrink Sleeves For Girth Welds (Field Coating)

•

0435-JH0902-00-PL-SPC-0011

Specification for Pipeline Welding

•

0435-JH0902-00-PL-SPC-0008

Specification for Hydrostatic Testing

Some requirements in this specification may be modified by specific requirements in the contract specification. In case of conflict, the specific requirements supersede this specification.


Page 5 of 34


2.4


3.0

GENERAL

3.1

The OWNER shall have the right to make any changes necessary to the Work. If the change results in increasing or decreasing the costs to the CONTRACTOR, the Contract price will be equitably adjusted. Such adjustments must be agreed on and authorized in writing by the OWNER before that part of the Work commences.

3.2

CONTRACTOR shall be liable for damage to any and all above or below grade existing man-made structures or natural features that may be located within or adjacent to the working area. Caution and due consideration shall be given to the protection and support of such properties and structures.

3.3

No additional compensation shall be allowed to the CONTRACTOR for any item in this Specification, "Pipeline Construction", unless specifically noted otherwise.

3.4

The CONTRACTOR shall preserve access roads from damage caused by the CONTRACTOR and shall promptly repair any such damage as directed by the OWNER at the CONTRACTOR’s expense. Unless otherwise approved by OWNER, hard surface roads shall be crossed by boring method.

3.5

The CONTRACTOR shall not enter into any agreements with landowners or tenants which in any way affects the compensation payable to the landowner by the OWNER. The CONTRACTOR shall limit his independent dealings with landowners or tenants to matters of schedule and information about construction. Where a special agreement with the landowner is deemed necessary by the CONTRACTOR, explicit written approval from the OWNER's representative shall first be obtained. Such agreement shall not change the Contract requirements for use and restoration of right-of-ways and adjacent areas to the satisfaction of OWNER.

3.6

Draining of pollutants onto the land or into a body of water are not permitted. All waste material must be collected and removed by the CONTRACTOR to an approved disposal area on an ongoing basis.

4.0

CONSTRUCTION

4.1

Fences This shall include work done on all fences on the right-of-way which it may be necessary to cut to permit passage of equipment onto or along the right-of-way. All


Page 6 of 34


fences which have been cut shall be closed with gates constructed as set out in the drawings and in a manner acceptable to the OWNER. 4.1.1

CONTRACTOR, having first ascertained from OWNER that permission has been secured from the property owner, shall furnish materials for and shall install a suitable, substantial gate or gap in every fence at the point of intersection of the proposed pipeline with the fence for access to land crossed by the line and for passage of construction equipment. Before cutting the fences to make these gates or gaps, CONTRACTOR shall brace and reinforce the fences on each side of the gap to be opened, in order to prevent damage to said fences. Gates or gaps shall be constructed that they can be securely closed and shall be the type specified by OWNER and shall satisfy land owner and tenant. CONTRACTOR shall furnish a watchman to maintain these gates where necessary to prevent livestock from entering or leaving the property or in any other instance where required by OWNER. CONTRACTOR will use only such roads through farms as are designated by property owners.

4.1.2

CONTRACTOR shall furnish all wire, posts, nails, or other equipment for construction of temporary gates and repairing of fences.

4.1.3

On completion of construction, the temporary gates shall be removed and fences restored by the CONTRACTOR to their original condition or better.

4.2

Clearing This shall include work necessary for the clearing of all trees, brush, hedges, or other obstacles, with the exceptions noted below, lying within the confines of the right-ofway.

4.2.1

4.2.2

4.2.3

Before clearing operations are started, CONTRACTOR shall familiarize itself with all special provisions included in the right-of-way easements secured by OWNER; and CONTRACTOR shall comply with these provisions. Where the right-of-way passes over or through farm yards, groves, orchards, gardens, lawns, ditches, canals, or similar valuable property, then only that amount of right-of-way necessary for actual ditching and laying of pipe shall be used; and the CONTRACTOR shall perform the work in such places so as to minimize the damages and if necessary shall hand ditch or tunnel through such places. Where timber is encountered, CONTRACTOR shall clear the right-of-way by removal of all trees, brush, stumps, and other encumbrances. CONTRACTOR shall remove all brush, stumps, and other loose debris so that the spoil bank from the ditching operations shall not fall on any foreign material that might become mixed with the excavated soil. All brush, trees, and other materials shall be burned or disposed of or removed by CONTRACTOR from the right-of-way to the complete satisfaction of OWNER, land owner, and tenant. The CONTRACTOR shall have all fires attended at all times and


Page 7 of 34


extinguish all burning embers before leaving the site of the fires and shall be responsible for any damage done by fire caused by the CONTRACTOR or his subCONTRACTOR. 4.2.4

Merchantable (over 15 cm at the base of the trunk) timber shall be cut in commercial lengths and disposed of as directed by OWNER. The CONTRACTOR shall comply with other requirements of right-of-way agreements or regulatory bodies having jurisdiction over lands and forests.

4.2.5

No cutting or clearing shall occur off the right-of-way without written approval from OWNER.

4.2.6

The CONTRACTOR shall furnish and maintain all necessary day and night warning signs, flares, lanterns, barricades, and flagmen when working on or near roads, highways, railroads, or other traffic ways to protect all persons and property from injury and to warn on coming traffic of the obstruction.

4.3

Grading This shall include all excavation, the forming of embankments, diverting of ditches or small streams, crossing channels, building of temporary bridges and roads, or other work performed to facilitate the movement of equipment onto and along the right-ofway. The CONTRACTOR is responsible for moving his men across or around watercourses.

4.3.1

Excess excavated material shall be placed in piles from which it may be replaced into its original position. Such material shall not be scattered along the right-of-way and shall not be placed in low areas traversed by the pipeline route without the consent of the OWNER.

4.3.2

Material removed from creek banks shall not be placed in the creek bed at points which will interfere with excavation of the ditch for the pipe across the creek bed or with any existing drainage. CONTRACTOR shall take necessary precautions to maintain flow of water in all ditches and channels to the satisfaction of OWNER and/or tenant and regulatory authorities. Where necessary, CONTRACTOR shall install flumes, tamp backfill, and perform such other operations as may be necessary to maintain normal flow of water.

4.3.3

No public streams shall be forded or bridged for passage of equipment until the CONTRACTOR has secured approval of the regulatory authorities having jurisdiction over same. The OWNER is to receive written notice of such approval.

4.3.4

CONTRACTOR shall grade off sharp points or hollows in order to allow the pipe to be bent and laid within the minimum radius of bends allowed by the Contract Documents.


Page 8 of 34


4.3.5

All grading shall be done as is necessary to minimize the necessity of over bends and sag bends.

4.4

Unloading, Hauling, Stringing, and Storing This work shall include all unloading, storing, hauling, stringing, and all handling of pipe, fittings, and all other materials except the unloading and storing done by OWNER prior to the execution of this contract by CONTRACTOR. All scheduling of material once it is made available by OWNER is the responsibility of the CONTRACTOR.

4.4.1

OWNER will keep CONTRACTOR informed as to the movements of materials and will endeavor to effect delivery of the materials in accordance with the schedule furnished for the convenience of the CONTRACTOR, but OWNER will not be responsible for delays over which it has no control. The CONTRACTOR shall be responsible for all costs for demurrage, storage charges, or claims of any nature whatsoever occasioned by his failure to unload the materials promptly on arrival at destination. OWNER may, at its option, establish central warehouses for the receipt and delivery of fittings, valves, and other miscellaneous small materials to CONTRACTOR, in which event CONTRACTOR agrees to accept delivery of, and unload said materials at such points.

4.4.2

CONTRACTOR will keep OWNER informed as to the locations of its unloading gangs so that OWNER may place his representative at points where CONTRACTOR is unloading material; and such representative will co-operate with the agent of CONTRACTOR, who is taking delivery of materials from the OWNER representative. Upon arrival at such delivery points, said material shall be checked for quantity and condition by representatives of both CONTRACTOR and OWNER. The authorized representatives making such checks shall make a written record thereof, which shall set forth the quantity and condition of the material; and upon completion, the same shall be signed by the parties making the same; and such record shall thereafter be conclusive as between the parties hereto. If the material is received in a damaged condition, an inspection must be made by an agent of the carrier before unloading or removal of such material and report of such inspection prepared and forwarded to OWNER.

4.4.3

Pipe shall be handled in a manner to prevent possible damage to pipe walls and pipe ends. Boomers shall always be used in cross-country or rough road handling. Pipe shall not be dropped or rolled off of or onto vehicles but shall be handled with suitable slings. Pre-coated pipe shall be handled at all times with wide non-abrasive canvas or leather belts, or other equipment designed to prevent damage to the coating. Rope is not to be used. Pipe stockpiled shall be carefully stacked and blocked to avoid damage to pipe or pipe coating. Pipe loaded out shall have suitable tie downs, supports and blocking to prevent shifting. Tie-down, supports, and blocking shall be of such material and construction to provide adequate protection to


Page 9 of 34


pipe and to pipe coating. Pre-coated pipe requires tarpaulin protection when being hauled on gravel roads. 4.4.4

CONTRACTOR shall assume full responsibility for damage to material occurring during locating, hauling, and/or unloading operation. Materials damaged in doing the work shall be replaced or restored at the Contractor’s expense and to the satisfaction of OWNER.

4.4.5

CONTRACTOR, at his expense, shall ensure that all construction materials consigned to any part of the work shall be properly stored to prevent theft, damage, deterioration or waste.

4.4.6

The CONTRACTOR shall be responsible for and shall pay the full cost of any temporary storage which may be necessary for the pipe or other materials including the cost of handling these materials and charges for storage except where the OWNER has already arranged for storage of such material.

4.4.7

It shall be the responsibility of the CONTRACTOR to string the pipe in such a manner so as to avoid excess or deficient quantities of pipe for the line.

4.4.8

CONTRACTOR shall string the pipe in such a manner as to cause the least interference with normal use of the land, street, or roadway and the passage of farm stock and equipment across the right-of-way. The pipe may be continuously strung except at river, railroad, or highway crossings where the pipe will be stacked by CONTRACTOR in a manner and at a location satisfactory to OWNER.

4.4.9

Coating and primer shall be unloaded from cars at destination points in such a manner as to prevent injury to containers. Containers of coating materials shall not be handled with hooks at any time and shall be stored with tops of containers up. Valves, fittings, and other materials shall be unloaded in a manner to prevent damage and shall be stored in a manner to prevent loss or deterioration and permit easy access for checking of quantities. Valves, flanged fittings, or other materials with finished surfaces shall always be placed on skids to prevent the finished surfaces from coming into contact with the earth. Small fittings, fiberglass wrapping material, and supplies shall be kept in suitable warehouses provided by CONTRACTOR at its expense.

4.4.10

4.5

Trenching This shall include all excavation, whether by trenching machine, power shovel, by hand, by blasting, or by other methods which may be necessary (after grading has been completed) to prepare a trench for the pipe with the minimum of cover between top of pipe and immediate ground level as set forth in these Specifications and the Job Description.

4.5.1

With reference to the right-of-way stakes, all stakes showing station numbers shall be offset by the CONTRACTOR in such a manner that they will remain for the


Page 10 of 34


duration of the job. Any re-staking made necessary by Contractor’s failure to preserve the stakes shall be charged to the Contractor’s account. 4.5.2

The trench shall be excavated on a true line with survey stakes provided by OWNER, to dimensions no less than those shown in the Job Description. The depth of the trench shall be measured from the level of the original ground on each side of the trench. It shall be necessary to provide additional depth ditch at certain locations such as roads, highways, railroads, drainage ditches, creeks, rivers, ravines, and other water courses, farm terraces, crossings of other underground structures, and where extra depth is required by any public authority having jurisdiction over same.

4.5.3

The above described additional depth ditching shall be known as "Normal Extra Depth Ditching", and no extra compensation will be paid.

4.5.4

OWNER may require CONTRACTOR to excavate the trench to additional depth to provide more cover than is required by "Normal Extra Depth Ditching" where the line crosses swamps or lands subjected to floods, where additional excavation is required to prevent freezing, to provide clearance for future installation of tile or drainage ditches, or where the right-of-way easement so requires. Such extra depth ditch shall be known as "Abnormal Extra Depth Ditch", and CONTRACTOR shall be compensated the unit price set forth in the Proposal for "Abnormal Extra Depth Ditch". CONTRACTOR will not be compensated for extra ditch unless 30 metres (100 feet) or more of continuous Abnormal Extra Depth Ditch is excavated.

4.5.5

CONTRACTOR shall dig the trench to such additional depth necessary to lay the pipeline under any other pipelines or underground structures, except drain tile, with at least 1 foot ( 0.3 m) clearance. Where drain tile is encountered, CONTRACTOR shall dig the trench so that the pipeline may be laid under with a clearance of a minimum of 6 inches (15 cm). When any drain tile is damaged, cut or removed, it must be temporarily repaired immediately if necessary, at Contractor’s expense. At the time such tile is damaged, the CONTRACTOR shall carefully and immediately mark the location of such damaged tile by means of a latch securely staked with a bright yellow flag attached thereto. Such markers shall be kept in place and shall not be removed except by the tile repair crew after tile has been repaired and such repairs have been inspected and approved by the landowner and the OWNER.

4.5.6

No blasting shall be allowed without permission of OWNER, and prior notice to landowners, adjacent landowners and other interested parties. When blasting is necessary for trench excavations, precaution must be taken to minimize the danger or inconvenience to landowners and tenants along the line, to telephone lines or other above-ground structures, and to the Owner’s or others' existing pipelines and other appurtenances. Extreme care shall be exercised so as not to scatter loose rock over the right-of-way and cultivated fields or cause damages to property. If loose rock is scattered, CONTRACTOR shall pick up such rock to the satisfaction of the landowner and the OWNER.


Page 11 of 34


4.5.7

OWNER desires to reduce to a minimum the required number of bends to lay the pipe to conform to the contour of the ground and maintain a normal covering. This ditch shall start sloping 100 ft (30 metres) before approaching any road, railway crossing and small water courses and slope out in the same manner to obtain required depth. It is Owner’s intention that the CONTRACTOR shall eliminate unnecessary bending by operating the ditching machine at various depths rather than by finishing grading the ditch by hand, whenever practicable.

4.5.8

CONTRACTOR shall provide temporary crossings, wherever necessary, to permit property owner or his tenant to travel or move his stock and equipment from one point to another on his property.

4.5.9

No payment will be made for over-excavation.

4.5.10

The CONTRACTOR shall square cut the bottom of the ditch as neatly as possible to avoid unnecessary handwork. Handwork will be required however, to remove rocks, hard clods, and protruding roots from the sides or bottom of the ditch or as required by OWNER.

4.5.11

In all cases where the ditch has been cut across private or public roads, the CONTRACTOR shall install temporary bridgework the full width of the road, of sufficient strength and properly constructed to ensure the safety of traffic. Instead of bridgework, the CONTRACTOR may backfill the ditch the entire width of the road or provide suitable diversions subject to OWNER APPROVAL.

4.5.12

The CONTRACTOR shall, whenever possible, complete the ditching, laying and backfilling of roads before the end of the work day so as to avoid hazards to night traffic.

4.5.13

Rocks, gravel or other hard materials in the ditch, which, in Owner’s opinion will injure the pipe or pipe coating shall be covered by the CONTRACTOR with soft earth or sand to give the pipe, when in the ditch, at least 4 inches (100 mm) of clearance from the rock or hard material. In such areas, on the approval of OWNER, the pipe may be supported on earth- filled sacks spaced as required by OWNER but in no case greater than 25 feet (7.6 m) apart.

4.5.14

The CONTRACTOR shall keep the ditch in good condition until the pipe is laid and inspected. All lumber, jacks, or other materials used to brace the ditch shall be furnished and removed by CONTRACTOR.

4.5.15

The CONTRACTOR shall de-water, shore, or do whatever may be required to excavate the ditch, install the pipe in it and backfill the ditch in accordance with these Specifications.


Page 12 of 34


4.6

Bending and Laying This shall include all work required to shape the pipe to conform to the ditch and joining this pipe adjacent to the ditch.

4.6.1

CONTRACTOR shall preferably provide for changes of vertical and horizontal alignment in pipeline by making elastic bends. Contractor may provide cold field bends, as its option for change of direction and change of slope. Company at its option, may authorised fabricated bends for installation at point where in company’s judgment the use of such bend is unavoidable.

4.6.2

Elastic Bend: The minimum allowable radius for elastic bends in the buried pipeline including that for continuous concrete weight coated pipe shall be in accordance with the relevant job standards. The elastic bend shall be continuously supported over its full length. A radius smaller then permitted in elastic bending shall require a cold bend.

4.6.3

Cold field bend:

4.6.3.1

Bends shall be made with uniform radius and the curvature shall be spread over as great a length as possible. Minimum radius of bend shall be forty (40) times the outside diameter of the pipe 18” and greater and shall not be less thirty (30) times for pipe outside diameter of the pipe 16” and lesser except where otherwise authorized by the OWNER.

4.6.3.2

All bending of coated pipes shall be done by the cold-smooth method using a bending machine with good pipeline construction practices or bending shoe on a tractor approved by OWNER. No fire or wrinkle bends will be allowed

4.6.3.3

Pipe which has been buckled, wrinkled, flattened, or the wall thickness reduced will not be allowed in the pipeline and shall be removed at the Contractor’s expense.

4.6.3.4

Contractor shall, before the start of the work, submit and demonstrate to company a bending procedure, which shall confirm to the recommendations of the manufacturer of the bending machine. The procedure shall include among the steps-lengths, max, degree per pull and method and accuracy of measurement during pulling of the bend. The bending procedure and the equipment use shall be subject to Company’s approval.

4.6.3.5

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 length shall be made by positioning the longitudinal welds alternatively 70mm above and below the plane passing though the natural axis in such a way that the bends are welded with the longitudinal welds displaced by about 150mm and situated in the upper


Page 13 of 34


quadrants. In case of vertical bends formed from the no. 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 respectively. 4.6.3.6

The ovalization caused on each pipe by bending shall be less then 2.5% of the specified diameter at any point. A check shall be performed on all bends in presence of owner 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 300mm.

4.6.3.7

The wall thickness of finished bends, taking into account wall thinning at the outer redius, should not be less then the design thickness. An addition of wall thinning as a percentage is given by the following empirical formula: Wall Thinning =

50 n+1

Where ‘n’ is the inner bend radius divided by pipe diameter. Pipe with measured wall thickness greater then the nominal wall thickness (i.e. with +ve tolerance) shall normally be used for making cold field bends. 4.6.4

OWNER may supply pipe with jointer welds, double-joint welds, and internal coating. All bending and handling of the pipe must be performed in a manner to prevent damage to the pipe and coating.

4.6.5

The distance between centre lines of bending points shall be such that there will be no distortion of the pipe or of the bend previously made and shall in no event be closer than ten (10) pipe diameters. No bend shall be made nearer than 1.5 metres to the end of the joint of pipe. When pipe is double-jointed before bending, bend shall not be closer to the weld than one (1) pipe diameter.

4.6.6

The intent of the foregoing Clauses is to produce bends which shall minimize the distortion of the pipe and which shall in no way impair the strength of the pipe. If OWNER so directs, and prior to the bending of any pipe to be used on the work, test specimens of any or all sizes of pipe to be used on the work shall be bent to determine the optimum bending and distortional limitations that will be used on the work. For such tests the CONTRACTOR shall furnish the labour and equipment necessary, and OWNER shall furnish the pipe.

4.6.7

The pipe shall be handled during laying, in such a manner as to prevent the ends and the wall from being damaged.

4.6.8

Skids shall be used to raise the pipe sufficiently to accommodate welding and the wrapping of joints.

4.6.9

Pipe shall be laid in such a manner as to allow slack in the line when lowered into the ditch.


Page 14 of 34


4.6.10

Miter and Unsatisfactory bends: No miter bends shall be permitted in the construction of the pipeline. Contractor shall cut out and remove any bend or bends, which do not meet the specifications and shall replace the same with the bends complying with specification at no additional cost to the owner. In the event the contract provides for supply of the line pipes required for replacement will be furnished by owner, but cost of replacement of such pipes shall be done by contractor. Cutting of factory made bends and cold field bends for any purpose are not permitted.

4.7

Welding This shall include the welding of pipe joints, fittings, etc.

4.7.1

All welding shall be done by the manual, electric shield-arc process unless written approval of an alternate method has been obtained from the OWNER prior to commencement of the work. The CONTRACTOR shall furnish all labour, equipment, tools and supplies including welding rods, oxygen, acetylene, and all other necessary materials.

4.7.2

All welding done under this specification shall be in accordance with latest edition of ASME Standard B31.4 "Pipeline Transportation Systems for Liquid Hydrocarbons, and other Liquid" and General Specification 0435-JH0902-00-PL-SPC-0011, Pipeline Welding.

4.7.3

OWNER reserves the right to have any and all welds checked by such nondestructive tests as X-ray, gamma ray, Magnaflux, ultrasonic, or any combination of these, or other inspection methods; and if the results of these inspections as determined by OWNER indicate that any weld is unsatisfactory, CONTRACTOR shall have the weld repaired or replaced at his own expense as directed by the OWNER.

4.7.4

After the welding operation, the pipe shall be left uncoated for a period not greater than twenty-four (24) hours to permit OWNER to conduct the non-destructive tests on the welds. The CONTRACTOR shall co-operate fully with the crew carrying out the tests. Whenever practical, OWNER will also conduct non-destructive tests on all tie-in welds. The CONTRACTOR will allow a reasonable amount of time for OWNER to conduct the tests on the tie-in welds, and OWNER will not unduly delay the tie-in operation.

4.7.5

The internal surface of each pipe end shall be machine buffed a minimum length of 3/4 inch (19 mm) to remove all rust, scale, dirt, or other foreign materials before placing in alignment for welding.


Page 15 of 34


Preparatory to aligning pipe, all paint, rust, scale, dirt, or other foreign materials that might affect the welding operation shall be removed prior to welding; and any suitable means approved by OWNER may be used for thoroughly cleaning the bevelled ends of pipe prior to the actual welding. 4.7.6

CONTRACTOR shall recut or trim all such pipe ends as may be necessary to maintain correct alignment and spacing of the pipe, using a bevelling machine or a type approved by OWNER.

4.7.7

The adjoining lengths of pipe shall be accurately aligned by use of an alignment clamp of a type and manufacture satisfactory to OWNER. Clamps shall not be removed until fifty (50%) percent of the stringer bead has been completed. Pipe ends shall be spaced not less than one-sixteenth (1/16) inch nor more than one-eighth (1/8) inch for welding and under no circumstances will OWNER pass welds which are not properly built up nor in which the spacing of the pipe is improper. The maximum high-low allowed for adjoining pipes of equal nominal wall thickness shall be one thirty-second (1/32) inch for nominal wall thickness 0.281 inch or less, and one sixteenth (1/16) inch for heavier wall pipe. Any greater misfit due to unequal nominal wall thickness shall be scattered about the periphery but shall not exceed three thirty seconds (3/32) inch. The pipe shall not be hammer-marked.

4.7.8

Striking the arc on the pipe at any point other than the welding groove will not be permitted. Any section of pipe which has been arc burned shall be cut out and replaced at Contractor’s expense.

4.7.9

The first bead shall be applied completely around the pipe and each bead shall be thoroughly cleaned of all scale, coating, slag and other foreign material prior to the application of the succeeding bead; and the method of cleaning shall be approved by OWNER. The completed weld shall be cleaned free of scale and oxides. The hot pass shall follow the stringer bead as closely as possible and not more than five (5) joints shall separate the operations at any time. No two welding passes shall start in the same place.

4.7.10

At the completion of the day's work all welds that have been started shall have hot pass completed. The length of line in which only stringer beads and hot passes have been applied shall be limited to 30 metres at the end of each day's work. Should a section of the line containing unfinished welds fall from the skids, the CONTRACTOR shall immediately report the same to the Inspector. Defects or cracks in welds shall be cut out. All costs of rebevelling and rewelding shall be borne by the CONTRACTOR.

4.7.11

whenever cold weather conditions are encountered, it will be necessary to preheat the joint to be welded to prevent weld cracking. Preheating shall be done by an approved method which will provide uniform heating. The area to be heated shall


Page 16 of 34


cover at least 3" (76 mm) on each side of the joint. All preheating temperatures shall be measured by pyrometric crayons or other suitable devices approved by OWNER. Where preheating is required, welds shall be protected from sudden cooling by insulated wrapping which is supplied by the CONTRACTOR. Maximum preheat temperature shall not exceed 180°C pending confirmation of linepipe tempering characteristics. 4.7.12

In the case of cold, rainy, windy, or stormy weather, CONTRACTOR shall provide protection for the welders at their work and care shall be taken to see that no welds are subjected to sudden variations in temperature. No welded section of pipe shall be rolled off the skids or dollies until the welds are thoroughly cool. Welding shall not be carried on when, in the judgement of OWNER, the weather is unsuitable for welding operation.

4.7.13

If any weld is burned or oxidized during welding, the entire weld shall be cut out by CONTRACTOR and the joint rewelded at Contractor’s expense. No metal shall be allowed to run inside the pipe. Under no circumstances shall mitred welds be allowed. All welds which in the judgement of OWNER are under the specified size or grooved, riveted, or undercut on the sides shall be cut out and rewelded at Contractor’s expense.

4.7.14

The final welding pass shall be as high as the outside diameter of the pipe but preferably 1/16" (1.6 mm) higher. Excessively high welds are to be cut down by filing or grinding.

4.7.15

No weld containing a crack of any length shall be considered satisfactory even though the weld should hold under a pull test.

4.7.16

Only one repair attempt per defective weld will be allowed. If repair attempt is unsuccessful, weld shall be cut out and replaced at Contractor’s expense. If weld contains three or more defects, no repair attempt shall be allowed. Total weld replacement shall be at the Contractor’s expense. All welds shall be crayoned on the top quarter of pipe by CONTRACTOR, according to numbers assigned to the welders by CONTRACTOR; and CONTRACTOR shall furnish OWNER with a record of all numbers assigned. No numbers shall be reassigned.

4.7.17

The open ends of the line shall be securely closed at the end of each day's work to prevent the entrance of small animals, reptiles, etc. and other obstructions and shall not be re-opened until the work recommences. Night caps shall be placed over the open ends of tie-in sections, or both ends of long sections. These night caps are to be furnished by CONTRACTOR and approved by OWNER. Any obstruction which may occur in the line shall be removed by CONTRACTOR at his expense and to the satisfaction and approval of OWNER. The line must be delivered to OWNER entirely free from dirt, obstructions, and other foreign substances.


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4.7.18

CONTRACTOR shall provide for each welder a suitable container for welding rod stubs. Welding rod stubs are not to be deposited on the right-of-way or pipe trench at any time.

4.7.19

All materials, equipment, and supplies necessary to the performance of this work must be satisfactory to OWNER. Any materials, equipment, or supplies that are not satisfactory must be discarded and approved material, equipment and supplies substituted therefore. The welding rod specifications and the welding procedure shall be submitted to OWNER for approval prior to the commencement of welding.

4.8

Testing Welders OWNER shall require each welder employed by the CONTRACTOR to pass welding tests in accordance with the latest edition of API Specification 1104. CONTRACTOR shall be required to furnish all equipment and supplies required for these tests, with the exception of the pipe nipples which OWNER shall furnish. After the OWNER has determined that the welder meets Owner’s requirements, the CONTRACTOR shall issue an identifying stencil to that welder and each weld made by that welder shall be so identified. Any weld worked on by more than one (1) welder shall be stencilled by each and every welder participating in the weld. OWNER will record the stencil and name of the welder. If the welder should leave the job, his identifying stencil shall be voided and not duplicated.

4.8.1

OWNER shall reserve the right to cut any weld from the pipeline and that weld shall then be tested in the manner stated below. If the weld conforms to all Owner’s requirements, OWNER will reimburse the CONTRACTOR for the cost of replacing the weld, except that OWNER shall be permitted to cut one (1) test weld made by each welder from the line at no cost to OWNER. If the test weld shall fail in any of the standard OWNER tests, the welder may not be permitted to continue welding on the pipeline. If two (2) or more welders participated in making the weld which failed, the CONTRACTOR and OWNER shall determine which welder or welders are responsible for the defective work. All welds which fail shall be replaced at no expense to OWNER. If it is not possible to pull the pipe back into position after a weld has been removed, a nipple with a minimum length of 1.1 m shall be set in and two (2) welds shall be required to close the line. OWNER reserves the right to cut any of these replacement welds from the pipe if it so desires. OWNER reserves the right to test welds as it deems necessary.

4.8.2

By cutting out welds, the physical test procedure is as follows: (a)

Eight (8) coupons shall be cut from circumference of test pipe at 45 degree angles.


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(b)

Four (4) coupons shall be prepared for tensile test and tested in an approvedtype, tensile-testing machine. Coupons selected for the tensile shall be taken from top and bottom centre and two (2) sides; however, if radiographic inspection indicates a defect in the weld in other portions of the pipe, one (1) coupon shall be cut from the indicated defective portion of the weld and the other three (3) coupons taken at ninety (90°) degrees from the said coupon. Coupons shall break in the pipe metal away from weld.

(c)

Two (2) coupons shall be prepared for bend test. One (1) bar shall be bent around a 13 mm diameter rod so that the root of the weld is on the inside of the bend. The coupon shall bend ninety (90°) degrees without fracture of the metal. The other bar shall be bent around a 13 mm diameter rod so that the face of the weld is on the inside of the bend. The coupon shall bend ninety (90°) degrees without fracture.

(d)

One (1) coupon shall be prepared for nick-break test. The coupons shall be broken in the nicked portion by a sudden blow and the fractured surface shall show complete penetration through the entire thickness of the pipe wall and shall be free from oxides, slag inclusions, pin holes, or other defects.

(e)

In the event any coupon fails in any of the above tests, remaining coupons shall be subjected to the test that failed and in the event of failure of any of these coupons; the weld shall be deemed to be defective.

4.8.3

Radiographic or X-ray Inspection - The CONTRACTOR will furnish space and equipment to move, locate, and/or handle radiographic or X-ray equipment when job conditions necessitate.

4.8.4

A joint record of results of each weld test shall be made by OWNER and the Contractor’s representative. Except for the one (1) weld per welder, each weld cut out which satisfactorily passes Owner’s Standard Tests shall be paid for by OWNER in accordance with the unit price per weld as set forth in the Proposal. The joint record made by OWNER and CONTRACTOR shall indicate the location of the weld by Survey station number and stencil number and the result of the test. This record shall be signed by an authorized representative of both OWNER and CONTRACTOR and must be made on the day the test is performed. No reimbursement will be made for any weld not covered by a signed record completed in the above-described manner.

4.8.5

The work prescribed in this Section will be paid for as a part of the Proposal or as part of items entitled REBEVELLING PIPE and TEST WELDS of the Proposal, whichever is appropriate.

4.9

Pigging This work shall include the pigging and sectional testing of the pipe strings prior to laying the final tie-ins.


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4.9.1

The finished lines shall be delivered to OWNER free from all foreign materials and objects, and such defects as flattening, excessive weld protrusion, etc. Scrapers, of a pattern acceptable to the OWNER, shall be air-driven through all lines. Scrapers shall have a gauging plate 13 mm smaller in diameter than the inside diameter of the pipe.

4.9.2

In the case of the scraper lodging in the pipe, or leaks being found, all cut-outs, replacements and repairs shall be made by the CONTRACTOR at his expense. The testing and swabbing shall then be rerun.

4.10

Coating The line pipe will be supplied by OWNER with coating. CONTRACTOR will be responsible for coating the pipe at all joints and any other locations as required to ensure complete protection of the buried pipe.

4.10.1

The coating of field joints or repairs to damaged coating shall be at least as equal in effectiveness to the coating applied over the main body of the pipeline. All such field joints and repairs must be inspected with the use of the holiday detector in the presence of Owner’s representative.

4.10.2

Application of coating in the field shall be as per General Specification 0435-JH090200-PL-SPC-0012 “Field Joint Coating (Heat Shrink Sleeves)”.

4.10.3

Any coating material which in the opinion of OWNER has been damaged by atmospheric conditions, reheating, overheating, or other operations shall not be used and must be reported to Owner’s representative.

4.10.4

The CONTRACTOR shall notify OWNER in advance of any and all cleaning, coating, and wrapping operations.

4.11

Testing for Holidays CONTRACTOR shall pass a Stearns Electronic Holiday Detector or equal type of holiday detector, set at a voltage (maximum of 15000 volts) per mil of coating thickness as recommended by coating manufacturer, over pipe after all pipe is coated and just ahead of the lowering operation. If the coated and wrapped pipe has been laid on skids, the coating and wrapping must be checked at each point of contact with the skids. All holidays shall be plainly marked immediately after detection and shall be patched to the satisfaction of the OWNER. OWNER reserves the right to have the CONTRACTOR repass the Holiday Detector over any section of the pipeline when, in the opinion of the OWNER, it is necessary.

4.12

Protection of Coated Pipe


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Sections of coated pipe shall be carried and not dragged. Extreme care shall be taken when coating may be damaged by movement. When the OWNER deems it necessary by reason of hot weather, CONTRACTOR shall furnish materials and whitewash any loops, slack loops, or spans. At all times coated pipe shall be handled by belt slings. The width of the belt slings shall be equal to approximately one (1) diameter of the pipe. Care shall be used to prevent damage to coating when belt is removed after pipe is lowered. 4.13

Lowering-In This shall include all work necessary to lower pipe into trench after coating operation has been completed.

4.13.1

All brush, skids, pipe, metal of any kind, rocks, large clods, sticks, projecting rocks, and other hard objects shall be removed from the trench into which the pipeline is to be lowered so that the protective coating shall not be punctured or abraded.

4.13.2

The trench shall be made wide enough where slack loops are lowered into the trench so that no coating will be rubbed off.

4.13.3

Whenever the bottom of the trench contains projecting rocks which might damage the pipe or coating, the bottom of the trench shall be padded with a minimum of 4" (102 mm) of sand or soft soil to be furnished and installed by CONTRACTOR, all of which shall be approved by OWNER.

4.13.4

The pipe shall be lowered into the trench as soon as the coating has hardened sufficiently so that the lowering will not cause holidays. This shall be checked by picking the pipe up after it has been lowered in and checking with a holiday detector. If this check shows holidays, the pipe must be lowered to skids until it has had sufficient time to properly harden.

4.13.5

Wide non-abrasive slings, belts, or rubber tire and cradles shall be used in all lowering of the pipeline. The CONTRACTOR shall lower line in such a manner as to provide sufficient slack and to the satisfaction of OWNER. The line shall not be dropped or subjected to jar or impact.

4.13.6

All coated and wrapped pipe, which has been supported in any manner, shall be subjected to close inspection and checked with a holiday detector to see that the coating is undamaged and if found damaged shall be patched.

4.13.7

CONTRACTOR shall furnish sufficient proper equipment during the lowering-in operation to prevent bending of the pipe or damage to coating. Where ditch is excavated in rock, padding will be provided as specified in Clause 4.19 and 4.20 entitled "Rock Trench and Earth Padding".

4.13.8 4.13.9

Where multiple lines are installed in a common ditch, a minimum of 6 inch (15 cm) spacing shall separate the individual lines. Individually placed mounds of earth at


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approximately 20 foot (6 m) intervals shall be placed in the ditch between the lines prior to backfilling to assure separation of the lines. 4.14

Backfill This shall include all work necessary to backfill excavated material in the ditch, and restore creek banks, hillsides, or other places where the right-of-way has been graded.

4.14.1

Immediately after the pipe has been lowered, it shall be weighted by filling the ditch over the pipe with backfill material. After the ditch has been filled to the level of surrounding ground, one tread of a heavy tractor shall run over backfill to pack the backfill. This tamping operation is not to be done through rocky land where the coating might be damaged or through sections where drainage tile is encountered and might be damaged. After the above tamping operation, the remaining backfill shall be spread over the pipeline ditch in a manner acceptable to the OWNER and the land owner.

4.14.2

Pipe, fittings, or appurtenances shall not be backfilled unless the pipe has the proper fit and the required cover and has been approved for backfill by OWNER.

4.14.3

Where the pipe has been laid under streets, sidewalks, or railroads, backfill shall be done as set out in Clause 4.17 entitled Highway and Railway Crossings.

4.14.4

All material used for backfill shall be of an acceptable quality free from large lumps, wood or other extraneous materials. In particular, backfill in contact with pipe shall be entirely free from stones, rocks or boulders.

4.14.5

All surplus rock removed from the ditch shall be disposed of to the satisfaction of the OWNER, land owner, and the tenant. All roads, pavements, hillsides, creek banks, terraces, and other places where the CONTRACTOR has moved earth to facilitate the movement or operation of its equipment shall be restored by CONTRACTOR to their original profile and condition.

4.14.6

Openings shall be made in the backfill to permit passage of surface water through the backfill. Particular care shall be exercised in order that all drainage ditches shall be maintained and left unobstructed to prevent the backing up of water against the spoil bank or backfill, thereby flooding areas or diverting said water.

4.14.7

The CONTRACTOR shall furnish the material and install breakers as may be required by OWNER to prevent water from running down the ditch and washing out the backfill.

4.14.8

Throwing of welding rod, cans, trash, lumber and other foreign substances of any kind into the pipeline ditch will not be permitted.


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4.14.9

The trench must be left with a crown having a height of between 8"(204 mm) and 20”(508 mm) unless otherwise specifically directed by the OWNER.

4.14.10

CONTRACTOR shall at all times keep the completed backfill to within 600 m of the lowered-in line.

4.15

Clean-Up and Fence Repair This shall include all work necessary to remove surplus material from the right-ofway and to finish grading the back-fill and right-of-way and to repair fences.

4.15.1

Before the work is finally accepted, CONTRACTOR shall remove from the right-ofway and adjacent property, as well as from public and private roads, and the channels of streams and ditches, all surplus blasted or excavated material. All underbrush, broken skids, and other such debris shall be burned or otherwise disposed of as specified by the OWNER. Oil drums, sheet metal from paint barrels, and other objects shall be gathered up and removed from the right-of-way. Sheet metal or other material shall not be placed in the pipeline ditch and covered up as a means of disposal.

4.15.2

All materials originally furnished by OWNER and not used in THE WORK will be picked up regardless of locations at time of clean-up and delivered to Owner’s storage site or warehouse as directed by OWNER.

4.15.3

On sections of pipeline where there is rock excavation, all loose rock deposited by such operation, both on right-of-way, and on land adjacent to right-of-way, shall be picked up and disposed of by CONTRACTOR. The backfill shall be piled over the ditch and then smoothed down with a grader or harrow.

4.15.4

In all areas, all spoil from sidehill cuts will be returned to its original position.

4.15.5

In cultivated farm land or improved lands, the right-of-way soil shall be thoroughly loosened on completion of clean-up by the use of a deeptillage chisel plow (Graham plow or equivalent).

4.15.6

Upon completion of construction of the line, permanent repairs shall be made to all fences by using good quality and like kind of fencing materials. All fence repairs must be satisfactory to the Owner’s representative and land owner or tenant.

4.15.7

Where the pipeline has been laid within street and improved roadway rights-of-way, the surface of such streets and improved roadways shall be restored using new materials of like quality with those found in the original improvement to the satisfaction of the OWNER and the governmental authority having jurisdiction over that portion of THE WORK.

4.15.8

Upon completion of clean-up operations, all off right-of-way damage claims will be settled promptly with land owners. Representatives of both CONTRACTOR and


Page 23 of 34


OWNER will be present in the settlement of ALL claims and for signing of releases by land owner or tenant on approved forms. 4.15.9

Clean-up progress will be reported to show only the amount of continuous clean-up from the starting point to the first section skipped. The only exception of the above is that clean-up progress will be reported as completion with deduction of skips which may be made around short areas with the written approval of the OWNER when ground conditions justify the skip. It is understood that when such skips are permitted, CONTRACTOR agrees to bring men and equipment back to complete clean-up at such skips as soon as ground conditions permit or as soon as the OWNER may request at no additional cost.

4.16

Testing This shall include all work and equipment necessary to test and repair the completed pipeline or section of pipeline. Contractor shall ensure the testing activities of the project are carried out which include at least the following: •

Coordinate the interface of the testing between Sub-contractor(s) and Vendor(s).

•

Obtaining any approval or work permit requited for testing activity.

•

Testing plan based on the testing sequence of activities.

•

Testing procedures – cleaning and dewatering, swabbing, calliper survey, drying, nitrogen purging and mothballing with nitrogen when required.

•

Provide experience and qualified personnel.

•

Testing spare parts, necessary equipment, tools, consumables, oil free compressors, launcher/ receivers, scrapers or pigs, etc.. List of equipment and tools ie gauges, dead weight testers, temperature probes, scraper (pig) tracker equipment’s etc..

• 4.16.1

The CONTRACTOR shall hydrostatically proof test all lines as shown in the test schedule. Prior to this test the CONTRACTOR shall run a line scraper through the completed sections with compressed air, to ensure that the line does not contain any obstruction. Main line valves should be in the full open position. The scraper shall be fitted with a gauging plate as shown on the appropriate drawing. If the scraper hangs up and will not pass through, it will be the responsibility of the CONTRACTOR to remove the obstruction and re-insert the scraper at the discretion of the Owner’s Representative. Upon successful completion of this scraper run, it shall be removed from the test section. The Owner’s Representative shall be present to witness the removal of the scraper.


Page 24 of 34


Temporary low pressure headers will be installed on each end of the continuous section and will be used for launching & receiving of the scrapers (pigs). The headers will be welded onto the ends of the section to be cleaned with at least 3 welding passes completed (root run, hot pass and fill run). No NDT will be carried out on these welds, however the welders shall be qualified to appropriate procedures. 4.16.2

The hydrostatic test shall be for twenty-four (24) hours or longer as required by public authority and shall be recorded by a pressure recorder supplied by CONTRACTOR and must be checked with Dead Weight Tester supplied by CONTRACTOR. For test pressure see specification 0435-JH0902-00-PL-SPC-0008 - Specification for Hydrostatic Testing.

4.16.3

The CONTRACTOR must make his own arrangements for obtaining water required for the tests and disposing (including government permits) of it after completion of the test.

4.16.4

Procedures for supply of test water and testing of water purity shall be approved in writing by OWNER. The water used for the test must be clean, free of silt, suspended material or harmful corrosive components.

4.16.5

CONTRACTOR must supply all fill pipes, pumps for filling and testing the pipeline and any other equipment required.

4.16.6

All valves and appurtenances must be checked by the CONTRACTOR, prior to filling the pipeline, to ensure that they are in proper working order. Valves and fittings must be greased and checked for tightness before filling.

4.16.7

When filling any section, a sphere or pig must be run immediately in front of the water. If a sphere is used, it must be inflated to a diameter three (3%) percent greater than the inside diameter of the pipe. It may be necessary to hold a back pressure of air on the pig or sphere to prevent it from running away from the water. When all sections are filled, entrapped air must be blown off at all available access points.

4.16.8

Warning signs should be placed along the right-of-way at all public crossings and at all points specified in alignment sheets where there is exposed pipe or appurtenances.

4.16.9

Where methanol or glycol is required the CONTRACTOR shall be required to supply this material.

4.16.10

Prior to starting the test, check all fittings for tightness. Install bull plugs and blind flanges except where gauges, recorders, or pumps are connected.

4.16.11

The pressure pump and connections must be checked before the test commences to ensure that they are capable of handling the job and withstanding the pressure.


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4.16.12

All leaks or pressure drops must be accounted for and remedied or repaired by the CONTRACTOR to the satisfaction of the OWNER.

4.16.13

Upon completion of the stand-up test, the pressure shall be bled from the section. Care must be exercised when removing bull plugs or blanking plates to avoid injury or damage due to a pressure build-up through a leaking valve. The CONTRACTOR will purge the entire section of water by using a pig or sphere driven by compressed air. Subsequent to this initial run, additional runs with a pig or sphere may be required by the OWNER to ensure that all of the water has been removed from the test section.

4.16.14

The pipeline internal inspection system may consist of gauging and calliper pigging methods. The gauging may be run before the calliper or the geometry pig to ensure the pipeline has no major dent and ovality in the test section. Upon completion of drying, the pipeline will be packed with the dry air. Report will be prepared by the Contractor for the whole cleaning, testing and drying. All the activity should be attended and verify by the OWNER. Written form shall be submitted to the OWNER at the end of every activity for review and approval. Contractor and OWNER shall initial to the report form.

4.16.15

Procedures for disposal of test water shall be approved in writing by OWNER. Disposal of test water shall be in accordance with requirements of local authorities and good environmental practice.

4.16.16

OWNER will supply the product to be placed in the lines by CONTRACTOR after the test and the line is free of water.

4.17

Highway and Railway Crossings This shall include all work necessary to haul and string, excavate, bore, weld casing, install vent pipes, and install pipe and casing under railways and roadways where such casing is required, and to backfill and repair such excavations.

4.17.1

OWNER shall procure all easement permits for crossings, but CONTRACTOR shall perform no excavation on the highway or railroad right-of-way without approval by the OWNER. CONTRACTOR shall familiarize itself with all the requirements and restrictions of crossing permits and shall conduct the work in strict accordance with such requirements and restrictions, including notification of proper authorities having jurisdiction as may be specified by OWNER.

4.17.2

CONTRACTOR shall not cut into any highway, surface of concrete, asphalt, gravel, oil, or any binding material without written permission from the governmental authority under whose jurisdiction a permit is issued. When permission is granted to


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the CONTRACTOR to cut such a surface, CONTRACTOR shall effect barricades and post warnings to prevent injury or damage to traffic. CONTRACTOR may, however, instead of bridging, backfill the ditch the full width of such roadway when specifically permitted to do so by OWNER and provided adequate maintenance is furnished. 4.17.3

CONTRACTOR shall provide crossings, wherever necessary, to permit property owner or his tenant to travel or move his stock and equipment from one point to another on his property. Where the surface of a highway has been cut to install pipe and/or casing, the crossing shall be back-filled and tamped to the satisfaction of OWNER and the governmental body having jurisdiction. CONTRACTOR shall furnish and haul water to wet the backfilled dirt if directed by OWNER, in order to obtain the proper degree of compaction.

4.17.4

Casings, if required, for all such crossings shall be welded into one continuous length and shall not be coated. The pipe to be installed within the casing shall receive coating as specified herein. Before placing pipe in casing, insulators shall be installed. After casing and pipe have been installed, the space between the pipe and casing shall be sealed at each end of the casing as per drawings. Two (2) vent pipes shall be welded into the casing and extended above ground to the right-of-way line of the highway or railroad unless otherwise required. Such vent shall be constructed by CONTRACTOR of materials furnished by OWNER and to such dimensions as are shown on the detailed drawings.

4.17.5

Where crossings do not require casing, the CONTRACTOR is to bore through the crossing using pilot pipe and then replace the pilot pipe with the carrier pipe. The pilot pipe shall not coated and have similar size with the carrier pipe. CONTRACTOR will supply necessary pilot pipe for boring through the crossing. After the pilot pipe is through the roadway, the carrier pipe is to be welded to the pilot pipe and pulled into position under the roadway.

4.18

Waterway Crossings This shall include all work, equipment, materials not furnished by OWNER and all other things necessary for the construction of the pipeline ready for use by OWNER across drainage ditches, valley, streams, rivers and adjacent low land and flood plains. This section shall apply to crossings upon which payment is included in the unit prices bid for the pipeline construction.

4.18.1

The trench for said pipe shall be excavated to a width of at least 1 foot (0.3 m) greater than the O.D. of the pipe to be placed therein and shall be a depth sufficient to provide 3 feet (1 m) minimum cover or as shown on accompanying drawings. Unless shown on the Plans, the grade will limit sag bends to a distance of not less than 12 feet (3.6 m), measured landward from the point of maximum high water elevation.


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4.18.2

That section of the pipe to be laid across such streams and adjacent low land shall be weighted with river weights where directed by OWNER.

4.18.3

CONTRACTOR shall conduct operations so as not to hinder the flow of water.

4.18.3.1

The gradient of the stream bed shall be maintained by not leaving spoil banks of excavated material of other objects in the stream bed.

4.18.3.2

Stream banks shall be restored to the original grade and cleared of any foreign objects.

4.18.3.3

Rock riprap shall be placed at locations designated by the OWNER to protect the banks and pipeline.

4.19

Rock Trench Rock Trench is defined as trench in rock which can be excavated to the CONTRACT requirements only by drilling and blasting, excluding trench in frozen ground.

4.19.1

When such is encountered, the trench shall be of such a depth as to provide required cover over the completed pipeline and an additional depth of 3 feet (1 m) below the bottom of the pipeline.

4.19.2

The CONTRACTOR shall exercise extreme care when blasting so as not to scatter rock fragments over the right-of-way or cultivated fields, or cause damage to persons or property. The CONTRACTOR shall pick up any such scattered rock and dispose of same to the satisfaction of OWNER and the land owner and/or tenant. In no instance shall such rock be utilized for padding or backfill material.

4.19.3

The CONTRACTOR shall secure all necessary permits and conform with all legal and safety requirements in connection with the use of explosives if they are used anywhere on the WORK.

4.19.4

The CONTRACTOR shall take every precaution to protect the land owner, the tenant, the workmen, the public and OWNER from any injury, damage, loss, or harm which might arise because of the use of explosives and shall use only experienced and competent workmen to supervise, handle, haul, load, place, and detonate the explosives.

4.19.5

Refuse from dynamite containers, cartridges, and caps shall be disposed of to the satisfaction of OWNER and in no case shall they be disposed of in the backfill of the trench or on the right-of-way.

4.19.6

No blasting will be allowed without prior written permission of OWNER and prior notice to landowners, adjacent landowners and other interested parties.


Page 28 of 34


4.20

Earth Padding This shall include all work, material and equipment necessary to install earth padding in trench excavated in rock.

4.20.1

Where earth padding is used, earth shall be placed in trench to completely encase pipe. Earth shall be placed in trench bottom to a minimum depth of 4" (102 mm) and on top of pipe to a minimum depth of 6 "(150 mm) to protect the pipe coating from injury.

4.20.2

Where suitable earth is available along the right-of-way and Line List restrictions will permit, the CONTRACTOR, with Owner’s approval, may use this material as trench padding where directed by the OWNER. Where necessary or where the CONTRACTOR desires to obtain suitable earth from sources outside the right-ofway, the CONTRACTOR shall procure at his expense such suitable earth and haul and place as specified by OWNER.

4.21

Rock Shield This shall include all work, material and equipment necessary to install a rock shield covering of the pipe.

4.21.1

In areas with gravel or small stones in the ditch, a 40 mil polyethylene rock shield will be applied as required by the OWNER. The rock shield will be supplied by the CONTRACTOR in rolls and will be applied in a spiral wound wrap with a minimum overlap of 1/2" (13 mm).

4.22

Rock Riprap This shall include all work necessary to furnish and place riprap at creek and river banks, hillsides, levees, or other places where water may wash the backfill away.

4.22.1

CONTRACTOR shall restore river banks to the original profile and shall provide additional protection by furnishing and placing sufficient rock riprap to protect the pipeline at river banks.

4.22.2

The work is to be done in a manner satisfactory to and having the approval of the OWNER and any other official body having jurisdiction.

4.23

Concrete This shall include all labour and materials necessary to form and place concrete, reinforcing steel, and anchor bolts used on the line.

4.23.1

Excavations for concrete shall be cut to the dimensions shown on the Drawings. Excavations cut greater than these dimensions shall be completely filled with


Page 29 of 34


concrete, and CONTRACTOR will receive no additional compensation for concrete in excess of that shown on Drawings. 4.23.2

All concrete and material shall conform to General Specifications 0435-JH902-00-CISPC-0002 (Specification for Concrete WORKS) and shall be approved by the OWNER. Concrete shall have a minimum compressive strength of 3050 psi (21 MPa).

4.23.3

Concrete, reinforcing steel, and anchor bolts shall be placed in conformance with the dimensions prescribed in the plans covering the installation.

4.23.4

The concrete must be protected from rapid drying for a period of four (4) days after pouring and shall be protected from any temperatures below 41°F (5°C) for a like period. CONTRACTOR shall pour anchor blocks at such locations along the pipeline as may be designated by the OWNER.

4.24

River Weights This shall include all work necessary to supply, unload, store, haul, string, and install river weights on the pipeline at locations and in a manner designated by the OWNER.

4.24.1

Weights shall be installed at locations as designated by the OWNER. The weights shall be fitted securely to the pipe and all bolts shall be firmly tightened. Where weights are installed on long sections of pipe, care shall be taken in handling to prevent buckling of the pipe.

4.24.2

All necessary padding required shall be installed in conjunction with the weights.

4.25

Electrolysis Test Leads This shall include all labour, equipment, material, and other services required to install contact wires in accordance with typical Drawing as per bid document.

4.25.1

Test leads shall be installed by the Cadweld method. No brazing will be permitted.

4.25.2

CONTRACTOR shall install electrolysis test lead stations at locations specified by the Company and in accordance with Drawings.

4.25.3

In general electrolysis test lead stations shall be installed at approximately 2 mile (3 km) intervals throughout the entire length of the pipeline, at all foreign pipeline crossings, and at all cased crossings.

4.25.4

Electrolysis test lead stations are to be installed immediately following lowering-in and to be completed during backfilling.


Page 30 of 34


4.25.5

The wires are to be attached to the pipe using a No. 15 (15 gram) charge of powder.

4.26

Valve Installations This shall include all labour and equipment for setting valves including pigging, purging, blowing and cleaning of lines.

4.26.1

All risers shall have either a concrete sleeper or pile support at rising and sand bags installed for a minimum of 40 feet (12 metres) if pipe is not resting on virgin soil. All such work will be performed by CONTRACTOR.

4.26.2

CONTRACTOR shall be held responsible for accurate alignment of valve installations and shall set them at locations designated by and to the satisfaction of OWNER.

4.26.3

CONTRACTOR shall perform all of the installation in accordance with Specifications.

4.27

Painting This shall include all labour and materials necessary to paint exposed sections of the pipeline and metal structures.

4.27.1

In those instances where the pipeline is not buried in the trench but exposed, as in the case of spanning deep washes and creeks where it may be supported on Aframes, the exposed section of pipe and supporting metal structures will be painted with one (1) coat of pipeline primer and two (2) coats of aluminium paint or as per Painting & Protective Coating Specification (0435-JH0902-00-PI-SPC-0003) to be furnished by CONTRACTOR.

4.27.2

The pipe coating will be applied to the remainder of the exposed section. All pipe and metal structures to be painted shall be thoroughly cleaned so as to be free from scale, rust, grease, or other foreign substances.

4.27.3

The primer shall be brushed on. The two (2) coats of aluminium paint may be sprayed on with an approved mechanical spray. All work shall comply with generally accepted painting standards.

4.28

Crossing of Major Rivers This shall include all work, equipment, and materials not furnished by OWNER, required for construction of the pipeline across Major Rivers as listed in the Job Description(SOW).

4.28.1

For all specifications for grading, welding, coating, etc., not detailed below, refer to the appropriate section of this Specification.


Page 31 of 34


4.28.2

The pipe trench shall be excavated to a width and depth sufficient to provide the minimum cover directed by the OWNER or as per the Drawings supplied.

4.28.3

Unless shown on the plans, the grade will limit sag bends to a distance of not less than 1 foot (0.3 m), measured landward from the point of maximum high water elevation.

4.28.4

All of the welds are to be 100% X-rayed by CONTRACTOR.

4.28.5

The crossing pipe may be weighted with a continuous coating of reinforced concrete, if indicated in the Job Description and on the Drawings forming part of these Specifications. CONTRACTOR shall be responsible for the materials and application of this concrete coating. Thickness, density and aggregate of the concrete sheath shall be as noted on the Drawings and shall be applied in such a manner as to assure perfect adherence to the reinforcing and pipe coating. The concrete coating shall be continuous over each assembled pipe section except for 1 foot (.3 m) at each end. The concrete shall be made equivalent to ASTM Specifications C-94. An air entraining agent shall be used to yield four to seven percent of air by volume. Clean, pure water is to be used in the concrete mix. The concrete shall be reinforced with a minimum of 2" x 2" x 15 gauge steel wire reinforcing mesh carefully shaped and placed around the pipe. The concrete coating must have a minimum compressive strength of at least 4,000 psi (27.6 MPa) in three days, and shall be cured for at least forty-eight (48) hours before the pipe is handled and three days before it is laid. Just prior to the installation of the concrete sheath, the coating on the pipe sections shall be checked with a holiday detector, and all holidays repaired. Wire reinforcing mesh shall be carefully placed encircling the pipe and permanently spaced 25 mm from the pipe line coating in a manner to avoid damage to the coating. Encircling forms shall be installed with appropriate spacers to ensure a uniform thickness of concrete. These spacers shall be designed in such way as to ensure they will not cause damage to the pipe coating. The concrete shall be applied to prevent voids and honeycomb.

4.28.6

The welded joint between two such lengths shall also be double wrapped with tape and concrete coated in accordance with the foregoing specifications.

4.28.7

The concrete coating may be applied by "guniting" or by forming and pouring.

4.28.8

A pressure test is to be placed on the pipeline by the CONTRACTOR before it is installed in the trench. This test will be hydrostatic and is to be for duration of six (6) hours. All liquid must be removed from the line immediately after the test. Test pressure as per Job Description.


Page 32 of 34


4.28.9

Special care must be exercised to ensure that the entire length of line is backfilled resulting in a uniform river bottom when the job is finished.

4.28.10

Rock riprap and/or sand or earth filled bags shall be placed at locations designated by the OWNER to protect the banks and pipeline.

4.29

Riprap Except as otherwise noted in the list of special requirements, CONTRACTOR may reserve the use of timber from the right-of-way for use as riprap in wet areas.

4.29.1

In areas where riprap must be obtained from off the right-of-way limits, the CONTRACTOR shall obtain written permission from the landowner or government authority before removing timber.

4.29.2

The limbs and tops must be removed from timber before it is used as riprap.

4.29.3

In those areas where it is required by the landowner, tenant, or government authority, riprap must be removed at the conclusion of construction and disposed.

4.30

Pups

4.30.1

All pups 3.6 feet (1.1 m) and over shall be moved ahead daily and installed in the line.

4.30.2

There shall be a full joint of pipe installed between pups.

5.0

SAFETY

5.1

On all pipelines, these safety rules and specifications shall apply: (a)

All construction will comply with health and safety regulations of the local authority having jurisdiction.

(b)

Hard hats will be worn by all personnel on the job sites; CONTRACTOR will supply hats for his personnel.

(c)

CONTRACTOR is to supply two fire extinguishers whenever tie-ins to existing lines are being made.

(d)

All tie-ins to existing lines will be done according to a written tie-in procedure approved by CONTRACTOR and OWNER. Hot-Work Permits are required for all tie-ins.


Page 33 of 34


(e)

Existing pipeline rights-of-way are not to be used as storage or parking areas without approval of the OWNER.

(f)

Equipment is to cross existing pipelines only at locations approved by the OWNER. Extra fill is to be provided as padding at those locations, to the satisfaction of the OWNER.

(g)

Location of underground lines shall been carried out by the CONTRACTOR. The centrelines of existing pipelines adjacent to the new right-of-way and the locations of lines to be crossed have been flagged with Fluorescent Yellow tape.

(h)

CONTRACTOR is to ensure that all foremen are in possession of pipeline drawings before breaking ground.

(i)

Before any crossing is started the CONTRACTOR shall locate all foreign lines, expose using hand tools for 60 centimetres on either side of line(s) before any mechanical excavation is started on the easement of the foreign line.

(j)

Rural gas utilities and cable crossings shall be handled in a similar manner as foreign pipeline crossings.

(k)

No unauthorized personnel or equipment shall be permitted on R.O.W. during testing of any description.


Page 34 of 34

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) SPECIFICATION FOR MAGNETIC CLEANING ANG ELECTRONIC GEOMETRY PIGGING


SPECIFICATION FOR MAGNETIC CLEANING ANG ELECTRONIC GEOMETRY PIGGING

0435-JH0902-00-PL-SPC-0009 04 Sept, 09


Doc. No. 0435-JH0902-00-PL-SPC-0009 Rev. B

Page 1 of 12


SYNOPSIS



DESCRIPTION

PREPARED BY

CHECKED BY

APPROVED BY

A

Issued for IDC

D. Memnathan

S. Ishwad

N. Agarwal

B

Issued for Review

D. Hemnathan

S. Ishwad

N. Agarwal


DATE

CLIENT APPROVAL

27 August 09

N/A

DATE

04 Sept. 09

Page 2 of 12


SCOPE OF WORK AND TECHNICAL SPECIFICATIONS PART I: SCOPE OF WORK 1.0

OBJECTIVE The objective of the present survey is to clean “constructional metallic debris” of the pipeline and obtain the record of internal geometry in "As laid" condition of the pipeline. It is therefore required to run the magnetic cleaning pig and Electronic Geometry Pig so as to identify, characterize (Sizing and Location), and evaluate any geometrical injurious defects that might have got introduced during installation.

2.0

SCOPE OF WORK Essentially the Scope of Work comprises of running the Magnetic Cleaning Pig and Electronic Geometry Pig through each segment of the pipeline. All facilities /services numerated below (not limited to) which the CONTRACTOR deems necessary to fulfil the WORK shall have to be arranged by him at no extra cost and time to the owner. Pipeline laying contractor shall carry out the cleaning and gauging operation. However for satisfaction of EGP contractor, to get the interpretable data, if any more cleaning is required he shall do the same without any time and cost implication to the company.

2.1

Activities: a. Mobilisation of all equipment e.g. Magnet cleaning pigs, Electronic Geometry pigs, pig locating and pig tracking devices, spares, consumables, Communication system, transportation and personnel. It is expressly understood that this does not limit the scope of work of the CONTRACTOR in any way. The quantities to be mobilised for different equipment (different types of pigs, pig tracking device) accessories, spares, and consumables need to be carefully evaluated by the bidder taking in to the consideration that Cleaning and Geometry inspection of each segments should be carried out without any constraint. CONTRACTOR is to mobilise all types of required pigs, accessories, spares, pig locating and tracking devices, in adequate number for completion of entire works within the contract price without depending turnaround time of bringing the pig received


Page 3 of 12


from previous run from receive station to launch station. As such no turn around period shall be allowed. Contractor shall submit operation manual/procedure manual and data sheets for pigs before commencing the job for OWNER/CONSULTANT approval. b. Carrying out adequate number of Magnet cleaning pig runs by running suitable Magnet cleaning pigs in each pipeline segment covered under SCOPE OF WORK including pig tracking till such time CONTRACTOR is satisfied with himself about the degree of cleanliness of pipeline segment and provide detailed daily site report for each run in the approved format before commencing the subsequent run. However, the constructional ferrous debris permitted with magnetic cleaning pig shall not exceed 5 Kg/100KM. In case debris received is more than this amount, the contractor shall be required to make subsequent run(s) until at least the above limit is achieved. c. CONTRACTOR to carry out adequate number of electronic geometry (Electronic Geometry) pig runs in each pipeline segment covered under SCOPE OF WORK including pig tracking for each pipeline segment to generate valid and interpretable geometry data of the pipeline and analysis of data of the Electronic Geometry survey to detect the nature, extent and location of geometry defect as detailed in Para 3.0 Part-II Technical Specifications. Contractor to provide detailed daily site report for each run in the approved format before commencing the subsequent run. The tool should be capable of inspecting entire length of the pipeline segment i. e. from launcher to receiver in a single run. Battery life should be adequate and commensurate with the run time required travelling the pipeline length. The electronic recorder system should have requisite data storage capacity. The drive cups should have requisite resistance to wear and tear to maintain effective seal throughout the entire run time. The measurement shall cover the entire 360o of internal pipe wall circumference using properly oriented and sufficient quantity of sensors. d. Demobilisation of all equipment, tools and personnel on completion of field activities for all segments. e. Final data analysis of the Geometry Inspection record at the Contractor's data analysis centre. The analysis shall consist minimum of following: •

Defect sizing (Depth&length) for all "significant defects" (Deformation >= 2% of ID).

•

Identification of all pipeline permanent features e.g. valves, tees etc.


Page 4 of 12


f.

•

Identification of potentially hazardous defects likely to affect structural integrity of the pipeline.

•

Preparation of final processed inspection logs and preparation of complete WORK report giving interpretation of the inspection logs and giving defect sizing.

•

The CONTRACTOR will transfer all the processed data generated on a floppy disc and CD with user-friendly operation on a compatible PC.

•

Providing all the raw and processed data along with the software package for enabling OWNER/CONSULTANT to study the data as required. The software should be user friendly.

BACK UP SERVICES The bidders are free to avail back up services from any Local and international pigging company of repute for specialized services including special pigs, personnel, data analysis etc. However, the bidder in his bid shall clearly mention the name, address, contact person, telephone, fax, e-mail etc. of the company whose services are proposed to be availed by the bidder. Bidder to note that the main bidder shall be responsible for the entire SCOPE OF WORK in conformity with all provisions of the tender document

2.2

PROPELLING MEDIUM Since pipeline is not commissioned, contractor shall use compressed air as propelling medium for which single compressor of 900 cfm capacity shall be used. The compressor should have the capacity to develop pressure upto 10KG/CM2. Contractor shall also keep one compressor of the same capacity mentioned above as stand by. However, Contractor should mobilise higher capacity compressors in order to complete the magnetic cleaning and electronic geometry inspection to meet any contingency like stuck up pig/ early completion of pigging work. Contractor has to arrange all the facilities required for pressurising air into the pipeline and running the pigs at required speed so that valid and interpretable data by running Electronic Geometry pig is generated by using the above media.

2.3

DEFECT VERIFICATION At the discretion of the OWNER/CONSULTANT Identify at least two verification dig sites (In case SIGNIFICANT defects are detected during Electronic Geometry Pigging) for each pipeline segment jointly with HPCL from the recorded data and provide WP/HPCL defect sheet indicating distance from the nearest pipeline feature or reference marker to facilitate location of defect in the field.


Page 5 of 12


The contractor shall depute his representative to observe the verification at verification sites for proving that field log detected anomalies conform to sizing, including linear positions. 2.4

FINAL WORK REPORT The final work report shall be for each segment including Magnet Cleaning and Electronic Geometry pig runs details with operational and functional parameters, daily detailed site report of each run with observations, individual feature report, velocity plot of Electronic Geometry pig, etc as detailed out at Para 7.0. Of part II.

3.0

PIG TRACKING The movement of any type of pig put into the pipeline during Magnetic cleaning and Electronic Geometry Pigging shall be required to be monitored along the pipeline length from launcher to receiver trap. The BIDDER shall detail out the complete methodology of pig tracking proposed to be deployed by him including complete technical details of the equipment and device proposed to be used for this purpose. It is proposed that pig tracking would be done in a discrete manner at least 5 to 10 KM intervals on each pipeline segment at preselected locations. The exact KM chainage of these locations shall be decided at site in consultation with the CONTRACTOR and CONSULTANT/OWNER.

4.0

ABNORMAL SITUATIONS: The objective of this section is to write down foreseeable abnormal circumstances for taking appropriate measures, should such a condition arise during implementation of Project. The OWNER has foreseen the following abnormal conditions. However, if the BIDDER foresees any other abnormal condition, he is free to make a mention of the same in his technical BID offer:

4.1

TOOL FAILURE CONTRACTOR is required to get valid interpretable and verifiable data for each segment of the pipeline. In case CONTRACTOR'S equipment fails to perform electronic geometry inspection to generate valid data for any of the pipeline segment, CONTRACTOR will make extra runs to get valid and physically verifiable data without any additional cost and time implication to the company.

4.2

STUCK-UP TOOL


Page 6 of 12


The BIDDER shall detail out a contingency plan in his BID as proposed by him in case any of the pigs get stuck up. The plan shall identify procedure for exactly locating the stuck up pig, detail procedure for retrieval of pig, equipment, including support facilities required to retrieve the pig. If Pig does not move from stuck up location, by any measure, then the pipeline section shall have to be cut for retrieval of Pig. Necessary fabrication and modification of pipe with new pipe piece after retrieval of pig shall be done by Contractor at no extra cost to the OWNER. Locating the stuck up pig and its retrieval shall be responsibility of the contractor. After modification pigging Contractor shall run Gauge pig to check internal restriction, if any. 5.0

MISMATCH OF INSPECTION RESULTS WITH ACTUAL DEFECTS DURING SITE VERIFICATION: In case of variance between the results of physical defect verification and the results reported by the contractor on the basis of Electronic Geometry Survey (after considering the tolerance as provided in the contract) segments, this shall be considered as a failed run and shall be dealt as per Cl.4.1 above.


Page 7 of 12


PART II TECHNICAL SPECIFICATIONS 1.0

INTENT The intent of the specification is to setforth the requirements of the Electronic Geometry Survey of the pipelines to help bidder quote his unit rate price in the schedule of rates. This requirement is not intended to be all inclusive and use of guidelines set-forth does not relieve the contractor of his responsibility of successfully carry out all activities and to obtain reliable and valid data from the EGP tool about condition of the pipeline as defined under Scope of work.

2.0

MAGNET CLEANING PIG RUNS Prior to launching of Electronic Geometry pig, contractor shall complete all activities required to establish adequate cleanliness of pipeline to the satisfaction of the contractor and to verify the internal geometry of the pipeline with relation to ovality, dent etc. Contractor shall decide the number of Magnet cleaning pig runs and the choice of the Magnet cleaning pig for each cleaning run as suitable for the purpose to obtain internal condition adequately clean so as to obtain valid and interpretable inspection data from the Electronic Geometry pig and to safeguard Electronic Geometry pig against damage due to debris as detailed out at Para 2.1(c) Part-I Scope of Work and Technical Specifications. The cleaning pigs for successive cleaning pig runs shall be selected by the contractor in such a manner that effective cleaning i.e. 5kg/100km ferrous debris is achieved. The detailed specifications of Magnet cleaning pig shall be furnished in the offer.

3.0

ELECTRONIC GEOMETRY PIG RUNS The Electronic Geometry pig should be capable of recording the entire length of each segment i. e. from launcher to receiver in one single run and therefore its electronic recorder system should have requisite data storage capacity. Battery life therefore should be adequate to commensurate with the run time required to travel the pipe length of each segment and the drive cups should have requisite resistance to wear and tear to maintain effective sealing throughout the entire run time. Bidder to furnish


Page 8 of 12


a calibration certificate for EGP prior to mobilization of equipment, OWNER reserves the right of witnessing calibration test at Contractors designated location at Owner’s expenses. The measurement shall cover the entire 360o of internal pipe wall circumference using properly oriented and sufficient no of sensors. The tool shall be capable to identify and locate the following features as a minimum. •

Individual Girth weld

•

Dent, ovality, buckles, or any other out of roundness, change in pipeline I.D. and difference of thickness.

•

Valves or any partially closed valves.

BIDDER to supplement the following information in his Bid, so that same can be checked w.r.t the parameters given in Para 4.0 below as required. a. Accuracy of locating indication/I.D. Reduction w.r.t. to axial length (Metres). b. Max. % Of Nominal pipeline ID tool can pass (% ID) c. Minimum deformation level Reported (as % of ID) d. Accuracy of Measurement (% of ID) e. Bend radius tool able to negotiate 4.0

DEFECT SIGNIFICANCE The following information/performance is expected out of the Electronic Geometry pig inspection:

4.1

Inspection of entire length of each segment to be completed in one single run.

4.2

Accuracy of defects: The best accuracy offered and guaranteed by the BIDDER for each category of defect should be clearly spelt out. However, the tool should have minimum capabilities as under. Minimum Detection level for dent: 2% of ID Sizing Accuracy for dent : +0% of ID, -25%of measured value


Page 9 of 12


Minimum detection level for Ovality: 5% of ID Sizing Accuracy for Ovality: +/- 1% of ID Location Accuracy Axial: 0.1% from Permanent Features. The tool should be capable of negotiating minimum 3D bend and 15%reduction in Pipe ID. 5.0

Max. Run Length of Live Tool: The BIDDER must specify in his offer the max. length which can be inspected in one single continuous run by the tool proposed by him. It is required to complete the entire run length of each segment of the pipeline in a single run. The length of each pigging segment shall be based on the length of hydro testing of the pipeline. However, length of pigging segment of 60 Km to 70 Km shall be acceptable.

6.0

Data Analysis: Bidder shall carry out the data analysis for EGP. BIDDER shall provide all raw and processed data and his software package along with his compatible hardware. The software package shall be user friendly. It should provide full capability for data study.

7.0

FINAL WORK REPORT The BIDDER shall include in his offer the most appropriate reporting procedure envisaged for the subject pipeline. This will have to be mutually agreed between the successful bidder and consultant/owner. However, any reporting system shall include but not limited to the following: •

A detailed report in respect of each pipe segment of running each of the preinspection tools such as Magnet cleaning pig.

•

Detailed report about running of the Electronic Geometry pig including but not limited to the operational and functional details. - Details describing the type, size and location of individual mechanical defects. The location of each defect should be suitably listed with reference to permanent pipeline features, girth weld no., relative and absolute distance.

•

A detailed report in respect of each defect for which sizing has to be done indicating its length, depth and axial location suitably referenced.


Page 10 of 12


•

Preliminary site report for each pipe segment for each running of Magnet cleaning, and Electronic Geometry pig runs stating comments/observations of each run, pig condition, operating parameters, and total time required.

•

Velocity plot of the Electronic Geometry pig along the length of the segment.

The format and Performa of the above report shall be mutually agreed upon between the successful BIDDER and CONSULTANT/OWNER. All the data generated by the CONTRACTOR shall be compiled in a floppy disk and CD having user-friendly operation on a Compatible PC along with the software necessary for review/analysis of data. This is required to facilitate selection of significant defects, their chainage and sizing. CONTRACTOR will furnish this floppy disk and CD as part of report.

8.0

BID EVALUATION CRITERIA (TECHNICAL) Bidder should satisfy the entire following technical and past experience requirement, failing which their Bids summarily rejected and shall not be considered for technical evaluation. Bidder should submit documentary evidence to substantiate his claim for his past experience in the form of work order/ completion certificate.

9.0

•

Bidder should have carried out satisfactory electronic geometry pigging (Caliper pigging) of pipeline of diameter 16"or above for at least 50 km single continuous length during last five years.

•

Bidder should have completed at least 500 Km cumulative length of pipeline inspection by electronic geometry pigging (Caliper pigging) tool in single or combination of 8”and/or above pipeline dia in last ten years.

•

Bidder should have full-fledged calibration and testing facility for Electronic Geometry Pig tool including test loop of similar size and data interpretation facilities.

•

Bidder's proposed tool should be capable of detecting minimum 2% of ID dents.

•

Bidder should own the proposed tool.

INFORMATION TO BE FURNISHED BY BIDDER IN HIS OFFER FOR EVALUATION


Page 11 of 12


•

If bidder proposes to engage back up agency then scope of work and responsibility of back up agency shall be furnished.

•

Specifications of Magnet cleaning pigs and Electronic Geometry pig for required pipe sizes.

•

Details of Electronic Geometry pig in following respect:-

. a.

Max.% of Nominal pipeline ID tool can pass(% of ID)

b.

Minimum deformation level reported (as % of ID) Accuracy of measurement (% of ID)

c.

Bend radius tool able to negotiate

•

Details of pig tracking equipment and pig tracking procedure.

•

Pig stuck contingency plan.

•

Proposed methodology for execution of pipeline pigging.

•

Methodology of Work

•

Schedule of work


Page 12 of 12

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) TECHNICAL SPECIFICATION FOR PRECOMMISSIONING OF PIPELINE SYTEM

Guru Gobind Singh Refinery Products Evacuation Project (GGSRPEP) Raman Mandi- Bahadurgarh and Raman MandiBathinda Multiproduct Pipeline TECHNICAL SPECIFICATION FOR PRECOMMISSIONING OF PIPELINE SYSTEM

0435-JH0902-00-PL-SPC-0010

29 July 2009


DOC. No.: 0435-JH0902-00-PL-SPC-0010 Rev. B

Page 1 of 13


SYNOPSIS Disclaimer This report has been prepared on behalf of and for the exclusive use of Hindustan Petroleum Corporation Limited (HPCL), and is subject to and issued in accordance with the agreement between Hindustan Petroleum Corporation Limited (HPCL) and WorleyParsons. WorleyParsons accepts no liability or responsibility whatsoever for it in respect of any use of or reliance upon this report by any third party. Copying this report without the permission of Hindustan Petroleum Corporation Limited (HPCL) or WorleyParsons is not permitted.


DESCRIPTION

PREPARED BY

CHECKED BY

APPROVED BY

DATE

CLIENT APPROVAL

DATE

th

A

Issued for IDC

B

Issued for Review

D Hemanathan

S.Ishwad

J Wallace

24 JULY 09

J Wallace

29 JULY 09

N/A

th

D Hemanathan

S.Ishwad


N/A

Page 2 of 13



SCOPE

4

1.1

DEFINITION'S

4

2.0

GENERAL

4

3.0

RESPONSIBILITY OF CONTRACTOR

4

3.1

PRE-COMMISSIONING

5

3.2

COMMISSIONING

6

4.0

PRE-COMMISSIONING ACTIVITIES

7

4.1

PRE-COMMISSIONING CHECKS

7

4.2

COMMISSIONING RELATED ACTIVITIES

10

5.0

DOCUMENTATION

11

6.0

SPARES AND CONSUMABLES

12

7.0

SAFETY

12

8.0

OTHERS

13


Page 3 of 13


1.0

SCOPE The specification covers the minimum technical requirements for testing and commissioning of Ramanmandi to Bahadurgarh and Ramanmandi to Bathinda pipelines of Guru Gobind Singh Refinery Products Evacuation Project pipelines including Commissioning activities such as pre-commissioning checks, dewatering, swabbing, flushing/blowing, leak testing etc.

1.1

DEFINITION'S For this specification the following definitions shall apply: OWNER – Hindustan Petroleum Corporation Ltd CONSULTANT – Worley Parsons, Mumbai (WP) CONTRACTOR - The Company named as such in the deed SHALL/MUST/ISTO BE - A mandatory requirement SHOULD - A non-mandatory requirement, advisory or recently amended.

2.0

GENERAL The scope of work for testing & commissioning including Pre – Commissioning actives shall include but not limited to the manpower, machinery & equipments, detailed Procedures, Manuals & Communicable, Communications etc. to perform the work satisfactory. Contractor shall prepare detailed procedures for furnishing technical piping, dewatering, swabbing, pigging & commissioning of the pipeline, covering all accepts of work for company’s approval. Contractors shall design & supply all temporary line connections Valves, Instruments, as required during the various operations. In the event of any details which are not fully addressed, it is warranted by Contractor that work shall be performed in accordance with owner’s specification & the best recognized practices in the on shore pipeline industry.

3.0

RESPONSIBILITY OF CONTRACTOR


Page 4 of 13


The pipeline contractor shall be responsible for all the pre-commissioning and commissioning activities that need to be carried out for Ramanmandi to Bahadurgarh and Ramanmandi to Bathinda pipelines for the GGSR Products Evacuation project. 3.1

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

Carrying out pre-commissioning checks of the pipeline system including Pig Launchers/Pig Receiver at Despatch Station/Receipt Stations, Sectionalizing Valve (SV) Stations and their associated facilities under the scope of work to ascertain that the GGSR Products Evacuation project (Ramanmandi to Bahadurgarh and Ramanmandi to Bathinda pipelines) has been mechanically completed in all respects.

•

Checking of field instruments, laying out summary of pipeline, checking of communication system, checking of Electrical, Instrumentation system, controls & interlock etc.

•

Dewatering of Pipeline and above ground piping, flushing/air-blowing and leak testing of piping i.e. piping and equipments under their scope of work.

•

Supply and supervision of manpower for pre-commissioning.

•

Operation of machinery and equipment for pre-commissioning.

•

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

•

Erection of all temporary facilities like pig launcher/receiver, line connections, spool pieces, pigs and requisite accessories, valves, instruments, manpower etc. as required during various operations.

•

Preparation of detailed pre-commissioning procedures, activity schedules, bar charts, schemes etc. This shall include preparation of detailed procedures for dewatering, electronic geometric pigging / caliper pigging (By other Contractor), idle time preservation (if applicable), removal of idle time preservers (if applicable, flushing/blowing, leak testing and shall address the sequence and methodology describing all operations, data on materials, equipments,


Page 5 of 13


instruments, consumables (e.g. Pigs and associated items), 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 at various stages. The pipeline contractor shall demonstrate to the OWNER / WP representatives (for approval) the successful completion of all the abovementioned activities. In the event of any detail, which is not fully addressed, the pipeline contractor should warrant that work shall be performed in accordance with the relevant codes, OWNER / WP representative’s specifications and the best recognized engineering guidelines and practices being followed in the on-shore gas pipeline industry.

3.2

COMMISSIONING In order to execute and perform commissioning related activities, the pipeline contractor shall be responsible for providing all support/assistance required for commissioning under the overall guidance and supervision of OWNER / WP engineers/ representatives. Contractor shall submit a detailed commissioning procedure for OWNER/ WP approval. The pipeline contractor shall be also responsible to coordinate with the Composite Contractor(s), who is responsible for commissioning of the cathodic protection of the entire pipeline so that the commissioning process can proceed uninterruptedly in a harmonious manner for the entire GGSR Product Evacuation project. Commissioning assistance broadly covers the following activities: •

Commissioning checks including Safety Review prior to start of commissioning activities to achieve ‘Ready for commissioning’ status for pipeline

•

Surveillance of pipeline and attending leaks and operation of SVs and metering station at Dispatch Station/Receipt Stations whenever required.

•

Supply and supervision of manpower for commissioning. Manning of SV and Dispatch Station/Receipt Stations for pig tracking, pig receiving and other activities.


Page 6 of 13


•

Supply and operation of machinery and equipment for commissioning, if required.

•

Supply of Nitrogen and its associated accessories for purging required for carrying out commissioning.

•

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

•

Any other assistance of required by OWNER / WP.

•

Erection and supply all temporary line connections, spool pieces, strainers, valves, instruments, manpower etc. as required during various operations.

•

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

•

Stabilization and total system operation for 72 hrs. with all instruments, controls & interlocks working satisfactorily at normal operating conditions. On completion of this stage one month operating run period will start.

•

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

•

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

4.0

PRE-COMMISSIONING ACTIVITIES

4.1

PRE-COMMISSIONING CHECKS

4.1.1

Pre-commissioning checks shall be carried out for the pipeline system to ascertain that the pipeline system has been mechanically completed in all respect. These checks shall cover all the facilities of the main cross country pipeline starting from Ramanmandi to Bathinda and Ramanmandi to Bahadurgarh including, Receipt Stations, Sectionalizing Valve Stations, as applicable. The pre-commissioning checks shall include the following:

A)

System Checks


Page 7 of 13


The entire facilities shall be checked against the latest P&ID’s, Engineering and Vendor Drawings/Documents and other design specifications. Any shortcoming observed shall be listed down in the form of punch lists and these should be duly attended or liquidated. The pipeline contractor should check the stations systems from the angle of pre-commissioning and commissioning and spell out any additional requirement of vents/drains, temporary arrangement/modification etc. that may be required during the pre-commissioning and commissioning activities and arrange for the same in consultation with the OWNER / WP representative. B)

Checking of Field Instrument All the field instruments like actuated valves, shutdown valves, transmitters, solenoid valves, shut down switches, alarms etc. shall be checked physically and also for their intended application by simulating the actual conditions. 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, 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 Instrument, controls & Interlocks This is to check that instrument controls and interlocks are functional as per the normal operating conditions.

G)

Checking of Utilities This is to check that utilities like power, CCVT system, etc. are available prior to start-up.


Page 8 of 13


H)

Any other checks as may be considered necessary.

4.1.2

Pre-commissioning works for the above ground piping (Dispatch Station, Metering Stations, and Receipt Stations etc. under the scope of work)

4.1.3.

Dewatering (Hydro Test Water) General Dewatering of a piping system shall be done subsequent to the hydro-test of the respective piping section. During the dewatering operation, the major quantity (to the maximum extent possible) of hydro-test water shall be removed from the main interconnecting piping work in the stations. A standard blind shall be arranged and provided at the inlet and outlet nozzles of pumps and sump tank to avoid entry of debris/dirt/mud etc., before start-up of pre-commissioning activities. Operational Requirements The dewatering operation of the piping work in the stations shall consist of physically draining the water content in the piping work by opening low point drains and/or end flanges. If required air shall be used to push-off water from the pipes, The pipeline contractor shall arrange suitable compressor for such purposes. Flushing/Blowing of Aboveground Piping in the Terminal Flushing/blowing of the above ground piping with water/air to remove debris/dirt/mud from within the piping has to be performed by the pipeline contractor. Subsequent to water flushing, to ensure complete cleanliness of the piping work, air blowing/cardboard blasting method has to be adopted. All instruments, control valves, orifice plates etc. to be dismantled from the piping work and any gap produced should be bridged with suitable temporary spool. Proper supporting of the piping, during such flushing/blowing activities is to be ensured by the pipeline contractor. The pipeline contractor has to make arrangement of clean water/air for this flushing / blowing activities The pipeline contractor should submit a plan/methodology for carrying out such activities detailing out each aspect/step.


Page 9 of 13


Acceptance Criteria The pipeline contractor shall specify when flushing/air blowing is completed to the satisfaction of the owner/WP’s representative, and shall obtain approval of the owner/WP’s representative before proceeding to the next step. 4.1.3.2 Internal Cleaning of Equipment General Equipments like Pig Launcher, filters, Corrosion Inhibitor Dosing Tanks, Sump Tanks and Pig Receiver are to be checked for internal cleanliness and ensured by the pipeline contractor. Acceptance Criteria The pipeline contractor has to demonstrate cleanliness of the internals of all equipment to the satisfaction of the owner/WP’s representative and obtain approval for final box up of the equipment. 4.1.3.3 After dewatering / swabbing is over & all functional checks carried out as specified as pre-commissioning checks drying s of the pipeline is to be closed out with compressed air. The pipeline shall be dried to achieve a content dew point as specified in specification for cleaning & drying 0435-JH0902-00-PLSPC-0009. 4.1.3.4 Trial Run of Rotating Equipments The pipeline contractor has to arrange for trial run of the sump pump with water for short duration of time. The pipeline contractor has to arrange all temporary arrangements required for such trial runs. The pipeline contractor has to submit procedure/method statement regarding how he plans to take such trial runs and take approval of the owner/WP’s representative, before actually proceeding for the same. If pump vendor(s) is available for such trial run, the pipeline contractor has to provide all sorts of assistance to the pump vendor and help the vendor in completing the successful trial run. 4.2

COMMISSIONING RELATED ACTIVITIES


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Safety Review Prior to Start of Commissioning Activities A pre-startup safety review of the cross-country pipeline system shall be arranged by the pipeline contractor, involving all concerned in the commissioning. The WP/owner’s representative shall also participate in the prestartup safety review. The pipeline contractor shall generate all requisite formats to record the findings of such Safety Review. Ready for Commissioning After completion of pre-commissioning activities and Company approved safety startup review followed by liquidation of review punch list points, the pipeline contractor shall notify the WP/owner’s representative that the pipeline systems in totality are ready in all respects for hydrocarbon-in. ‘Ready for commissioning status’ shall be jointly assessed by WP/owner’s representatives, composite work contractor, Pipeline contractor. After such joint assessment, if all the criteria are met, it will then be declared by the Owner that the entire pipeline system has reached a stage of ‘Ready for Commissioning’. It should be noted that if the actual commissioning of the stations is taken up after idle time of sufficient length, then before starting the rotating equipment again, revisioning of the rotating equipments has to be done in presence of pump vendor(s). The pipeline contractor has to provide all sorts of assistance during such revisioning activities. 4.2.1

Commissioning and Stabilization The pipeline contractor shall be responsible for providing all necessary assistance to carry out commissioning activities under the overall guidance and supervision of WP’s engineers/representatives/Owner for the entire pipeline system. Commissioning of pipeline shall be considered completed when the line is charged with product natural gas at operating pressure and the total system operated at normal operating pressure for a minimum period of 72 hrs with all the instruments, controls & interlock satisfactorily at normal operating conditions. Contractor shall submit a detailed commissioning procedure for company’s approval.

5.0

DOCUMENTATION The pipeline contractor shall submit the complete description, detailed procedures and time schedule for all of the following activities for approval of the WP/Owner’s representatives.


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•

Pre-commissioning Checks

•

Dewatering

•

Swabbing

•

Flushing / Blowing

•

Low Pressure Leak Test with Air

•

Drying

•

Idle Time Preservation (if applicable), including Removal of Preservers

All these documents should be prepared covering all aspects of HSE, quality assurance and quality control plans. The pipeline contractor shall ensure that his documents are related to “as-built” conditions of the pipeline, equipment and structures involved. Documents shall also contain all safety plans, procedures to be followed while carrying out the activities. Upon successful completion of the work, the pipeline 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 check sheets. 6.0

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

7.0

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


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commissioning and commissioning activities. A dedicated safety department from the pipeline contractor’s side should be available for the job. 8.0

OTHERS The pipeline 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.


Page 13 of 13

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) GENERAL SPECIFICATION FOR PIPELINE WELDING


GENERAL SPECIFICATION FOR PIPELINE WELDING 0435-JH0902-00-PL-SPC-0011 06 July 09



Page 1 of 25


SYNOPSIS



DESCRIPTION

PREPARED BY

CHECKED BY

APPROVED BY

A

Issued for IDC

D. Hemnathan

S. Ishwad

J. Wallace

B

Issued for Review

D. Hemnathan

S. Ishwad

J. Wallace

DATE

06 July 09

CLIENT APPROVAL

DATE

N/A

06 July 09

TABLE OF CONTENTS


Page 2 of 25


1.0

GENERAL....................................................................................................................... 5

2.0


2.1 2.2 2.3 2.4 2.5

Codes and standards ...................................................................................................... 5 Reference Documents..................................................................................................... 5 Document precedence .................................................................................................... 6 Specification Deviation/Concession Control .................................................................... 6 Quality Assurance/Quality Control ................................................................................... 7

3.0

WELDING EQUIPMENT, TOOLS AND SUPPLIES ........................................................ 7

4.0

PIPELINE MATERIALS .................................................................................................. 7

5.0

ELECTRODES, FILLER WIRES AND FLUXES ............................................................. 7

6.0

SHIELDING GASES ....................................................................................................... 8

7.0

QUALIFICATION OF WELDING PROCEDURES ........................................................... 8

7.1 7.2 7.3

General ............................................................................................................................................ 8 Records.......................................................................................................................................... 10 Welding Procedure Specification (WPS) .................................................................................. 10

8.0

WELDER QUALIFICATION .......................................................................................... 12

9.0

PRODUCTION WELDING............................................................................................. 13

9.1 9.2 9.3 9.4 9.5 9.6

Cleaning and Pipe Beveling........................................................................................................ 13 Alignment of Pipe ......................................................................................................................... 13 Pre-Heating and Interpass Temperature and Post-Weld Heat Treatment (PWHT)........... 14 Tack Welds.................................................................................................................................... 15 Line-up Clamps............................................................................................................................. 15 Working Clearance....................................................................................................................... 15

10.0

AUTOMATIC WELDING ............................................................................................... 16

11.0

FITTINGS...................................................................................................................... 16

12.0

INTERPASS CLEANING .............................................................................................. 16

13.0

ARC STRIKES .............................................................................................................. 16

14.0

MULTIPLE JOINT WELDING ....................................................................................... 16

15.0

MARKING WELDS ....................................................................................................... 16

16.0

PROXIMITY OF WELDS ............................................................................................... 17

17.0

END PROTECTION ...................................................................................................... 17

18.0

WEATHER LIMITATIONS............................................................................................. 17

19.0

STANDARDS OF ACCEPTABILITY............................................................................. 17

20.0

INSPECTION AND TESTING ....................................................................................... 17

21.0

RADIOGRAPHIC INSPECTION.................................................................................... 18

22.0

ULTRASONIC INSPECTION ........................................................................................ 18

23.0

MAGNETIC PARTICLE INSPECTION .......................................................................... 19


Page 3 of 25


24.0

DEFECT ACCEPTANCE LEVELS................................................................................ 19

25.0

REPAIR OF WELDS ..................................................................................................... 20

26.0

OTHER WELDING ........................................................................................................ 21

27.0

WELDING MATERIAL DISPOSAL ............................................................................... 22

28.0

RECORDS .................................................................................................................... 22

APPENDIX A - SUMMARY OF PIPELINE MATERIALS ......................................................... 23 APPENDIX B - ABBREVIATIONS........................................................................................... 24


Page 4 of 25


1.0

GENERAL This specification provides the requirements for fabrication and field welding of HSD/MS/SKO/ATF Oil pipelines and related facilities, which are associated with the GGSR Product Evacuation Project for Ramanmandi to Bahadurgarh 18” pipeline and Ramanmandi to Bathinda 10” Pipeline. This specification supplements the codes listed in Section 2 of this document.

2.0


2.1

Codes and standards The latest edition of the following codes and standards shall establish the minimum standards for the work. The CONTRACTOR may use alternate standards that meet or exceed those listed if approved by the OWNER. American Society for Testing and Materials (ASTM) •

ASTM 370

Mechanical Testing of Steel Products

•

ASTM 639

Preparation and use of bent-beam stress corrosion test specimens

American Petroleum Institute (API) •

API 5L


•

API 1104

Welding of Pipelines and Related Facilities

American Society of Mechanical Engineers (ASME) •

ASME B31.4

Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids

American Society of Non-destructive Testing (ASNT) •

RP SNT-TC-1A

Personal Qualification and Certification in Non-destructive Testing

British Standards Institute (BS) • 2.2

BS 5135

Process of Arc Welding of Carbon and Carbon Manganese Steels

Reference Documents The following documents are part of this specification:


Page 5 of 25


2.3

•

0435-JH0902-00-PL-SPC-02/03/04

Specification for Linepipe

•

0435-JH0902-00-PL-SPC-0031

Specification for Scraper Trap and End Closures.

•

0435-JH0902-00-PL-SPC-0020

Specification for Isolation joints

•

0435-JH0902-00-PL-SPC-0014

Specification for Induction Bends

•

0435-JH0902-00-PL-SPC-0021

Specification for Pipeline Barred Tees

•

0435-JH0902-00-PL-SPC-0022

Specification for Pipeline Ball Valve

•

0435-JH0902-00-PL-BOD-0001

Basis of Design

Document precedence The CONTRACTOR shall notify the OWNER of any conflict between this specification, the related data sheets, the Codes and Standards and any other specifications noted herein. The resolution and/ or interpretation precedence shall be obtained from the OWNER in writing before proceeding with the design or manufacture. In case of conflict, the order of precedence shall be:

2.4

•

Description of Project Scope and statement of requirements

•

Project Specifications and Drawings

•

Industry Codes and Standards

•

Equipment Data Sheets

•

Equipment Narrative Specification

Specification Deviation/Concession Control Any technical deviations to the specifications and its attachments including, but not limited to, the Data Sheets and Narrative Specifications shall be obtained by the CONTRACTOR only through the CONCESSION REQUEST format. The CONCESSION REQUESTS require the Owner’s review/ approval prior to implementation of the proposed changes. Technical changes implemented prior to OWNER approval are subject to rejection.


Page 6 of 25


2.5

Quality Assurance/Quality Control The CONTRACTOR shall have in effect at all times a QA/QC programme which clearly establishes the authority and responsibility of those incharge of the quality system. Persons performing quality functions shall have sufficient and well defined authority to enforce quality requirements that initiate, identify, recommend and provide solutions to quality problems and verify the effectiveness of the corrective action. The OWNER reserves the right to inspect materials and workmanship at all stages of production and to witness any or all tests. The CONTRACTOR shall provide the OWNER with regard of a copy of its production and inspection plan for review and inclusion of any mandatory OWNER witness points.

3.0

WELDING EQUIPMENT, TOOLS AND SUPPLIES All welding machines, line up clamps, bevelling machines, cutting torches and other equipment, tools and supplies used in connection with the welding work shall be kept in good mechanical condition so as to produce sound welds. The welding machines shall have all necessary controls for making current adjustments for all pipelinewelding requirements. Sufficient meters, portable or permanent shall be provided to calibrate machines and to regulate voltage and amperages as may be needed. The ground clamps shall be dependable and not arc the pipe. The clamps shall be located close to the point of welding wherever possible. Any equipment, which, in the opinion of the OWNER is not adequate for the quality of welding required, shall be replaced by the CONTRACTOR.

4.0

PIPELINE MATERIALS Line pipe, induction bends and fittings shall be supplied in accordance with the specifications listed in clause 2.2 of this specification.

5.0

ELECTRODES, FILLER WIRES AND FLUXES Storage and handling procedures for consumables shall be submitted to the OWNER for review and approval. The CONTRACTOR shall maintain a system of traceability, whereby the batch no. of the welding consumables are related to weld numbers on which they are used. Each tin or packet of electrodes or reel of filler wire and bag of flux shall be clearly marked with their respective batch number. Manufacturer’s Certification shall be supplied to EN 10204, 3.1.C for each batch of welding consumables in accordance with ANSI/AWS 5.01.


Page 7 of 25


Welding consumables used during production shall be of the same manufacturer, brand and AWS type as those used during welding procedure qualifications. 6.0

SHIELDING GASES In addition to the requirements of Section of API 1104, the following requirements shall apply to the procurement, handling, storage and use of shielding gases. The shielding gases shall be welding grade. Argon gas shall be used for the gas tungsten arc welding process. Argon shall meet the following requirements: Argon

:

99.995% minimum

Each container of gas shall be identified with the gas type, mixture and purity. Unmarked containers and/ or contaminated gases shall be removed from the work site. The shielding gas manufacturer shall have an adequate quality system to ensure that the purity of the shielding gases complies with the specifications and shall issue a certificate of compliance to the specified purity levels.

7.0

QUALIFICATION OF WELDING PROCEDURES

7.1

General The CONTRACTOR shall submit detailed welding procedure specifications for approval by the OWNER to cover the range of materials, diameters and thicknesses in the work prior to commencement of welding procedure qualification tests. Separate welding procedures shall be submitted and qualified for the following: •

Pipeline welding

•

Tie-in welding

•

Welding of fittings (bends, valve pup pieces, anchor flanges, if any, isolation joints, scraper traps, etc.) shall be separately qualified.

•

Welding of weldolets to the main pipeline

•

Attachments (saddles, split tees, CP attachments)

•

Repair welding

The following welding processes are pre-approved for use this project: •

Gas Tungsten Arc Welding (GTAW) – Manual

•

Shielded Metal Arc Welding (SMAW) – Manual


Page 8 of 25


The Welding processes other than those listed above may be submitted for OWNER approval. As a minimum, OWNER approval shall require the following conditions be met: •

CONTRACTOR has knowledge and previous satisfactory experience with the process and/or system.

•

CONTRACTOR has a successful past history using the process and/or system and this must be supported with documentary evidence. This shall be subject to OWNER review.

•

All welding operators have been qualified on the machine/equipment and have worked on production welds using this process for other projects.

Welding procedures are required for all production welding including butt welds, fillet welds, and all associated repairs. The repairs shall be qualified in accordance with Clause 7.3.2. Welding progression for repair welds shall be root uphill and balance vertical down. The Weld direction shall be vertical down for Mainline Welding. For all tie-in welds, joints where an external line-up clamp is used and for full penetration repairs, the root bead shall be deposited in the uphill progression. All fillet welds shall be carried out with low hydrogen electrodes. No single pass welds, or internal root sealing welds shall be allowed, except for an automatic root pass applied internally that is an integral part of the welding procedure when approved by the OWNER. Preheat shall be specified on the Welding Procedure Specification when it is required and shall be qualified during weld procedure qualification testing. The following methods of preheat are acceptable: •

Electric induction

•

Electric resistance

•

Oxy-fuel gas

The use of oxyacetylene gas for preheating is not permitted. When oxy-fuel gas is used for preheating, full encirclement rings are preferred. If hand-held torches are approved by the OWNER, a minimum of two oxy-fuel gas torches shall be used on pipe diameters greater that NPS 6, when preheating manually.Oxygen cutting torches are not permitted. The CONTRACTOR shall notify the OWNER of the date and location of the Welding Procedure Qualification Test welding at least 72hrs before the start of any qualification test. The OWNER reserves the right to witness all Welding Procedure Qualifications Tests and Welder Qualification Tests.


Page 9 of 25


Where pipes or fittings of unequal wall thickness are to be welded, the end preparations shown in ASME B31.4 7.2

Records Each WPS shall have a unique identification no. and the revision status in order to identify the changes.

7.3

Welding Procedure Specification (WPS) In addition to the requirements of Section 5.3 of API 1104, the following minimum details shall be included on the Welding Procedure Specification/ Welding Procedure Qualification Record.

7.3.1

•

Project Identifications.

•

Consumables trade names, type and batch number (in WPQR).

•

Interpass temperature (maximum).

•

Nozzle diameter for automatic welding (if applicable).

•

Fit up tolerance.

•

Oscillation width and frequency for automatic welding (if applicable).

•

Electrode stick-out length (if applicable).

•

Time lapse between end of root pass and start of hot pass.

•

Preheat method and temperature.

Welding Procedure Qualification Testing (WPQT) a)

All welding procedures shall be qualified on project material. Pre-qualified welding procedures may be permitted with regard of the prior approval from the OWNER. Welding procedure shall be qualified under simulated conditions similar to the planned installation using the same welding, alignment and preheat equipment that will be used in production. Sufficient test welds shall be made to include repair procedure qualification and all required mechanical testing. The parameters of qualification testing shall be monitored and recorded by calibrated clamp meters or portable arc monitors and digital thermometers.

b)

All procedure qualification test welds shall be allowed to cool for a minimum of 24 hours to cool the test piece to ambient temperature and then fully radiographed prior to destructive tests. For mechanized or semi-automatic welding equipment, other than SAW, a minimum of three consecutive complete test joints is to be made.


Page 10 of 25


If possible, pipe to be used for qualification shall be selected among the heat exhibiting the highest carbon equivalent. Pipe supplier to provide histogram of Carbon Equivalent Values (C.E.V) for all pipes supplied. Pipe selected for WPQT must be, maximum C.E.V. of the project material, OWNER allows to production weld + 0.03 C.E.V. of the qualified metal, if it exceeds the tolerance level then CONTRACTOR shall carry out hardness test alone on the new test specimen.

7.3.2

7.3.3

c)

The qualification welds shall be destructively tested in accordance with regard of API 1104.

d)

In addition to API 1104, ONE SET (THREE SPECIMENS) OF Charpy Vnotch Impact test shall be conducted as per the following: •

The test specimen position shall be from the Weld center line, Fusion line and Fusion line +2mm.

•

The standard specimen size shall be 10 x 10mm.

•

If the thickness is not permitting the standard size, the reduced thickness size of 10 x 7.5mm, 10 x 5.0mm specimens shall also be used.

•

For standard size specimen the minimum average value is 52 Joules and minimum Individual value is 39 Joules as per the line pipe specification.

•

The values for reduced thickness size shall be calculated by multiplying the standard size values with regard of 0.75 for 10x7.5 mm size and with regard of 0.5 for 10x5.0 mm size.

•

The test temperature shall be at 0°C

Qualification of Repair Weld Procedure a)

Cracked welds shall not be repaired and removed form the line.

b)

The repair welding procedure shall be established and qualified to demonstrate that the weld with regard of suitable mechanical properties and soundness can be produced.

c)

The procedure shall include the method of excavation and the additional NDT requirement.

Weld Procedure Approval a)

CONTRACTOR shall review, witness and submit for approval all nondestructive and destructive testing. All mechanical testing shall be carried out by a certified testing facility subject to the approval of the OWNER.


Page 11 of 25


8.0

b)

All mechanical Testing of Procedure Qualification tests shall be witnessed and certified by an Independent Inspecting Authority approved by the OWNER.

c)

Following qualification the CONTRACTOR shall prepare a Weld Procedure Specification (WPS), for use on site. The CONTRACTOR shall then submit the complete package of WPSs and Weld Procedure Qualification Records (WPQRs) for approval by the OWNER.

d)

Production welding shall not commence until the WPSs and WPQRs have been approved by the OWNER.

e)

The package shall consist of at least the following:•

Register cross-referencing WPQR to WPS.

•

WPS (see Figure 1 of API Standard 1104).

•

WPQR (see Figure 2 of API Standard 1104)

•

NDE and visual inspection reports.

•

Mill and certificates for pipes.

•

Batch certificates for consumables.

•

Heat treatment charts, if applicable.

•

All third party certified mechanical test results certificates from the test laboratory.

WELDER QUALIFICATION CONTRACTOR shall use only skilled workmen for welding. Each welder employed by the CONTRACTOR shall be required to pass a welding test on steel compatible with regard of the project material for the type and methods of welding he will perform including attachment welds. No welder shall work on any phase of the pipeline unless he has been tested and approved by OWNER. Testing shall be in accordance with regard of API 1104 Section 6. For pipe diameter over 12 ¾ inch, two welders can be qualified on one test coupon depends on the requirement of test specimens. Testing of prospective welders shall be at Contractor’s expense. CONTRACTOR shall furnish all welding materials and equipment similar to those, which will be used for production welding. CONTRACTOR shall provide test nipples. The weld shall be examined and tested by CONTRACTOR and witnessed and approved by OWNER. The welders shall be qualified according to the Approved Welding procedure Specification for Construction, and shall be used the same consumables approved in the AFC WPS.


Page 12 of 25


The qualification of the test weld shall be determined by radiography + Mechanical testing (Nick Break and Bend Test) as mentioned in API 1104 clause 6.5.2. Test welds shall be free from cracks and lack of fusion. Other defects shall be within the limits of API 1104. Each welder / operator shall be given a unique number, which shall be marked in paint on all welds produced by him. A list of qualified welders shall be kept up to date and available for OWNER inspection. Should a welder leave the job, his number shall not be duplicated. A welder’s competence certificate, which includes reference to the corresponding WPS number, the essential variables, and the test results, shall be issued for each welder or welding operator for each test. Any welder found responsible for an unacceptable level of defects/ repairs, shall, at OWNER request, be removed from production. At the discretion of the OWNER, the welder in question may be retested after a agreed upon period of retaining.

9.0

PRODUCTION WELDING All welding shall be performed in accordance with API 1104 and this specification.

9.1

Cleaning and Pipe Beveling The following requirements shall be met by CONTRACTOR: •

If undesirable debris is present the pipe shall be swabbed along its full length immediately prior to alignment with regard of the pipeline.

•

All the bevels shall be clean from dirt and mill scale a minimum of 25mm from the edge before alignment of the pipes.

All the field bevels shall be visually inspected and accepted prior to alignment. All field bevels on line pipe shall be made with regard of a beveling machine. Hand beveling shall not be permitted. All field bevels shall be cut evenly and the land finished at right angles to the longitudinal axis of the pipe, with regard of no rough surfaces. Line pipe will be supplied with regard of a standard API bevel of 30°, +5°, -0° and with regard of a root face of 1.59mm +/- 0.79mm. 9.2

Alignment of Pipe The alignment of the joints shall be as follows: •

Mainline

– With Pneumatic operated Internal Line up Clamp.


Page 13 of 25


•

Tie-in

– Mechanical External Clamp.

•

CP Attachments – Tack welds.

Longitudinal seams of adjacent pipes / bends shall be aligned as tabled below: Type of alignment Position of seams Pipe to cold bend or cold Top half of the Pipe bend to cold bend (horizontal / vertical) Pipe to hot bend or hot Top half of the Pipe bend to cold bend (horizontal / vertical)

Min staggering distance 150mm

150mm

In addition to the above, special cases where it is considered impractical to meet the specification requirements due to some site constraints or the other, the situation has to be considered on case to case and the staggering distance still be decided by the OWNER. Maximum misalignment or offset shall not exceed 1.6mm prior to welding the root bead. 9.3

Pre-Heating and Interpass Temperature and Post-Weld Heat Treatment (PWHT) The need for appropriate levels of welding preheat shall be determined during the welding procedure qualification. The minimum preheat temperature shall be applied in accordance with the approved WPS. The use of oxyacetylene gas for preheating shall not be permitted. When fuel gas is used for preheating, full encirclement rings are preferred. If hand held torches are approved by the OWNER, a minimum of two fuel gas torches shall be used on pipe diameters greater than NPS 12, when preheating manually. For all thicknesses greater than 20mm, welding of pipe to fittings or fittings to fittings, for pre-heating induction heating/ electrical mats shall be used. Preheat for fitting to pipe shall be 100°C min. or as per the approved WPS. All tie-in welds, repairs, fillet welds and fitting-to-pipe welds shall be preheated to 50°C above that required for similar pipe-to-pipe butt welds. The interpass temperature shall not exceed 275°C. The entire joint length shall be preheated simultaneously. The pre-heating temperature shall cover an area of at least 25mm width on either side of the weld and shall be maintained over the full length of the weld until the weld is completed. Any requirements for post-weld heat treatment shall be established during welding procedure qualification tests. In such cases the specific requirements for heat treatment shall be included in the welding procedure specification by the


Page 14 of 25


CONTRACTOR and shall be subject to the approval of the OWNER. For repair welds, preheat shall be a minimum of 100°C. If PWHT is necessary, the CONTRACTOR shall submit a detailed procedure to the OWNER for approval. This shall include all details required by ASME VIII, Div 1, para UCS 56. Radiographic inspections in accordance with clause 21 of this specification shall be carried out on 100% of the length of welds after PWHT has been completed. A chart recording of each post-weld heat treatment shall be produced. 9.4

Tack Welds Tack welds when approved by the OWNER shall be a minimum of 50mm long and shall be welded with the same Welding Procedure Specification used for the root pass and by a qualified welder. All tack welds shall be welded vertical-up. Preheat of tack welds shall be the same as the approved welding procedure specification for that pipe or fitting grade, size and thickness. Tack welds incorporated into the final weld shall be ground to a featheredge at each end to ensure adequate fusion on the root pass.

9.5

Line-up Clamps Internal line-up clamps shall be used to hold the pipes firmly in position. Unless otherwise agreed in writing by the OWNER, internal line-up clams shall not be removed before the completion of the first pass. For all tie-ins (closing welds) and all welds where external line-up clamps are used, vertical-up welding shall be used for the root pass. External line-up clamps may be removed when the root pass is at least 50 percent complete and equally spaced around the pipe circumference, subject to the pipe remaining adequately supported. The pipes on both sides of the weld joint shall not be raised, lowered, or otherwise moved, until both the root pass and the second pass (hot pass) have been completed, unless the CONTRACTOR can demonstrate to the satisfaction of OWNER that the root pass alone is adequate to resist deformation and cracking.

9.6

Working Clearance The working clearance shall be such as to afford the welder maximum comfort during welding. A minimum 400mm clearance shall be maintained.


Page 15 of 25


10.0

AUTOMATIC WELDING All the field welding activities shall be done with regard of manual welding hence this Clause is not applicable.

11.0

FITTINGS The welding of pipeline fittings to pipe and/or fittings to fittings shall meet the requirements of this specification.

12.0

INTERPASS CLEANING Each weld pass shall be cleaned to remove all welding slag and foreign matter prior to welding the successive pass. Cleaning methods shall be in accordance with the approved Welding Procedure Specification.

13.0

ARC STRIKES Arc strikes shall be avoided outside the weld bevel. Should arc strikes occur outside the weld bevel area, they shall be removed by grinding and inspected by magnetic particle examination to ensure freedom from cracks. The remaining wall thickness shall be checked by ultrasonic testing. If the reading is below the Specified minimum wall thickness of the pipe, either the defective pipe shall be cut off, or repaired with an approved repair procedure with prior approval from the company.

14.0

MULTIPLE JOINT WELDING Multiple joint welding may be performed either manually or by automatic processes, providing the process is in accordance with regard of a qualified procedure approved by the OWNER.

15.0

MARKING WELDS All welds shall be given a unique number in sequence. The sequence shall be recorded on identification weld reports and/ or field drawings. The weld numbering sequence and tractability shall be addressed in the Contractor’s procedure and submitted to the OWNER for approval. The weld numbers shall be legible/ identifiable up to the post padding/ backfilling operations. Punch or steel stamping shall not be permitted.


Page 16 of 25


16.0

PROXIMITY OF WELDS Adjacent circumferential welds in pipelines shall be separated by a minimum of 2 times the outside diameter or 500mm whichever is greater. The distance can be reduced to 500mm in the above ground pipe at valve stations and pipe on the plant side of anchor blocks or expansion loops at end stations. Branches, fittings and attachments shall be separated away from other welds on the pipeline. The minimum separation shall be the greater of either:

17.0

•

Diameter of Branch/ Fitting

•

Four (4) times the wall thickness of the thickest component

•

50mm

END PROTECTION Pipe ends shall be adequately protected during transportation, handling and fabrication and installation. The bevel protectors, where provided, shall remain in place until the pipe is added to the string rack or when fabrication commences. On completion of stage fabrication or end of work shift or end of the day, end caps shall be placed over open ends.

18.0

WEATHER LIMITATIONS The applicable welding procedure approved by the OWNER shall be strictly adhered to at all times with regard to welding parameters and environmental conditions. The welding may not be performed when, in the judgment of the OWNER, the quality of the completed weld would be impaired by the prevailing weather conditions. These conditions include, but are not limited to, airborne moisture, sand or dirt particles and high winds. Windshields and enclosed welding stations may be used when practical.

19.0

STANDARDS OF ACCEPTABILITY The standards of acceptability for all welding shall be in accordance with the requirements of API Standard 1104, Section 9.

20.0

INSPECTION AND TESTING The CONTRACTOR shall provide all weld inspection.


Page 17 of 25


Each weld shall be cleaned by a power brush to remove all slag, spatter, etc. before inspection. All welds shall be inspected 100 percent by visual examination. In addition, all butt welds shall be inspected 100 percent by radiographic inspection. All Non-destructive Testing (NDT) procedures shall be submitted for OWNER approval and shall be qualified individually on the welding procedure qualification tests, or when agreed to by the OWNER, on a production weld. Where geometry of the welds does not allow radiographic testing, ultrasonic testing or other approved non-destructive testing methods may be used. Such instances shall be approved by the OWNER. The NDT operators shall be qualified to ASNT-SNT-TC-IA Level II and sections 8.3 and 8.4 of API 1104. The work shall be supervised by a Level II or Level III engineer. The NDT operators shall have current certification for the work undertaken and their qualification certificates shall be subject to approval by the OWNER.

21.0

RADIOGRAPHIC INSPECTION The CONTRACTOR shall supply all labour and materials necessary to perform radiographic inspection. Any weld which in the OWNER’s opinion, is not satisfactory as indicated by radiographic inspection shall be repaired or cutout and re-welded at the CONTRACTOR’s expense. All the NDT Procedures are subject to OWNER approval and shall be in accordance with API 1104.

22.0

ULTRASONIC INSPECTION Ultrasonic examination is required as follows: •

A zone 100mm wide around planned cutouts for nozzles, branches, etc.

•

To verify minimum wall thickness after grinding

•

Initial testing of automatic welds At the commencement of welding with regard of an approved automatic process (other than SAW) all welds shall be tested 100% by ultrasonic examination until OWNER is satisfied that the process is under complete control (minimum of 50 welds).


Page 18 of 25


•

Where radiographic inspection does not clearly show compliance of the weld with regard of this specification.

OWNER reserves the right to test proposed UT operators prior to acceptance using the approved procedures on a test weld. Ultrasonic inspection procedures when required shall be submitted to the OWNER for approval, prior to use. 23.0

MAGNETIC PARTICLE INSPECTION CONTRACTOR shall supply Magnetic Particle Inspection (MT) procedure for review and approval by OWNER. Magnetic particle inspection is required for the following: •

On removal of arc strikes

•

For confirmation of defect removal on repair joints

•

For branch welds

•

For CP attachments & fillet welds

•

After grinding the attachment removal area

OWNER reserves the right to test proposed MT operators prior to acceptance, using the approved procedure on a test weld. 24.0

DEFECT ACCEPTANCE LEVELS All acceptance levels specified below are in addition to API Standard 1104: •

The internal root penetration shall not exceed 2mm.

•

The external weld reinforcement shall be uniform and in no area shall the weld cap be lower than the adjacent pipe wall. The height of the reinforcement shall be 2.5mm.

•

An isolated pore greater than 25 percent of the pipe thickness or 3mm whichever is the smaller in any direction, shall be considered unacceptable.

•

The maximum permitted individual length of inadequate penetration without high-low shall be 25mm. The maximum aggregate length of defect shall be 8% of weld length in any weld less than 300mm in length.

•

The maximum permitted individual length of inadequate penetration due to high-low shall be 50mm. The maximum aggregate length of defect shall be 75mm in any continuous 300mm length of weld.


Page 19 of 25


25.0

•

The length of individual incomplete fusion exceeds 25mm, shall be considered as a repair.

•

Burn through shall be considered as repair if it exceeds the limits given in API 1104 Cl. 9.3.7.

•

The length of an individual indication of Hollow Bead shall not exceed 13mm.

•

Cracks found by non-destructive testing in any form or orientation shall be unacceptable and shall result in the whole weld being removed, edges cut back and re-welded.

•

Tungsten inclusions shall be treated as individual inclusions and shall not exceed 2 per weld and 3mm in size, separated by a minimum distance of 50mm.

REPAIR OF WELDS The system for reporting defects shall be such that defects can be identified quickly and are accurately located. All the repairs shall be carried out in accordance with API 1104 and approved Repair procedures by the OWNER. The decision to proceed with repair in each instance shall be approved by the OWNER. The defects shall be removed by grinding, machining or arc-air gouging only. Arc-air gouging shall be performed in accordance with the procedures approved by the OWNER and only by the personnel who are competent to perform such work. Arc air gauging is not permitted on pipe less than 10mm thick. The cavity shall be finished by grinding to a bright and smooth finish with a tapered entry and exit profile. The length of the cavity shall be 50mm minimum. If repair excavations are less than 10mm apart they shall be linked into a single repair. Repair shall be attended two times maximum. If the 2nd time attempt fails to meet the requirements the weld shall be cut and rewelded. Weld repairs to the pipe body or to the body of fittings or bevels are not permitted. Single pass repairs are not permitted. The root repair from inside shall not be permitted. The total length of repair shall not be exceeds 40% of total weld length. For individual root repair the length shall not be exceed 20% of the total weld length and


Page 20 of 25


for partial penetration repair the individual length shall not be exceed 30% of the total weld length. If the above exceeds the joint shall be cut and rewelded. Repair procedures shall be qualified in accordance with regard of paragraph 7.3.2 of this specification.

26.0

OTHER WELDING No cutting or welding other than that required performing the permanent work will be allowed without written permission from the OWNER.


Page 21 of 25


27.0

WELDING MATERIAL DISPOSAL The CONTRACTOR shall clean welding areas for all trash, waste, rod stubs, etc., to the satisfaction of the OWNER.

28.0

RECORDS Permanent records shall be made, with full supporting information of all welds, including repairs and re-welds. Records shall include a pipe tracking system or field drawing, which identifies the final location, coordinates of each pipe and weld. In addition to hard copies, all project welding procedures (WPS and PQR) shall be furnished on diskettes with suitable software. All welding repairs shall be reported to the OWNER on a monthly basis per spread and per welder/ automatic machine, with analysis of the type of defects. This shall be presented in a software package approved by OWNER.


Page 22 of 25


APPENDIX A - SUMMARY OF PIPELINE MATERIALS

ITEM LINE PIPE Outside Diameter (mm) Wall Thickness (mm) Material Grade Pipeline Burial Depth Estimated Length Excluding Spares/ Route Allowance NPS 10 X 6.4 Thk. NPS 18 X 7.9 Thk. NPS 18 X 7.1 Thk. NPS 18 X 6.4 Thk. Manufacturing Method COATINGS Standard


PIPELINE 273.0 and 457.0 6.4 (NPS 10), 7.9 (NPS 18), 7.1 (NPS 18) and 6.4 (NPS 18) API 5L GR.B (NPS 10), GR X 60 (NPS 18) 1.0 m to 2.0 m (Approx.) Metres 29608 76200 20000 148500 ERW or SAW (NPS 10 &18) Internal – None External – 3LPE

Page 23 of 25


APPENDIX B - ABBREVIATIONS AADL AC AFC ANSI ASTM API API RP ASME AWS BOD BOF BS BVS CEN CP CSWIP D DC DWTT EIA EMR EPC ESD FCAW GMAW GTAW HAZ HDPE HF-ERW HMP HSE HV ISO LDS LSBD MAOP MPI MSL MSS MW NACE

Average Annual Daily Load Alternating Current Approved for Construction American National Standards Institute American Society for Testing and Materials American Petroleum Institute American Petroleum Institute Recommended Practices American Society of Mechanical Engineers American Welding Society Basis of Design Basic Oxygen Furnace British Standard Block Valve Station European Committee for Standardization Cathodic Protection Certification Scheme for Welding Inspection Personnel Nominal Outside Diameter Direct Current Drop Weight Tear Tests Environmental Impact Assessment Extra Moisture Resistant Engineering, Procurement and Construction Emergency Shutdown Flux Cored Arc Welding Gas metal Arc Welding Gas Tungsten Arc Welding Heat Affected Zone High Density Poly Ethylene High Frequency Electric Resistance Welding Hazard Management Process Health Safety and Environment Vickers Hardness International Organization for Standardization Leak Detection system Limit State Based Design Maximum Allowable Operating Pressure Magnetic Particle Inspection Mean Sea Level Manufacturers Standardization Society Molecular Weight National Association of Corrosion Engineers


Page 24 of 25


NB NDT NFPA OD PAMS PCS PCN PE PFS PQR PRT PSL

Nominal Bore Non Destructive Testing National Fire Prevention Association Outside Diameter Portable Arc Monitoring System Pipeline Construction Specification Personnel Certification in NDT Polyethylene Process Flow Scheme Procedure Qualification Record Pressure Reduction Terminal

PWHT

Post Weld Heat Treatment Quality Control Quantitative Risk Assessment Right of Way Remote Terminal Unit Submerged Arc Welding Synchronous Digital Hierarchy International System of Units Shielded Metal Arc Welding Nominal Thickness Transformer Rectifier Unit The Welding Institute Uniform Building Code Uninterrupted Power Supply Ultrasonic Testing (inspection) Work Practice Welding Procedure Specification Wall Thickness

QC QRA ROW RTU SAW SDH SI SMAW t TRU TWI UBC UPS UT WP WPS WT

Product Specification Level


Page 25 of 25

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) SPECIFICATION FOR CONCRETE WEIGHT COATING


SPECIFICATION FOR CONCRETE WEIGHT COATING 0435-JH0902-00-PL-SPC-0013 04 August 09


Doc. No: 0435-JH0902-00-PL-0013 Rev. B

Page 1 of 15


SYNOPSIS



DESCRIPTION

PREPARED BY

CHECKED BY

APPROVED BY

A

Issued for IDC

D. Hemnathan

S. Ishwad

J. Wallace

B

Issued for Review

D. Hemnathan

S. Ishwad

KMN Pillai

Doc. No: 0435-JH0902-00-PL-0013 Rev. B

DATE

26 July 09

CLIENT APPROVAL N/A

04 August 09

Page 2 of 15

DATE


TABLE OF CONTENT 1.0

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

2.0

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

3.0

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

4.0

MATERIALS ..................................................................................................................... 5

5.0

COATING REQUIREMENTS......................................................................................... 6

6.0

APPLICATION METHOD ............................................................................................... 7

7.0

EQUIPMENT..................................................................................................................... 7

8.0

MEASUREMENTS & LOGGING................................................................................... 8

9.0

PROCEDURE QUALIFICATION................................................................................... 8

10.0

APPLICATION OF REINFORCEMENT AND CONCRETE COATING.................. 9

11.0

TOLERANCES ............................................................................................................... 12

12.0

WEIGHING...................................................................................................................... 12

13.0

INSPECTION AND TEST ............................................................................................. 12

14.0

COATING OF FIELD JOINTS ..................................................................................... 13

15.0

REPAIRS......................................................................................................................... 13

16.0

MARKING ....................................................................................................................... 14

17.0

UNLOADING, TRANSPORTATION, STORING AND HAULING ......................... 14

Doc. No: 0435-JH0902-00-PL-0013 Rev. B

Page 3 of 15


1.0

SCOPE

1.1

This specification defines the minimum technical requirements for the materials, application, inspection, handling and other activities for external concrete weight coating of pipeline.

2.0

DEFINITIONS For this specification the following definitions shall apply: OWNER

: Hindustan Petroleum Corporation Limited,

CONSULTANT

: Worley Parsons Engineering India Pvt. Ltd.

EPC CONTRACTOR

: The Company names as such in the deed.

SHALL/MUST/IS TO BE

: A mandatory requirement

SHOULD

: A non-mandatory requirement, advisory or recommendation

3.0

REFERENCE DOCUMENTS

3.1

Reference has been made in this specification to the following latest publication codes and standards: i) ASTM A-185

: Welded steel wire fabric for concrete Reinforcement

ii) ASTM C-642

: Specific gravity, absorption and voids in hardened concrete.

iii) ASTM C-138

: Unit weight, yield and air content of concrete.

iv) ASTM C-309

: Liquid membrane forming components for curing concrete.

v) ASTM A-82

: Specification for steel wire, plain, for concrete reinforcement.

vi) ASTM C-39

Compressive specimens.

strength

of

cylindrical

concrete

vii) IS - 269

: Indian Standard Specification for Ordinary and Low Heat Portland Cement. (1959; Reaffirmed 1999)

viii) IS – 456

: Plain and Reinforced Concrete – Code of Practice

Doc. No: 0435-JH0902-00-PL-0013 Rev. B

Page 4 of 15


(3rd Revision – 2000)

4.0

ix) IS – 6909

: Indian Standard Specification for Sulphate Resistant Cement.(1990; Reaffirmed 1997 )

x) IS-8112

: Indian Standard Specification for High Strength Ordinary Portland cement

xi) IS-383

: Indian Standard Specification for Coarse and Fine Aggregates from Natural Sources for Concrete

xii) IS-2386 (Parts I thru' VIII)

: Indian Standard Methods of test for aggregates concrete

MATERIALS The CONTRACTOR shall supply all the materials necessary for the performance of the work. All materials supplied by the CONTRACTOR, which in the opinion of OWNER, do not comply with the appropriate specifications shall be rejected and immediately removed from site by CONTRACTOR at his own expense. All materials for concrete coating shall comply with following requirements.

4.1

CEMENT

4.1.1

Portland Cement (conforming to IS-269), or High Strength Ordinary Portland Cement (conforming to IS-8112) shall be used.

4.1.2

Sulphate Resistant Cement shall be Cement (conforming to IS 6909 ) shall be used wherever the soil is corrosive.

4.1.3

Cement which has hardened or partially set or which has become lumpy shall not be used.

4.1.4

Test Certificates from the cement Manufacturer shall be supplied to the OWNER for all batches of cement delivered to site.

4.1.5

Cement which are more than six months old shall not be acceptable.

4.2

AGGREGATES

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Page 5 of 15


4.2.1

Aggregate shall comply with the requirements of IS:383 and shall be tested in accordance with IS:2386.

4.2.2

Fine Aggregates 'Fine Aggregates' shall mean any of the following, as defined in IS:383: i) Natural sand,ii) Crushed stone sand, iii) Crushed gravel sand Sand shall be well-graded from fine to coarse in accordance with Table 4 of IS:383.

4.2.3

Coarse Aggregates Use of coarse aggregates shall be subject to OWNER approval.

4.2.4

Aggregates shall be clean and free from injurious amounts of salt, alkali, deleterious substances or organic impurities.

4.3

WATER The water shall be limpid, 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 by the CONTRACTOR before use and the test reports shall be submitted to the Owner’s representative for approval.

4.4

REINFORCEMENT Concrete coating shall be reinforced by a single layer or multiple layers of steel reinforcement according to the provisions hereinafter described. Reinforcement shall be Fe 500.

4.4.1

Reinforcement shall consist of welded steel wire fabric manufactured in rolls (ribbon mesh) and shall conform ASTM A-185. Steel wires in the ribbon mesh shall conform to ASTM A-82.

4.4.2

Steel wires shall be galvanised at finished size. The diameter of the wire and wire spacing (mesh) dimensions shall be selected according to the following criteria. • 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 OWNER.

4.5

Concrete grade –35 shall be used

5.0

COATING REQUIREMENTS

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Page 6 of 15


Pipes shall be concrete coated to a 75 mm thickness or as specified in the relevant drawings and as per the design documents. Concrete Coating shall be applied in marshy & water logged areas. Necessary anti-buoyancy calculations shall be carried out during detailed Engineering Specifying requirement of Concrete coating Concrete shall conform to the following:

CONTRACTOR shall be permitted to select any proportioning of materials to achieve the specified requirements of concrete density and weight. 6.0

APPLICATION METHOD Concrete coating shall be applied by impingement method. Any alteration or modifications to the method described in the specification shall be submitted to the OWNER for approval. The application method shall ensure the basic characteristics of concrete coating in compliance with the minimum requirements of this specification. CONTRACTOR shall submit to the OWNER, prior to commencement of work, the procedure of concrete application for approval. Wherever practical, the specified total thickness of concrete coating shall be applied in a single pass.

7.0

EQUIPMENT The equipment used for performing the concrete coating shall be capable of doing so with a reasonable degree of uniformity with respect to thickness, density and strength. The proportioning equipment and procedure shall be of the type to ensure consistently proportioned materials by weight. Concrete shall be mixed in a mechanical mixer, which

Doc. No: 0435-JH0902-00-PL-0013 Rev. B

Page 7 of 15


shall ensure thorough mixing of all materials. Any equipment that tends to separate the ingredients shall not be used. 8.0

MEASUREMENTS & LOGGING

8.1

CONTRACTOR shall submit detailed methodology in their procedure for measurement and logging. All measurements as mentioned below shall be taken during the work stages and clearly logged in a proper 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 wall thickness.

8.2

The logging methodology shall include minimum the following details:

a)

Line pipe 1) Field identification number 2) Mill serial Number 3) Length (m) 4) Weight (kg) 5) Average outside diameter (mm)

b)

Corrosion Coating 1) Type of coating 2) Thickness of coating (mm) 3) Weight of coated pipe (kg) 4) Date of corrosion coating application

c)

Concrete Weight Coating 1) Batch identification number 2) Date of placing of concrete coating. 3) Average concrete coating thickness. 4) Wet weight of coated pipe (weight and dated of weighing) 5) "Dry weight" of concrete coated pipe (Weight and date of weighing or related weight 28 days after placing of concrete and so identifiable) 6) "Unit dry weight" of concrete coated pipe. 7) "Negative buoyancy" (unit) of concrete coated pipe

8.3

No concrete placing shall be done before items 1 to 9 listed above have been logged. In addition, each batch / shift shall be identified and logged against cube samples taken for compressive strength and dry density.

9.0

PROCEDURE QUALIFICATION

Doc. No: 0435-JH0902-00-PL-0013 Rev. B

Page 8 of 15


Before commencement of the work, CONTRACTOR shall perform all tests, either in the laboratory or in field to properly select type of mix, which meets the requirements of section 5.0 of this specification. 9.1

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 first determined. For each mix the following shall be accurately checked and recorded: i) Proportions and weights of the respective materials used ii) The water/cement ratio iii) The grading of the aggregates.

9.2

Samples shall be prepared and tested in accordance with ASTM C-642 to determine the dry specific gravity (28 days after placing).

9.3

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.

9.4

The mix so determined shall then be used for sampling of concrete to be submitted to compressive strength tests as per ASTM C39 / IS 516.

9.5

Frequency of sampling for tests for density and compressive strength of concrete shall be as follows:

10.0

APPLICATION OF REINFORCEMENT AND CONCRETE COATING

10.1

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.

10.2

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 water / cement ratio constant at its correct value, determination of moisture contents in both fine aggregates and coarse aggregates (if used) shall be made as frequently as possible. Frequency for a given job shall be determined by the OWNER according to weather conditions.

10.3

REINFORCEMENT APPLICATION

10.3.1 Prior to placing of reinforcement, the protective coating of each pipe length shall be carefully inspected visually and by holiday detectors. If damages are found, they shall be repaired before start of the work. Foreign matters, if any, shall be removed from the surface of the protective coating.

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10.3.2 Reinforcement shall be placed around the pipe in such a way as to cover whole pipe length or sections to be concrete coated. The reinforcement shall protrude a minimum 50 mm from the finished concrete coating at the pipe ends. 10.3.3 Splices and attachments shall be done by binding with steel wire having 1.5mm diameter. Circular and longitudinal joints of wire fabric in sheets shall be lapped at least for one mesh. The spiral lap shall be one mesh while the spliced lap shall be three meshes. 10.3.4 Reinforcement shall rest on synthetic resin spacers forming a "Crown" whose number shall be such as to avoid contact of the steel reinforcement with the pipe's protective coating. Spacing between the two consecutive 'crown' centres shall be 500 to 1000m. 10.3.5 One layer of reinforcement steel shall be provided for concrete thickness up to 60 mm. The reinforcement steel shall be embedded approximately midway in the concrete coating thickness. For concrete thickness above 60mm two layers of reinforcing steel shall be provided. If application method requires more than one pass of concrete, one reinforcement layer for each pass is to be applied irrespective of the concrete coating thickness. 10.4

CONCRETE PLACING

10.4.1 Concrete shall be placed within a maximum of 30 minutes from the time of mixing (adding water to mix) and shall be handled in such a way so as to prevent aggregate segregation and excessive moisture loss. Concrete containers shall continuously be kept clean and free from hardened or partially hardened concrete. 10.4.2 Placement of concrete shall be upto the specified thickness in one continuous course, allowance being made for splices of reinforcement and providing reinforcement in the right location. 10.4.3 No 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. 10.4.4 All pipes shall be kept clean and free from cement, concrete and grout either inside or outside of the uncoated sections. 10.4.5 The coatings at each end of the pipe shall be bevelled to a slope of approximately twoto-one (2:1). 10.4.6 Bevel protectors shall be kept in place throughout the coating application and after. 10.4.7 Suitable means shall be provided to ensure that the temperature of the concrete, when placed, does not exceed 32°C.

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Page 10 of 15


10.5

WINTER CONCRETE COATING

10.5.1 In ambient temperatures below 4 Degree C concrete must be protected from the effects of frost by warming the aggregates and / or warming of the mixing water and additionally ensuring an air temperature of 6 Degree C in the vicinity of the concrete. 10.5.2 Storing and curing of coated pipe shall not take place at temperatures below 1.5 Degree C, until the concrete has aged sufficiently to have achieved a crushing strength of at least 10 N/mm2. 10.6

RECLAIMED CONCRETE

10.6.1 Use of reclaimed rebound shall be done only with the written permission of the Owner and to the satisfaction of the Owner’s inspector. 10.6.2 When use of reclaimed rebound is permitted by the Owner, this material shall be added to and thoroughly intermixed with freshly batched concrete in a secondary mixture of a type, acceptable to the Owner’s representative. 10.6.3 The amount of reclaimed material used shall not exceed 5% of the total mix by weight and shall only be added in an even flow during a continuous coating operation. 10.7

CUT BACK ON CONCRETE COATING Both ends of each joint for the distance of 250mm or as specified in the Contract document, shall be completely free of concrete to facilitate field joints.

10.8

HANDLING AFTER APPLICATION Contractor shall take precautions to prevent detrimental movement of pipe after coating and to minimise handling stresses whilst concrete is hardening and curing.Identity of each pipe shall be preserved during and after the coating process by transfer of pipe information to and outside of concrete coating at each end of the all pipes.

10.9

CURING

10.9.1 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 section shall be handled gently by suitable means to prevent undue distortion. 10.9.2 Curing shall be performed by application of an approved curing membrane using sealing compounds and shall meet the requirements of ASTM C-309. The curing compound 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 non-

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Page 11 of 15


inflammable and shall not react with any ingredient of the concrete, the reinforcement, the anti-corrosion coating or steel pipe. The application of the curing compound shall be done 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. 10.9.3 Before handling and hauling of 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 pipes shall be initiated only after seven days provided that the concrete coating suffers no damage. 11.0

TOLERANCES

11.1

CONCTRACTOR shall maintain a surface tolerance of + 6mm on outside diameter of the coated pipes measured by diameter tape. The diameter of each coated pipe shall be obtained at five (5) points, spaced at equal intervals between end points.

11.2

The acceptance weight tolerance for any single pipe shall be limited to (-)2% to (+)5% of the calculated theoretical weight. The theoretical weight shall be calculated using total weight of the pipe with concrete and corrosion coating.

11.3

Acceptable weight tolerance from the approved mix, during production shall be as follows: i) + 3% for each type of aggregate ii) + 2% for aggregate as a whole iii) + 3% for the total quantity of water iv) + 3% for cement

12.0

WEIGHING

12.1

The test specimen shall be selected at equal intervals during the course of production.

12.2

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.

13.0

INSPECTION AND TEST

13.1

Before concrete coating the pipe shall be pre -tested at a pressure equivalent to 95% 0 SMYS of pipe material. The test pressure shall be held for a period of 6 hours & reading

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Page 12 of 15


logged at equal intervals. During the Test CONTRACTOR check all welds for leakage. Failure if any during the test shall be rectified by the CONTRACTOR. 13.2

After curing, every length of concrete coated pipe shall be non-destructively tested by suitable means such as "ringing" to determine if any suspected defects are present. In case this indicates faulty coating, cores shall be removed from coating and inspected. When defective coating appears from cores, the concrete coating shall be removed from the pipe lengths.

13.3

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. For this purpose provisions should be made during placing of concrete such as to leave atleast a point of exposed steel reinforcement whenever the latter shall terminate inside of concrete coating.

13.4

During the tests 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 section. Repairable concrete coating shall be clearly marked while the nonrepairable ones shall be removed from the pipe lengths.

14.0

COATING OF FIELD JOINTS

14.1

The CONTRACTOR shall coat the uncoated pipe surface at field welds in accordance with methods approved by OWNER. CONTRACTOR shall submit a detailed procedure for joint coating for Owner’s approval.

14.2

The reinforcement for the field welds shall be same as that for line pipe coating with the same number of layers and the same space between layers as for the existing coating. The edges of this netting must be carefully secured with Galvanized wire to the reinforcement extending from the existing coating. The reinforcement shall not make direct /electrical contract with the pipe. Synthetic resin spacer blocks shall be used to keep the reinforcement away from the corrosion coated pipe surface.

14.3

The composition of the concrete shall be the same as that of the concrete coating of the pipe.

14.4

When moulds are used if approved by the OWNER, the CONTRACTOR shall prevent air being trapped by applying mechanical vibrators or by striking the outside of the moulds with suitable sticks.

15.0

REPAIRS

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The following are repairs that will be permitted to coating due to unavoidable damage in handling and in storage (This applies only to concrete that has hardened). 15.1

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 percent of the total thickness of the coating at the point of damage.

15.2

Damage due to spalling of an area of less than 0.1 m2 (1 square foot) where the remaining concrete is sound will be accepted without repairs.

15.3

Damage due to spalling of an area of 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 area at the top. The repaired area shall be moist cured for a minimum of thirty six (36) hours before further handling.

15.4

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 mm (four inches). The resulting coating shall be equal in eight, 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 further handling.

16.0

MARKING

16.1

Every concrete coated pipe length shall be clearly marked by a suitable type of paint (i.e., red and/or white lead paint). Markings out 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.

16.2

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.

17.0

UNLOADING, TRANSPORTATION, STORING AND HAULING

17.1

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.

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Precautions shall be taken to prevent contamination, to maintain the cleanliness and against effects of hot or cold weather or other adverse climatological condition. 17.2

During the operations of loading, unloading and stock-piling, the pipe sections shall be handled in such a way so as to avoid damages to pipe ends, protective and/or concrete coating.

17.3

Stacks shall consist of a limited number of layers such that the pressure exercised by the pipes' own weight does not cause damages to coating. Stacking with more number of layers shall be agreed upon with the OWNER 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.

Doc. No: 0435-JH0902-00-PL-0013 Rev. B

Page 15 of 15

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) SPECIFICATION FOR HOT INDUCTION BEND


SPECIFICATION FOR HOT INDUCTION BEND 0435-JH0902-00-PL-SPC-0014 25 July 09



Page 1 of 16


SYNOPSIS



DESCRIPTION

PREPARED BY

CHECKED BY

APPROVED BY

A

Issued for IDC

D. Hemnathan

S. Ishwad

J. Wallace

B

Issued for Review

D. Hemnathan

S. Ishwad

J. Wallace


DATE

23 July 09

CLIENT APPROVAL N/A

25 July 09

Page 2 of 16

DATE



GENERAL....................................................................................................................... 4

1.1

Objective ..........................................................................................................................4

2.0


2.1

Codes And Standards ......................................................................................................4

2.2

Reference Documents......................................................................................................5

2.3

Document Precedence .....................................................................................................5

2.4

Specification Deviation / Concession Control ...................................................................5

2.5

Quality Assurance / Quality Control ..................................................................................5

3.0

MATERIALS ................................................................................................................... 6

4.0

MANUFACTURE ............................................................................................................ 7

5.0

INSPECTION AND TESTS ............................................................................................. 9

6.0

TEST CERTIFICATES .................................................................................................. 10

7.0

MARKING, PACKING AND SHIPMENT ....................................................................... 11

8.0

DOCUMENTATION....................................................................................................... 12

9.0

QUALITY ASSURANCE ............................................................................................... 12

FIG 1 - TEST SPECIMEN LOCATION..................................................................................... 13 FIG. 2 – LOCATION OF WELD SEAM .................................................................................... 14 ANNEXURE 1 – ABBREVIATIONS......................................................................................... 15


Page 3 of 16


1.0

GENERAL

1.1

Objective This specification gives the minimum requirements for design, manufacture, testing and supply of hot induction bends made from Longitudinally submerged arc (LSAW) carbon steel line pipes to be used pipeline systems handling non sour Hydrocarbon products for the GGSR Product Evacuation Project for Ramanmandi to Bahadurgarh and Ramanmandi to Bathinda Multiproducts pipeline.

2.0


2.1

Codes And Standards The following codes and standards, to the extent specified herein, form a part of this specification. When an edition date is not indicated for a code or standard, the latest edition in force at the time of Contractor’s proposal submitted shall apply. American Society of Mechanical Engineers (ASME) ASME B16.25

Butt Welding Ends

ASME B16.49

Factory made Butt Welding Fitting

ASME B31.4

Liquid Transportation System for Hydro Carbons and other liquids.

ASME SECTION II

Part ‘C’ Material Specifications – Welding Rods, Electrodes and Filler Metals

ASME SECTION V

Non Destructive Examination

ASME SECTION IX

Qualification Standard for Welding and Brazing Procedure

American Petroleum Institute (API) API 5L


American Society for Testing and Materials (ASTM) ASTM A370

Standard Test Methods and Definitions for Mechanical Testing Steel Products


Page 4 of 16


International Organization for Standardization (ISO) ISO 9000

Quality Management and Quality Assurance Standards Guidelines for Selection and Use

EN 10204

Inspection Documents for Delivery of Metallic Products

Manufacturers Standardization Society of the Valve and Fittings Industry (MSS) MSS SP75 2.2

High Test Wrought Butt Welding Fittings

Reference Documents The following specifications to the extent specified herein, form a part of this specification. Project Specifications 0435-JH0902-00-PL-SPC-0002

2.3


Document Precedence The CONTRACTOR shall notify the OWNER 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 the OWNER in writing before proceeding with the design or manufacture. In case of conflict, the order of precedence shall be:

2.4

•

National and/or Local Regulations

•

Project Specifications and Standards

•

Industry Codes and Standards

Specification Deviation / Concession Control Any technical deviations to this specification and its attachments including, but not limited to, the Data Sheets and Narrative Specifications shall be obtained by the CONTRACTOR/VENDOR only through CONCESSION REQUEST format. CONCESSION REQUESTS require Owner’s review / approval prior to implementation of the proposed changes. Technical changes implemented prior to OWNER approval are subject to rejection.

2.5

Quality Assurance / Quality Control The VENDOR shall have in effect at all times a QA/QC program which clearly establishes the authority and responsibility of those incharge of the quality system.


Page 5 of 16


Persons performing quality functions shall have sufficient and well defined authority to enforce quality requirements that initiate, identify, recommend and provide solutions to quality problems and verify the effectiveness of the corrective action. A copy of the Vendor’s QA/QC program along with ISO 9000 certification shall be submitted to the CONTRACTOR. CONTRACTOR shall be submitted these documents to HPCL/WP for review and concurrence prior to award. The Contractor shall identify in purchase documents to its SUBVENDORS all applicable QA/QC requirements imposed by the Owner, and shall ensure compliance thereto. The VENDOR shall submit certified reports of production tests as soon as the tests are completed satisfactorily. The OWNER reserves the right to inspect materials and workmanship at all stages of manufacture and to witness any or all tests. The VENDOR shall provide the CONTRACTOR with a copy of its Manufacturing and Inspection Plan for review and inclusion of any mandatory OWNER witness points 30 days after award but prior to the pre-inspection meeting. 3.0

MATERIALS

3.1

Bends shall be manufactured from Carbon Steel SMLS/LSAW line pipe suitable for bend manufacturing and in conformity with the relevant Project specifications.

3.2

Unless specified otherwise in the Purchase Order, pipes for fabrication of bends shall be free issued to the Contractor and Contractor responsibility to get done from the bend Manufacturer.

3.3

The Contractor responsibility to check wall thickness of the line pipe to be bent shall be selected to ensure that the minimum thickness after bending is equal to the design requirements including corrosion allowance.

3.4

Heat treatment procedure adopted shall be such that the finished bends achieve the required mechanical property requirements of the applicable Project Specifications. Heat treatment of bends shall be carried out as per the procedure established during the bend manufacturing procedure qualification and as approved by the WP.

3.5

Mechanical testing of test bends performed during the bend manufacturing procedure qualification as per Section 5.0 of this Specification, shall ensure that all bends made according to the qualified bending procedure have the required mechanical properties and destructive testing of production bends is not required. However, WP reserves the right to require destructive testing whenever production bending parameters or heat treatment parameters deviate from those established in the qualified procedures.


Page 6 of 16


4.0

MANUFACTURE

4.1

Material grade, bend size, bend radius and bend angle shall be as indicated in the Purchase Order. Unless specified otherwise, the bending radius for bends shall be minimum five (5) times the nominal outside diameter or specified else where in the tender.

4.2

Bends shall be manufactured by high frequency induction heating and forming method only with the qualified bending procedure qualification. The manufacturer shall maintain continuous records of the forming conditions for each bend.

4.3

Once the bending operation has commenced no stoppage shall be permitted until the entire bend has been completed.

4.4

If bending temperatures, bending rate, cooling medium volume or heat treatment temperature departs from the qualified manufacturing procedure, then the pipe shall be discarded and another bend shall be made in its place.

4.5

The longitudinal seam shall be located in the plane of minimum deformation (bend neutral axis). Acceptable tolerance on location of the longitudinal weld seam shall be ± 5° as shown in Fig. 2 (pg. 16).

4.6

Hot induction bends shall be manufactured from line pipe with positive wall thickness tolerance only.

4.7

Unless otherwise specified in the Purchase Order, the bevels at the ends shall be as per the relevant Project/ pipe specification

4.8

Bends shall not have any circumferential joint.

4.9

No repair by welding is allowed on any part of the bends.

4.10

Bulges, dents and flat areas shall not appear within 100 mm from 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 nominal outside diameter of the pipe.

4.11

The excess weld material at the inside of the bend shall be removed over a distance of 100 mm at both end.

4.12

All bends shall be provided with a tangent length at the ends. Tangent length shall be 500 mm or pipe outside diameter whichever is more.

4.13

Bend Manufacturing Procedure Qualification

4.13.1

Prior to start of production bending, Manufacturer shall demonstrate the suitability of the proposed manufacturing procedures for producing pipe bends that meet the


Page 7 of 16


requirements of this specification, by mechanically testing additional bends (test bends). 4.13.2

Test bends shall be made by using the pipe specified in Clause 3.1 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 (excluding bend angle). The test bend shall be bent to an angle of 90°.

4.14

Tolerances The finished bends shall conform to the following dimensional tolerances in addition to MSS-SP-75 or B16.49 requirements. However the ends of the finished pipe bend shall meet the dimensional tolerances of the relevant line pipe specification referred in Clause 2.2.

4.14.1

Bend Angle

: (±) 0.5°

Bend Radius

: (±) 1% of bending nominal radius.

4.14.2

The Manufacturer shall check the wall thickness of the pipe ultrasonically before bending along both the inside and outside radii, at approximately 15 degree intervals or 300 mm whichever is less. The wall thickness shall be measured ultrasonically after bending at the same locations measured before bending. These measurements shall be taken at four equally spaced locations around the pipe circumference at both welding ends of the bend. The measured wall thickness shall be at least equal to the pipeline nominal wall thickness specified in the purchase requisition.

4.14.3

Ovality in any plane along the finished bend shall not exceed 3%. Ovality shall be calculated using the following formula: (ODmax - ODmin) Ovality = -------------------------ODnom Where ODmax - Maximum Outside Diameter ODmin - Minimum Outside Diameter ODnom - Nominal Outside Diameter 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 of three measurements shall be taken for each bend.

4.14.4

Off Plane Off plane bends shall not exceed (θ/90) x 10 mm, where θ is the bend angle either at distances approximately equal to pipe diameter or 300mm whichever is less. The measurement shall be in accordance with MSS-SP-75 or B16.49


Page 8 of 16


5.0

INSPECTION AND TESTS

5.1

The Manufacturer shall perform all inspection and tests as per the requirements of this specification and MSS-SP-75 or B16.49 prior to shipment, at his works. Such inspection and tests shall be as a minimum, the following:

5.2

a)

Verify that the unfinished product arriving at Manufacturer's shop is in full compliance with the pipe specification.

b)

Visual Inspection

c)

Dimensional and tolerances check as per MSS-SP-75 or B16.49 and requirements of Section 4.0 of this specification.

d)

The non-destructive inspection on the finished bend shall be carried out as given below. Detailed NDT procedure shall be approved by WP prior to its use.

e)

The full circumference of both ends of each bend after bevelling shall be ultrasonically tested for laminations over a length of 25 mm and acceptance limits shall be as specified in the applicable line pipe specification referred in Clause 3.1 of this specification.

f)

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 VENDOR.

g)

Vendor to carry out 100% MPI on bevel ends for lamination to check the surface defects.

h)

Vendor to carry out 100% UT on longitudinal weld seam.

i)

The weld repairs are not permitted.

WP or WP nominated Inspector reserves the right to perform stage wise inspection and witness tests on all bends as indicated in Clause 5.1 at Manufacturer's facility, prior to shipment. Manufacturer shall give reasonable notice of time and shall provide without charge reasonable access and facilities required for inspection, to the WP’s Inspector. Inspection and tests performed or witnessed by WP's Inspector shall in no way relieve the Manufacturer's obligation to perform the required inspection and tests. Under no circumstances shall any action of the WP's Inspector relieve the Manufacturer of his responsibility for ensuring the quality of the bends.

5.3

All finished test bends shall be subjected to the following mechanical testing to confirm that the pipe bends manufactured meets all mechanical property requirements of Project specifications referred in Section 2.0 of this specification.


Page 9 of 16


The test specimen shall be taken from the bent portion of the bend (Fig.1, Pg. 15). For the following tests, number of specimens, specimen orientation with respect to longitudinal axis of the unbent pipe, test procedure and acceptance criteria shall be in accordance with the Project Specification referred in Clause 3.1 of this specification. a)

Tensile Test One tensile test shall be conducted on the base material of finished bend for each heat of steel used, to establish yield strength, ultimate tensile strength and elongation. The specimen shall be taken one at inside radius and one at outside radius of the bend.

b)

Fracture Toughness Test Charpy-V-notch test temperature shall be the same as specified in the relevant pipe specifications referred in clause 3.1. One set of three transverse specimens shall be taken from the outside radius and one set from the inside radius of the bend.

c)

Guided Bend Test Transverse weld test specimens shall be tested to face and root guided bend test.

d)

Hardness Test Hardness testing shall be performed on a test ring removed from the middle of the bend. Four specimens shall be prepared one from each quadrant. In case of bends fabricated from SAW pipes, one specimen shall have the longitudinal weld seam in the middle. Hardness shall be checked for base metal, weld metal and Heat Affected Zone (HAZ). 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 requalify 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 Section 8.0, tolerances on various controlling parameters.

6.0

TEST CERTIFICATES The Manufacturer shall submit the following certificates, in accordance with EN10204 3.1.C:


Page 10 of 16


a)

Test certificates of chemical analysis, mechanical tests, NDT, heat treatment, dimensional inspection and hydrotest carried out on pipe used for fabrication of bends.

b)

Test certificates of mechanical tests carried out on test bends.

c)

Test certificates of required non-destructive test inspection.

d)

Records of heat treatment for bends.

e)

Certified reports of dimensional tolerance for bends.

f)

Certificates of all other tests as required in this specification.

The certificates shall be valid only when signed by WP’s Inspector. Only those bends which have been certified by WP’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 i.e. rust, grease, etc. shall be removed from inside and outside of the bends.

7.3

A coat of antirust paint shall be applied on the bends for protection during transit and storage. The type of paint shall be as agreed upon with the owner.

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

Packaging shall be marked legibly with suitable indelible marking ink to indicate the following: a)

GGSR Product Evacuation Project

b)

Order number

c)

Package number

d)

Manufacturer's name

e)

Size (OD) and wall thickness (mm)

f)

Radius of bend (mm) and bend angle

g)

Inspection agency name or logo

h)

API 5L material grade

i)

Purchase Order No. and Item No.


Page 11 of 16


8.0

DOCUMENTATION

8.1

After placement of order, the manufacturer shall submit six copies of the 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

e)

Dimensional control procedure

f)

Pipe material used for bend manufacture

g)

Pipeline wall thinning calculation

h)

NDT procedures

i)

Quality Assurance and Quality Control

Upon successful completion of the bend manufacturing procedure qualification as per Section 4.13 of this specification, Manufacturer shall submit six copies of the qualified procedure to WP for approval. Regular production of bends shall commence only after the bend manufacturing procedure has been qualified and approved by WP. 8.2

Manufacturer shall submit one reproducible and six copies of the approved documents as stated in Clause 8.1 above.

8.3

Prior to shipment, the Manufacturer shall submit one reproducible and six copies of test certificates as listed in Clause 6.0 of this specification. Documents shall be in the English language only.

9.0

QUALITY ASSURANCE The Manufacturer shall operate a Quality System meeting the requirements of the relevant Part of ISO 9000. The Manufacturer’s Quality system shall be subject to WP approval prior to commitment to the Purchase Order. The WP reserves the right to conduct a Quality Audit at the Manufacturer’s facilities at any stage during manufacture.


Page 12 of 16


FIG 1 - TEST SPECIMEN LOCATION


Page 13 of 16


FIG. 2 – LOCATION OF WELD SEAM


Page 14 of 16


ANNEXURE 1 – ABBREVIATIONS AC AFC ANSI ASME ASTM API API RP ASME AWS AWWA BOD BOF BS CEN CPP CSWIP D DC DCS EPC ESD FCAW FED FM FMRC GMAW GTAW HAZ HDPE HF-ERW HMP HSE HV IP ISO LDS MADL MAOP

Alternating Current Approved for Construction American National Standards Institute American Society of Mechanical Engineers American Society for Testing and Materials American Petroleum Institute American Petroleum Institute Recommended Practices American Society of Mechanical Engineers American Welding Society American Water Works Association Basis of Design Basic Oxygen Furnace British Standard European Committee for Standardization Central Process Plant Certification Scheme for Welding Inspection Personnel Nominal Outside Diameter Direct Current Document Control Section Engineering, Procurement and Construction Emergency Shutdown Flux Cored Arc Welding Front End Design Factory Mutual Engineering Corporation Factory Mutual Research Corporation Gas metal Arc Welding Gas Tungsten Arc Welding Heat Affected Zone High Density Poly Ethylene High Frequency Electric Resistance Welding Hazard Management Process Health Safety and Environment Vickers Hardness Intelligent Pig International Organization for Standardization Leak Detection system Maximum Annual Daily Load Maximum Allowable Operating Pressure


Page 15 of 16


MOL MPI MSL MSS MW NACE NB NDT NFPA OD PAMS PCS PCN PFS PQR PRT PSL

Main Oil Line Magnetic Particle Inspection Mean Sea Level Manufacturers Standardization Society Molecular Weight National Association of Corrosion Engineers Nominal Bore Non Destructive Testing National Fire Prevention Association Outside Diameter Portable Arc Monitoring System Pipeline Construction Specification Personnel Certification in NDT Process Flow Scheme Procedure Qualification Record Pressure Reduction Terminal Product Specification Level

PWHT

Post Weld Heat Treatment Quality Control Quantitative Risk Assessment Right of Way Remote Terminal Unit Submerged Arc Welding Supervisory Control and Data Acquisition Synchronous Digital Hierarchy International System of Units Shielded Metal Arc Welding Supplementary requirements Nominal Thickness Transformer Rectifier Unit The Welding Institute Uniform Building Code Uninterrupted Power Supply Ultrasonic Testing (inspection) Work Practice Welding Procedure Specification Wall Thickness

QC QRA ROW RTU SAW SCADA SDH SI SMAW SR T TRU TWI UBC UPS UT WP WPS WT


Page 16 of 16

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) SPECIFICATION FOR MAJOR WATER CROSSING BY HDD


SPECIFICATION FOR MAJOR WATER CROSSING BY HDD 0435-JH0902-00-PL-SPC-0017 26 July 09


Doc. No: 0435-JH0902-00-PL-SPC-0017 Rev. B

Page 1 of 12


SYNOPSIS



DESCRIPTION

PREPARED BY

CHECKED BY

APPROVED BY

A

Issued for IDC

D. Hemnathan

S. Ishwad

J. Wallace

B

Issued for Review

D. Hemnathan

S. Ishwad

J. Wallace


DATE

26 July 09

CLIENT APPROVAL N/A

28 July 09

Page 2 of 12

DATE


TABLE OF CONTENT

1.0 2.0 3.0 4.0 5.0 6.0

SCOPE................................................................................................................4 DEFINITIONS......................................................................................................4 REFERENCES CODES AND STANDARDS.......................................................4 DESIGN & ENGINEERING .................................................................................4 CONSTRUCTION................................................................................................6 DOCUMENTATION...........................................................................................11


Page 3 of 12


1.0

SCOPE This specification defines the minimum technical requirements for the various activities to be performed by the CONTRACTOR For the engineering and construction of pipeline at major river crossings using directional drilling technique.

2.0

DEFINITIONS For this specification the following definitions shall apply: OWNER/CONSULTANT: Hindustan Petroleum Corp, Ltd. CONSULTANT: WorleyParsons, Mumbai. (WP) EPC CONTRACTOR: The Company named as such in the Contract. SHALL/MUST/IS TO BE: A mandatory requirement SHOULD: A non-mandatory requirement, advisory or recommendation

3.0

REFERENCES CODES AND STANDARDS Reference has been made in this specification to the latest edition/revision of the following codes, standards and specification. a) ANSI B 31.4 - Liquid Petroleum Transportation Piping Systems b) API RP 1102 - Steel pipeline crossing railroads and highways c) OISD 141 -

Design construction requirements for cross country hydrocarbon pipelines

4.0

DESIGN & ENGINEERING

4.1

The minimum requirement of limits of each river crossing shall be as defined in the preliminary drawings furnished by OWNER/CONSULTANT. CONTRACTOR may change the limits slightly to suit his requirement and installation technique, with prior written approval from OWNER/CONSULTANT and authorities having jurisdiction.

4.2

Within the entire limits of crosser, 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 below river bed, and at least 1.5 meters below the "specified” minimum scour level per stile


Page 4 of 12


for the river with rock sub-strata. CONTRACTOR shall establish the scour depths in consultation with authorities having jurisdiction and the same shall be approved by the OWNER/CONSULTANT. 4.3

The entry and exit points of the pipeline at ground level shall not come within the limits of crossing as defined for individual over crossings.

4.4

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.

4.5

CONTRACTOR shall submit the detailed calculations for stress analysis, overburden calculations, coating stresses etc. to OWNER/CONSULTANT for approval.

4.6

STRESS ANALYST CONTRACTOR shall determine the minimum allowable elastic bend radius for pipe from the following considerations.

4.6.1

Pipeline Maximum Longitudinal Stress During Installation. Total maximum equivalent stress in the pipeline due to tension, bending and overburden pressure down hole 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.

4.6.2

Pipeline Maximum Equivalent Stress During Final Hydrotest After installation, the pipeline shall be hydrostatically tested to a pressure of 1.5 times design pressure in accordance with Specification for Hydrostatic Testing. According to OISD 141 - the total of the following shall not exceed the SMYS of the pipe material. a) The combination stress due to expansion b) The longitudinal pressure stress c) The longitudinal bending stress due to external loads. In addition to the above, the sum of (a) shall less than 0.72 of SMYS and the sum of (b) & (c) shall not exceed 75% of SMYS. Further the equivalent stress


Page 5 of 12


computed considering the hoop & longitudinal stress shall not exceed 90% of SMYS. The equivalent stress calculation shall be based on maximum shear stress theory. 4.7

The minimum allowable radius of curvature for the pipeline shall be 1000 times the outside diameter of the pipeline.

4.8

PIPELINE CONFIGURATION ALONG THE SUPPORT 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 ton. CONTRACTOR shall also furnish a drawing of the launching ramp indicating the pipeline configuration. The distance between each roller shall also be specified.

4.9

CONRACTOR 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 OWNER/Consultant’s approval, Construction drawings shall indicate the pipeline profile with levels furnished at sufficient intervals. Details. such as, entry and exit angles, radius 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 OWNER/CONSULTANT … Before commencement of any installation works, CONTRACTOR shall furnish for OWNER/Consultant’s Approval all design calculations as specified above.

5.0

CONSTRUCTION The method of construction shall comply with all the conditions and requirement issued by Authorities having jurisdiction in the area where the work is to be performed. If no public road exists, CONTRACTOR shall arrange for access to his work area at no extra cost to OWNER/CONSULTANT. CONTRACTOR shall carry out geo-technical and hydrographical survey and the same shall be submitted to OWNER/CONSULTANT for review and approval.


Page 6 of 12


CONTRACTOR shall use three layer Polyethylene coating with 400-450 micron epoxy thickness pipes for execution of HDD. Spiral SAW line pipes shall not be used for HDD crossings. 5.1

INSTALLATION PROCEDURE CONSTRUCTOR shall, before commencing any work at site, submit for OWNER/Consultant’s approval a detailed installation procedure for each river crossing: The installation procedure as a minimum shall include the following a. Project Manpower deployment at site and co-ordination office. b. Time schedule for construction. c. Details of equipment: CONTRACTOR shall furnish the complete list of all equipment to he deployed for preparation of pipe string and installation of crossing including technical characteristics and capacity of each equipment, instrumentation, monitoring and control equipment. d. Preparation of fabrication yard and launching areas. e. Pipeline string preparation (hauling stringing, welding, etc.). f.

Pre & Post hydrostatic test procedure.

g. Method of installation covering all stages of construction, viz. Rig up, Pilot Hole, Back- reaming, Pulling. Rig Down, Back filling, etc. h. Calculations for maximum pulling force on the rig. The time schedule shall be in accordance with overall time schedule for the project. Approval by OWNER/CONSULTANT of the methods used by CONTRACT'OR shall in no way relieve CONTRACTOR from the sole responsibility for safe and satisfactory installation of the crossing, 5.2

ROW PREPARATION CONTRACTOR shall arrange additional land required for pipeline string preparation, rig set-up and launching operations. CONTRACTOR shall clear and grade the length of ROW required for installation of the land portion and drilled


Page 7 of 12


river crossing portion. CONTRACTOR shall do such grading on ROW as necessary and properly to perform the pipeline construction operations, 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 shall there be any undue interference with the normal use of the land and watercourses. 5.3

HANDLING, HAULING, STORING AND STRINGING OF PIPES AND OTHER MATERIALS CONTRACTOR shall be fully responsible for arranging and paying for storage areas. CONTRACTOR shall load, unload, transport and stock-pile the coated pipes using approved suitable means and in a manner to avoid damage to the pipe and coating. Transportation and handling of coated pipes shall also comply with requirements of API RP 5L-1. For transportation, stacking, loading and unloading shall be in accordance with Specification No. 0435-JH0902-00-PL-SPC-0005

5.4

PIPE STRING Complete pipe string shall he prepare as a single string for pulling:

5.5

LINING-UP, WELDING & FIELD JOINT COMPLETION The lining-up, welding and field joint coating completion shall be in accordance with Specification No. 0435-JH0902-00-PL-SPC-0012

5.6

INSTALLATION

5.6.1

Installation shall be taken in accordance with approved installation procedures.

5.6.2

The lateral offset of the actual exit point of the pilot hole from the calculated and theoretical exit point shall not exceed 3 to 5 metres of the length of the crossing, however the actual exit point shall not come outside the R0U limits of the pipeline. The length tolerance shall not exceed 3 to 5 metres of the crossing length, subject to the condition that the actual exit point shall be within the limits of crossing as defined in the approved drawings.

5.6.3

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.


Page 8 of 12


5.6.4

CONTRACTOR shall be responsible for maintaining the drilled hole till such time the pipeline is pulled in.

5.6.5

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 pull-back 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.

5.6.6

CONTRACTOR shall provide suitable facilities to OWNER/Consultant’s personnel to witness all stages of construction.

5.6.7

CONTRACTOR shall be responsible for the integrity of the corrosion coating and shall apply any necessary approved protective coatings. 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 tip at the exit point; b) Excavating the adjacent portion tip to and including the first held 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 coaling integrity checks shall be made be found acceptable by OWNER/CONSULTANT, the first pipe length/ joint shall be repaired and/or replaced as directed by OWNER/CONSULTANT. If the coating of second pipe length/ joint is also found damaged, CONTRACTOR shall propose further course of action and OWNER/Consultant’s instructions shall be followed. All such works shall be done at no extra cost to OWNER/CONSULTANT.

5.6.8

Before final hydrostatic testing, CONTRACTOR shall prove the diameter of the pipeline by passing a gauging (caliper) pig through the pipeline. The gauging pig shall have a diameter equal to 95% of the nominal internal diameter or the pipe. CONTRACTOR shall supply and install all temporary scraper launchers/ receivers and other equipment, piping and materials and consumables for the purpose.

5.6.9

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. CONTRATOR shall execute the work at the


Page 9 of 12


crossings as per guidelines of the authorities having jurisdiction and to the satisfaction of the OWNER/CONSULTANT. 5.6.10 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 as specified in the relevant specification and a straight pipe length of 12m, such that at the ends the top of the pipeline is minimum 1.0m below the natural ground level. 5.7

HYDROSTATIC TESTING

5.7.1

Pre- testing CONTRACTOR shall hydrostatically pre-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 hydrostatic pre-testing to a Pressure equivalent pressure of 95% SMYS as specified in this specification. After the temperature has been stabilized, the pressure shall be maintained in the pipeline for at least 6 hours and recorded by man thermograph during the test, CONTRACTOR shall check all welds for leakage. Failure, if any, during the test shall be rectified by the CONTRACTOR. The method adopted for pre-hydro testing shall be in accordance with Specification No. 0435-JH0902-00-PL-SPC-0008

5.7.2

Post Installation Hydrostatic Test Post installation hydrostatic test shall be in accordance with Specification No. 0435-JH0902-00-PL-SPC-0006

5.8

FENCING CONTRACTOR shall supply all materials and install G.I. Wire Chain link security fencing.

5.9

IDLE TIME PRESERVATION OF PIPELINE If directed by OWNER/CONSULTANT, CONTRACTOR shall supply all materials and consumables 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


Page 10 of 12


months from the date of completion of construction. Corrosion inhibitors and dosages shall be subject to OWNER/Consultant’s approval prior to use. 5.10

FINAL CLEAN UP After completion of construction, CONTRACTOR shall clear the sites of all balance material and debris to the satisfaction of OWNER/CONSULTANT and authorities having jurisdiction.

6.0

DOCUMENTATION

6.1

In addition to the documents specified elsewhere in this specification, CONTRACTOR shall submit to the OWNER/CONSULTANT six copies each of the following documents/records.

6.2

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 OWNER/CONSULTANT 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 consisting of the following:

i)

Density

ii)

type of mud and additive employed

iii)

Mixing, pumping and cleaning - Wash and drill pipe data, viz.

a)

Dimension and material properties,

b)

Data on APT classification,

c)

Type of inspection previously carried out on these pipes. Copies of the permits obtained from authorities having jurisdiction for the various works.


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Profile of the drilled hole along with the water level variations Records of l hydrostatic pre-testing and final testing Record of Non Destructive Testing of welds Clearance certificates from the land OWNER/Consultants, authorities having jurisdiction. Regarding satisfactory clean-up and restoration of pipeline ROU and work areas 6.3

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; Depth of cover to lop 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.

6.4

All documents shall be in English languagesly.


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HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) SPECIFICATION OF ISOLATION JOINT

Guru Gobind Singh Refinery Products Evacuation Project (GGSRPEP) Raman Mandi- Bahadurgarh and Raman MandiBhatinda Multiproduct Pipeline SPECIFICATION FOR ISOLATION JOINT 0435-JH0902-00-PL-SPC-0020 03 July 09


DOC NO.: 0435-JH0902-00-PL-SPC-0020 Rev. B

Page 1 of 17


SYNOPSIS



DESCRIPTION

PREPARED BY

CHECKED BY

APPROVED BY

A

Issued for IDC

D. Hemnathan

S. Ishwad

J Wallace

B

Issued for Review

D. Hemnathan

S. Ishwad

J. wallace


DATE

02 July 09

CLIENT APPROVAL N/A

03 July 09

Page 2 of 17

DATE



Introduction...................................................................................................................................... 4

2.0

Codes, Regulations and Standards ................................................................................................ 4

2.1

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

2.2

Reference Documents.....................................................................................................5

3.0

Document Precedence....................................................................................................5

4.0

Specification Deviation/Concession Control................................................................................. 5

5.0

Quality Assurance/Quality Control...................................................................................5

6.0

Materials .......................................................................................................................................... 6

7.0

Design and Fabrication................................................................................................................... 7

7.1

Mechanical ......................................................................................................................7

8.0

Electrical .........................................................................................................................9

9.0

Inspection and Tests ....................................................................................................................... 9

10.0

Test Certificates ............................................................................................................................ 10

11.0

Painting, Marking and Shipment ................................................................................................ 11

12.0

Documentation .............................................................................................................................. 11

13.0

Quality Assurance......................................................................................................................... 12

14.0

Quantity for the Project ............................................................................................................... 12

APPENDIX A - Dimension Details.......................................................................................................... 14 APPENDIX B - List Of Abbreviations.................................................................................................... 15


Page 3 of 17


1.0

INTRODUCTION This specification covers the minimum requirements for design, manufacture, testing and supply of isolation joints to be installed in pipeline/piping systems handling Petroleum Mulitiproducts for the GGSR Product Evacuation Project, Pipeline Ramanmandi to Bhantinda and Ramanmandi to bahadurghad field surface facilities. All isolation joints shall be suitable for the passage of inspection tools (pigs). The fittings shall be designed to meet the requirements of this specification and comply with specifications, standards, and codes stated in Section 2 of this document.

2.0


2.1

Codes and Standards •

ASME B 31.4

Liquid Transportation Systems of Hydrocarbons Liquid Petroleum Gas, Anhydrous Ammonia and Alcohols

•

ASME B 31.3

Chemical and Process Plant Piping System

•

ASME B 16.25

Butt Welding Ends

•

ASTM A 105

Specification for Forgings, Carbon Steel for Piping Components

•

ASTM A 234

Specification for Piping fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures

•

ASTM A 370

Mechanical Testing of Steel Products

•

ASME Sec VIII

Boiler and Pressure Vessel Code - Rules for Construction of Pressure Vessels.

•

ASME Section IX Boiler and Pressure Vessel Code –Welding and Brazing Qualification

•

API 1104

Specification for Welding Pipeline and Related Facilities.

•

MSS-SP-53

Quality Standard for Steel Castings and Forgings for valves, Flanges and Fittings and Other Piping Components - Magnetic Particle Examination Method.

•

MSS - SP - 75

Specification for High Test Wrought Welding Fittings

•

NACE RP0286

The Electrical Isolation of Cathodically Protected Pipelines


Page 4 of 17


2.2

•

EN 10204

Metallic Products - Type of Inspection Documents

•

ISO 9000-9004

Quality Management and Quality Assurance Standards.

Reference Documents •

3.0

0435-JH0902-00-PL-SPC-0003 Specification for Line Pipe

Document Precedence The CONTRACTOR shall notify the OWNER 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 the OWNER in writing before proceeding with the design or manufacture. In case of conflict, the order of precedence shall be:

4.0

•

Equipment Data Sheet(s)

•

Equipment Narrative Specification

•

Design General Specifications and Standards

•

Industry Codes and Standards SPECIFICATION DEVIATION/CONCESSION CONTROL Any technical deviations to the Specifications and its attachments including, but not limited to, the Data Sheets and Narrative Specifications shall be obtained by the CONTRACTOR only through CONCESSION REQUEST format. CONCESSION REQUESTS require Owner’s review/approval prior to implementation of the proposed changes. Technical changes implemented prior to OWNER approval are subject to rejection.

5.0

Quality Assurance/Quality Control The VENDOR shall have in effect at all times a QA/QC program which clearly establishes the authority and responsibility of those in charge of the quality system. Persons performing quality functions shall have sufficient and well defined authority to enforce quality requirements that initiate, identify, recommend and provide solutions to quality problems and verify the effectiveness of the corrective action. A copy of the Vendor’s QA/QC program along with ISO 9000 certification shall be submitted to the WP/HPCL for review and concurrence prior to award.


Page 5 of 17


The VENDOR shall identify in purchase documents to its SUBVENDORS all applicable QA/QC requirements imposed by the owner, and shall ensure compliance thereto. The VENDOR shall submit certified reports of production tests as soon as the tests are completed satisfactorily. The OWNER reserves the right to review QA/QC program and inspect materials and workmanship at all stages of manufacture and to witness any or all tests. The VENDOR shall provide the CONTRACTOR with a copy of its Manufacturing and Inspection Plan for review and inclusion of any mandatory OWNER witness points 15 days after award but prior to the pre-inspection meeting. 6.0

MATERIALS Material for the pressure containing parts of the isolation joints shall be as indicated in the Isolation Joint Data Sheet. The Material Grade and Dimensions of the connecting line pipe shall be as per pipeline spec B2 and C2 as specified in the Document 0435JH0902-00-PI-SPC-0001. The Material of the Isolation joint end connections shall be suitable for and compatible with the line pipe into which the isolation joints are to be welded. Other parts shall be as per Manufacturer's standard, which shall be subject to approval by Purchaser. The materials of construction shall be suitable for the non sour fluid composition given below clause 7.1. Acceptable material for the pressure containing parts excluding pups shall be ASTM A105, ASTM A234, conforming to MSSSP-75 or equivalent. Pup material shall be the same as that of line pipe material and shall comply with the document 0435-JH0902-00-PI-SPC-0001. Carbon steel used in the manufacture of isolation joints shall be fully killed. In addition to the requirements of the material specifications, chemical composition of each heat steel used in the manufacture shall be identical to the pipeline material as provided in project specification 0435-JH0902-00-PI-SPC-0001. Each heat of steel used for the manufacture of flanges and fittings shall have carbon equivalent not exceeding 0.41 (SMLS) & 0.39 (SAW), based on check analysis, calculated as per the following formula:

CE = C +

Mn + 6

Cr + Mo + V 5

+

Ni + Cu 15

Charpy V-notch test shall be conducted at 0°C for each heat of steel used in manufacture of pressure containing parts of isolation joints. Test procedure shall conform to ASTM A 370. The Charpy impact test specimens shall be taken parallel to the axis of the fitting (i.e. longitudinal specimen shall be taken). The average absorbed impact energy value of three full sized specimens of base metal weld metal and HAZ shall be 52 J and minimum impact energy value for any one specimen shall not be less than 39 J. No specimen shall exhibit less than 80 percent shear area.


Page 6 of 17


All forgings shall be furnished either in normalized, normalized & tempered or quenched & tempered condition. The maximum hardness of base metal, weld metal and HAZ of all pressure containing parts shall be 325 HV10. Hardness test shall be carried out as per ASTM A370, for each heat of steel used. The isolation material and the filler materials shall be suitable for long term exposure to the transported fluid at the design pressure and temperature. 7.0

DESIGN AND FABRICATION

7.1

Mechanical The Design Conditions of the pipeline into which the Isolation joint is to be installed shall be fully specified in the Requisition and Data sheets for the isolation joints. This is to include pressure, temperature. Manufacturer shall furnish the detail load calculation for hydro test bending fatigue test for Purchaser’s approval. Data of the process fluid characteristics: Property

MS EURO III & IV

HSD EURO III & IV

SKO

ATF

NAPTHA

Density Kg/m3 @ 15 Deg C

720-775

820-860

775-840

775-840

650-740

Viscosity(cST) at Amb. Temp

0.51 @ 38 Deg, C

2-5 @ 40 deg, C

0.9 @ 100 Deg, C

1.18 @ 37.8 deg C

0.521 @ 37.8 deg C

RVP, Kg/cm2 A, Max. @ 38deg C

0.61

0.1

0.3

0.3

0.7

Isolation joints shall be of integral type, fabricated by welding and with pups on either side as shown in Annexure 1. Bolted and threaded joints are not permitted. Isolation 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 + Axial Force (F).

The Axial force (F) shall be calculated as under: F Where,

=


0.1 x S x A

Page 7 of 17


0.1 S A

= = =

factor from ASME VIII Div.1 SMYS of connected pipe Metal cross-sectional area of connected pipe.

The allowable stress in this case shall be less than or equal to (f) x SMYS of the isolation joint material, where (f) is the Design Factor as specified in Data Sheet. Case II:

Hydrostatic Test Pressure

The hoop stress in this case shall be less than or equal to 0.9 x SMYS (for design code 31.4). Test pressure shall be at least 1.5 times of design pressure (for design code 31.3) of isolation joint material. The joint shall be capable of withstanding, as a minimum, the sustained and displacement loads (axial, bending and torsion) that the linepipe is capable of. All design parameters shall be as per Isolation Joint Data Sheet. Detailed calculations shall be submitted for Purchaser approval. In case any computer software is used, the theory employed and the validation manual shall be submitted to Purchaser. Isolation joints shall not restrict the pipeline bore and shall allow free passage of scraper and instrumented pigs. See also 4.1.10. Isolation joint design and materials shall be capable of being vacuum tested to 1 millibar. The joints between pipe pup pieces and main forging shall be full penetration butt weld type. Butt weld ends shall be prepared as per ANSI B 16.25. However, end preparation for butt welding ends having unequal thickness with respect to connecting pipe, shall be as per ASME B.31.4. Isolation joints shall be principally for aboveground application. In the event that underground installation is specified, the Isolation Joint Data Sheet shall incorporate the necessary modifications. All welds shall be made by welders and welding procedures qualified in accordance with the provisions of ASME Section IX. The procedure qualification shall include hardness test for all sizes and shall meet the requirements respective code. Repair welding on parent metal is not allowed. Repair of welds shall be carried out only after specific approval by Purchaser's Inspector for each repair. 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.


Page 8 of 17


The tolerances on internal diameter and out of roundness at the ends shall be as per the applicable connected pipe specification. The internal diameter shall be at least the internal diameter of the matching pipeline.

8.0

Electrical The average dielectric strength of the isolation joint shall be a minimum of 15 kV. Two cleats as shown in Annexure 1 shall be provided on the pups on either side of the isolation joint for connecting cables for measurement / shorting purposes. Cleats shall be attached to the pup pieces by welding.

9.0

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: All isolation joints shall be visually inspected. Dimensional checks shall be carried out as per the approved drawings. Chemical composition and mechanical properties including hardness shall be checked as per relevant material standards and this specification, for each heat of steel used. Non-destructive inspection of isolation joints shall be carried out as given below: NDT of all welds shall be carried out as per Owner’s approved QA/QC Requirement. Extent of NDT and acceptance criteria shall as per the requirements of this specification. All butt and repair welds of pressure containing parts shall be examined 100% by radiography. Acceptance limits shall be as per API 1104. Welds, which in Owner’s Inspector's opinion cannot be inspected by radiographic methods, shall be checked by ultrasonic or magnetic particle methods. Acceptance criteria shall be as per ASME Section VIII Div 1 2007 Edition Appendix 12 and Appendix 6 respectively. All forgings shall be wet magnetic particle inspected on 100% of forged or extruded surfaces. Method and acceptance shall be comply MSS-SP-53. The end section of the components to be welded shall be 100% ultrasonically tested for lamination type defects for a distance of 50 mm from the ends prior to being prepared. The presence of any discernible defects shall be cause for rejection.


Page 9 of 17


All fillet welds of thickness < 6 mm shall be examined 100% by Magnetic Particle Inspection and ≥ 6 mm shall be examined 100% by angle probe UT. Acceptance criteria for MPI and UT shall be as per ASME Sec. VIII Div 1 2007 Edition Appendix 12 and Appendix 6 respectively. Isolation joints shall be hydrostatically tested to a pressure as indicated in the Isolation Data Sheet in the following manner: 5 minutes at the hydrotest pressure Reduce to zero Repeat above procedure twice Manufacturer shall conduct both hydrostatic fatigue (combined bending) and torsional test. The test pressure shall be 80% of hydrostatic pressure test for 1 hour duration. This test shall be carried out for 5 cycles, holding for 5 minutes for each stage. After hydrostatic test, isolation joints shall be tested with air at 5kg/cm² for 10 minutes. The tightness shall be checked by immersion or with a frothing agent. No leakage will be accepted. Dielectric Test • Isolation resistance of each isolation joint shall be at least 25 megaohms, when checked with 500 - 1000 V DC. • In addition, prior to and after hydrotesting, each isolation joint shall be tested for dielectric integrity at 5000 V AC, 50 Hz for one minute and the leakage current before and after the hydrostatic shall be equal. Testing time, voltage and leakage shall be recorded and certified. No repairs shall be permitted to the isolation joints failed in the above-mentioned test. Purchaser's Inspector shall also perform stage wise inspection and witness tests 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 by the Purchaser's Inspector. 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.

10.0

TEST CERTIFICATES Manufacturer shall submit the following certificates in accordance with EN10204 3.1 B (Class III)


Page 10 of 17


•

Test certificates relevant to the chemical analysis and mechanical properties including hardness of the materials used for the manufacture as per relevant and this specification

•

Test reports on non-destructive testing.

•

Test certificates for hydrostatic and air tests.

•

Test reports of heat treatment carried out.

•

Test reports of electrical tests The Certificates shall be valid only when signed by the Purchaser’s Inspector. Only those Joints which have been certified by the Purchaser’s Inspector shall be dispatched from the Manufacturer’s works.

11.0

PAINTING, MARKING AND SHIPMENT After all inspection and test required have been carried out, isolation joint surface shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion resistant paint. Painting including the surface preparation shall be comply Project Specification, for External Painting and Protective Coatings 0435-JH0902-00-PISPC-0003. Isolation joints shall be marked with indelible paint with the following data: • • • • • •

GGSR Product Evacuation Project Manufacturer's name Suitable for____ inch diameter pipeline End thickness in mm Material P. O. Number and Tag No’s. (Refer Data Sheet)

Isolation joints shall be suitably protected to avoid any damage during transit. Metallic or high-impact plastic bevel protectors shall be provided for weld ends. Only those isolation joints which have been inspected and certified by Purchaser's Inspector shall be shipped.

12.0

DOCUMENTATION After placement of order, the Manufacturer shall submit, but not limited to, the following documents for Purchaser's approval.


Page 11 of 17


• • •

Fabrication drawings, material details and relevant calculations for pressure containing parts. Welding, Heat Treatment, Inspection and Testing Procedures. Quality Control Manual and Quality Control Plan.

Manufacture of isolation joints shall commence only after approval of the above documents. Once approval has been given by Purchaser, any changes in design, material and method of manufacture shall be implemented only after subsequent and specific approval of the Purchaser in writing. On receipt of written approval, the Manufacturer shall submit to Purchaser all approved documents as listed in MR. Prior to shipment, the manufacturer shall submit test certificates as listed in Clause 6.0 of this specification. Documents shall be in the English language only. 13.0

QUALITY ASSURANCE The Manufacturer shall operate a Quality System meeting the requirements of the relevant Part of ISO 9000. The Manufacturer shall ensure that his sub-suppliers operate a quality system meeting the specified conformance criteria to ISO 9000. The Manufacturer’s quality system shall be subject to the Purchaser’s approval prior to commitment to a Purchase Order. Major sub-suppliers shall be subject to identical approvals. The Purchaser reserves the right to conduct a Quality Audit at the Manufacturer’s/sub-supplier’s facilities at any stage during manufacture.

14.0

QUANTITY FOR THE PROJECT The quantity to be considered for quotation shall be as per the following table. The quantity to be procured will be finalized before the placement of order.

Tag No

Size

Rating

10-IJ01

10”

300 #

20-IJ01

10”

300 #


Minimum Wall thk (mm) for main size

Mating pipe material

Quantity

6.4

API 5L Gr. B, PSL 2

1

6.4

API 5L Gr. B, PSL 2

1

Page 12 of 17


10-IJ02

18”

600 #

7.9

60-IJ01

18”

600 #

7.9

70-IJ01 70-IJ02

18”

600 #

7.9

API 5L Gr. X60, PSL 2 API 5L Gr. X60, PSL 2 API 5L Gr. X60, PSL 2

1 1 2

The barred tee bevelled end thickness shall be at least equal to mating pipe wall thickness as mentioned in the above table.

The technical offer shall be complete in all respects as requested in this document. Incomplete offer will not be considered for technical evaluation.


Page 13 of 17


APPENDIX A - DIMENSION DETAILS

ISOLATION JOINT


Page 14 of 17


APPENDIX B - LIST OF ABBREVIATIONS

List Of Abbreviations AADL AC ANSI ASME ASTM API API RP AWS BOD BOF BS BVS C CE CEN CP CR CU DC DWTT EIA EPC ESD FBE FEED HAZ HDPE HF-ERW HMP HSE HV ISO J KPH KV LDS LSBD MADL

Average Annual Daily Load Alternating Current American National Standards Institute American Society of Mechanical Engineers American Society for Testing and Materials American Petroleum Institute American Petroleum Institute Recommended Practices American Welding Society Basis of Design Basic Oxygen Furnace British Standard Block Valve Station Carbon Carbon Equivalent European Committee for Standardization Cathodic Protection Chromium Copper Direct Current Drop Weight Tear Tests Environmental Impact Assessment Engineering, Procurement and Construction Emergency Shutdown Fusion Bonded Epoxy Front End Engineering Design Heat affected zone High Density Poly Ethylene High Frequency Electric Resistance Welding Hazard Management Process Health Safety and Environment Hardness-Vickers International Organization for Standardization Joules Kilometre Per Hour Kilo-volt Leak Detection system Limit State Based Design Maximum Annual Daily Load


Page 15 of 17


MAOP MN MO MPI MSL MSS MW NACE NB NDT NFPA NI OD PCS PE PFS PO PQR PRT PSL QA QC QRA ROW RTU SCADA SI TRU UPS UT V WP WPS WT

Maximum Allowable Operating Pressure Manganese Molybdenum Magnetic Particle Inspection Mean Sea Level Manufacturers Standardization Society Molecular Weight National Association for Corrosion Engineers Nominal Bore Non Destructive Testing National Fire Prevention Association Nickel Outside Diameter Pipeline Construction Specification Polyethylene Process Flow Scheme Purchase Order Procedure Qualification Record Pressure Reduction Terminal Product Specification Level Quality Assurance Quality Control Quantitative Risk Assessment Right of Way Remote Terminal Unit Supervisory Control and Data Acquisition International System of Units Transformer Rectifier Unit Uninterrupted Power Supply Ultrasonic Testing (inspection) Vanadium Work Practice Welding Procedure Specification Wall Thickness


Page 16 of 17


APPENDIX C TABLE OF COMPLIANCE The Vendor shall confirm below their acceptance of all the clauses contained in the specification or otherwise make clarifications or exceptions that shall be noted below:CLIENT : Hindustan Petroleum Corp, Ltd. REF. NO.: CONFORMS ALTERNATIVE SPEC. REF NO. Y/N Y/N 1.0

VENDOR REF. NO. CLARIFICATION

2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 13.0 14.0 Appendix A Appendix B Appendix C

Vendor shall give the compliance in the column provided.


Page 17 of 17

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) STANDARD SPECIFICATION FOR PIPE LINE MARKER


STANDARD SPECIFICATION FOR PIPE LINE MARKER

0435-JH0902-00-PL-SPC-0023 7th August 09


Doc. No.: 0435-JH0902-00-PL-SPC-0023 Rev. B

Page 1 of 6


SYNOPSIS



DESCRIPTION

PREPARED BY

CHECKED BY

APPROVED BY

A

Issued for IDC

D. Hemnathan

S. Ishwad

B

Issued for Review

D. Hemnathan

S. Ishwad


DATE

CLIENT APPROVAL

06 August 09

N/A

J. Wallace

KMN Pillai

07 August 09

Page 2 of 6

DATE


TABLE OF CONTENTS

1.0

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

2.0

REFERENCE CODES..................................................................................................... 4

3.0

GENERAL....................................................................................................................... 4

4.0

AERIAL MARKERS ........................................................................................................ 5

5.0

KILOMETER MARKERS ................................................................................................ 5

6.0

PIPELINE WARNING SIGN ............................................................................................ 5

7.0

ROU BOUNDARY MARKER .......................................................................................... 5

8.0

DIRECTION MARKERS.................................................................................................. 6

9.0

NAVIGABLE WATERWAY PIPELINE CROSSING WARNING SIGN ............................ 6

10.0

SPECIAL MARKERS .................................................................................................. 6


Page 3 of 6


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 Owner and CONTRACTOR.

1.3

Hereafter Refer Owner – Hindustan Petroleum Corporation Ltd. And WP – Worley Parsons, Mumbai

2.0

REFERENCE CODES Reference has been made in this specification to the latest edition of the following codes: 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 WP/HPCL.

3.2

The pipeline markers shall be fabricated and installed in accordance with the WP standard drawings included herein. Before start of fabrication of the markers, the CONTRACTOR shall prepare and submit for WP/HPCL'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. 0435-JH0902-00-PL-SPC-0003).

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.


Page 4 of 6


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 WP/HPCL. Refer WP Standard Drawing No. 0435-JH0902-00-PL-DRD-0001-10-1B 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 WP/HPCL. A kilometer marker is not required, if the relative distance between its location and any pipeline warning sign is less than 200 meters. Refer WP Standard Drawing no. 0435-JH0902-00-PL-DRD-0001-10-1C for details.

6.0

PIPELINE WARNING SIGN Pipeline Warning Sign shall in general be installed at: • • • • • • •

National and State Highway crossings Other Road Crossings Railway Crossings Minor Water Crossings (less than 15 m width) Minor Water Crossings (less than 15 m width) Major Water Crossings Vale Station

2 Nos. min. 1 No. min 2 Nos. min. 1 No. min. 2 Nos. min. 2 Nos. min 1 No. min.

And or any other location as shown in the approved drawings and as directed by the WP. Pipeline Warning Sign shall identify the existence of the pipeline and display the name of the Owner (HPCL), with an emergency telephone number, as shown in WP Standard Drawing No. 0435-JH0902-00-PL-DRD-0001-10-2C. 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


Page 5 of 6


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 WP Standard Drawing No. 0435-JH0902-00-PL-DRD-000110-2B for details. 8.0

DIRECTION MARKERS Direction Markers as shown in WP Standard Drawing No. 0435-JH0902-00-PL-DRD0001-10-1A 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 WP Standard Drawing No. 0435-JH0902-00-PL-DRD-0001-10-2A. 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.

10.0

SPECIAL MARKERS As directed by WP/HPCL, special markers shall be installed at location where following changes take place: • Change in pipeline diameter and wall thickness. • Change in type of pipe 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 100 m


Page 6 of 6

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) STANDARD SPECIFICATION FOR DOCUMENTATION FOR PIPELINE CONSTRUCTION

Guru Gobind Singh Refinery Products Evacuation Project (GGSRPEP) Raman Mandi- Bahadurgarh and Raman MandiBathinda Multiproduct Pipeline

STANDARD SPECIFICATION FOR DOCUMENTATION FOR PIPELINE CONSTRUCTION

0435-JH0902-00-PL-SPC-0025

06 August 2009



Page 1 of 9


SYNOPSIS Disclaimer This report has been prepared on behalf of and for the exclusive use of Hindustan Petroleum Corporation Limited (HPCL), and is subject to and issued in accordance with the agreement between Hindustan Petroleum Corporation Limited (HPCL) and WorleyParsons. WorleyParsons accepts no liability or responsibility whatsoever for it in respect of any use of or reliance upon this report by any third party. Copying this report without the permission of Hindustan Petroleum Corporation Limited (HPCL) or WorleyParsons is not permitted.


DESCRIPTION

A

Issued for IDC

B

Issued for Review

PREPARED BY

D Hemanathan D Hemanathan

CHECKED BY

S.Ishwad

S.Ishwad


APPROVED BY

DATE

J Wallace

2nd August 09

KMN Pillai

6th August 09

CLIENT APPROVAL

DATE

N/A

N/A

Page 2 of 9


TABLE OF CONTENTS

1.0

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

2.0

RECORDS ...................................................................................................................... 4

3.0

AS-BUILT DRAWING AND PIPE BOOK ........................................................................ 6


Page 3 of 9


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 WorleyParsons (WP) / HPCL at intervals as described in this specification and as directed by the WP.

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 WP/HPCL's record, review or approval as per the requirements of all other specifications included in the CONTRACT between the HPCL 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 HPCL and CONTRACTOR.

2.0

RECORDS The CONTRACTOR shall submit daily, weekly, monthly and after completion, to the WP/HPCL, various records and reports for WP/HPCL's documentation purpose during and immediately after the construction. This shall as a minimum include, but not limited to the following:

2.1

Daily • • • • • • • • •

2.2

Separate progress reports of all crews Daily welding results and repairs Actual weather conditions Application for deviations, if any Accidents Damages Activities required from WP/HPCL Materials Receipts Urgently required materials

Weekly • • • • •

Up-to-date list of confirmed Site Instructions issued by WP/HPCL Materials 'taken over' Materials defects and repairs Outstanding activities of WP/HPCL List of installed markers, chainage


Page 4 of 9


• • • • • • • • • 2.3

Monthly •

2.4

Required approval form WP 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

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 WP/HPCL 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. Minutes of meeting with WP/HPCL 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


Page 5 of 9


• • • • • • • • • • • • • • •

Pipe and welding book Material records and Accounting book Reports Material tests (coating, welding, painting) Computerised Potential Logging Test Water samples Cleaning, Pigging Report before hydrostatic test Hydrostatic test Calibration test Blasting trials Equipment certificates (dead weight tester, instruments, vessels, equipment) Manuals Major water crossings Waster disposal Disposal of water after hydrostatic test.

2.5

The CONTRACTOR shall submit to WP/HPCL, 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 WP/HPCL. 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 WP and submit to WP/HPCL. Upon completion of the work, the CONTRACTOR shall submit edited master tape plus six copies of video recording in VHS formats or any other format ordered by the HPCL. The duration of video recording shall be of 1/2 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 WP/HPCL 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)


Page 6 of 9


• •

Isometric drawings of installations Special installation.

Further CONTRACTOR shall prepare a pipe Weld Book. If required by the WP/HPCL, the CONTRACTOR shall update the diskettes for drawings issued for construction of the job. 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 WP/HPCL 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 "Asbuilt" information as well as one complete set of CD ROM containing "As-built" drawings shall be handed over to WP/HPCL. The CONTRACTOR shall prepare and submit a specimen of the layout of the drawings for WP'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-signallers). Location of ROU and of pipeline with respect of ROU. Type of soil. Type of rock.


Page 7 of 9


• • • •

Type of blasting and ripping Sand padding. Type of road pavement. Details of bank protection, number of insulators, seals.

The CONTRACTOR shall also prepare isometric drawings of installation (facilities) within terminals and stations 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 WP/HPCL 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 Date of stringing Data of welding Direction of working Weld number Welder number Type of welding, electrodes, diameter of electrodes etc. Heat treatment


Page 8 of 9


• • •

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 Wp/HPCL 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/Office 2000)

b. Drawings

AutoCAD 2004 and above.

For the purpose of preparation of As-built drawings, CONTRACTOR shall update the "Issued for Construction" drawings issued by the WP. It shall be the CONTRACTOR's responsibility to convert the drawings furnished by the WP in hard copy into CAD drawings including scanning, digitising and converting the drawings into a suitable format compatible with the AutoCAD 2004 and above. As-built drawings shall be prepared only on AutoCAD.


Page 9 of 9

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) SPECIFICATION FOR PIG LAUNCHER AND RECEIVER AND END CLOSER FOR INTELLIGENT PIGGING


SPECIFICATION FOR PIG LAUNCHER AND RECEIVER AND QUICK OPENING FOR INTELLIGENT PIGGING

0435-JH0902-00-PL-SPC-0031 26 June 09


DOC NO.: 0435-JH0902-00-PL-SPC-0031 Rev. 0

Page 1 of 20


SYNOPSIS



DESCRIPTION

0

Issued for Design

PREPARED BY

D. Hemnathan

CHECKED BY

S. Ishwad


APPROVED BY

J. Wallace

DATE

26 June 09

CLIENT APPROVAL

DATE

YES A.K.Jain

24/06/09

Page 2 of 20



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

1.1

Introduction ......................................................................................................................4

1.2

Specific Definitions ...........................................................................................................4

2.0

CODES, REGULATIONS AND STANDARDS ..................................................................4

2.1

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

2.2

Reference Documents......................................................................................................6

2.3

Document Precedence .....................................................................................................6

2.4

Specification Deviation/Concession Control .....................................................................6

3.0

scope of supply ............................................................................................................. 7

4.0

QUALITY ASSURANCE / QUALITY CONTROL ............................................................ 7

5.0

DESIGN REQUIREMENTS ............................................................................................. 8

5.1

System Components ........................................................................................................9

5.2

Barrels............................................................................................................................10

5.3

Quick Opening End Closures .........................................................................................11

5.4

Supports.........................................................................................................................12

5.5

Design Code ..................................................................................................................12

5.6

Design Pressure.............................................................................................................13

5.7

Design Temperature.......................................................................................................13

5.8

Auxiliary Equipment........................................................................................................13

5.9

Welding ..........................................................................................................................14

5.10

Inspection and Testing ...................................................................................................14

6.0

SURFACE PREPARATION AND PAINTING................................................................ 16

7.0

FINAL INSPECTION ..................................................................................................... 17

8.0

PREPARATION FOR SHIPMENT................................................................................. 17

9.0

CONTRACTOR (VENDOR) DATA REQUIREMENT LIST (VDRL) ............................... 18

10.0

SPARES ....................................................................................................................... 19


Page 3 of 20


1.0

SCOPE

1.1

Introduction This specification defines the minimum requirements for the Design, Fabrication, Inspection, Testing and Supply and Guarantee of Pipeline Pig Traps and quick opening devices along with pig handling facility for non sour service application. These are to be procured for the GGSR Products evacuation Project by HPCL. This specification supplements the codes and standards listed in Section 2 and the Equipment Specifications, Data Sheets and Drawings referenced herein.

1.2

Specific Definitions CONCESSION REQUEST

–

A deviation requested by the CONTRACTOR or SUBCONTRACTOR, usually after receiving the contract package or purchase order. Often, it refers to an authorization to use, repair, recondition, reclaim or release materials, components or equipment already in progress or completely manufactured, but which does not comply with COMPANY requirements. A CONCESSION REQUEST is subject to OWNER’S approval.

MANUFACTURER/ SUPPLIER/VENDOR (CONTRACTOR)

–

The party which manufacturers and/or supplies equipment, technical documents/drawings and services to perform the duties specified by OWNER

SUBCONTRACTOR

–

The party(s) which carry(s) out all or part of the design, procurement, installation and testing of the System(s) as specified by the CONTRACTOR

2.0


2.1

Codes and Standards CONTRACTOR shall meet or exceed the requirements of the latest edition of the following codes, regulations and standards, except as superseded herein. In case where more than one code, regulations or standard apply to the same condition, the most stringent shall be followed. In the event of conflict between this specification and other


Page 4 of 20


specifications or correspondence, the OWNER shall be consulted and a ruling in writing, shall be obtained before any work is started. The following codes and standards, to the extent specified herein, form a part of this specification. When an edition date is not indicated for any code or standard, the latest edition in force at the time of Contract award shall apply: American Petroleum Institute (API) API SPEC 5L API SPEC 1104

Specification for Line Pipe Welding of Pipeline and Related Facilities

American Society of Mechanical Engineers (ASME) ASME B16.5 ASME B16.9 ASME B31.4 ASME Section V ASME Section VIII ASME Section IX

Pipe Flanges and Flanged Fittings Factory-Made Wrought Steel Butt Welding Fittings Pipeline transportation systems for liquid hydrocarbons and other liquids Non-Destructive Examination Pressure Vessels, Division I Welding and Brazing Qualifications

American Society for Testing and Materials (ASTM) ASTM E 94 ASTM E 165 ASTM A 105 ASTM A 234 ASTM E 709

Standard Guide for Radiographic Testing Standard Test Method for Liquid Penetrant Examination Forgings, Carbon Steel for Piping Components Including Flanges, Fittings and Valves Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures Practice for Magnetic Particle Examination

Manufactures Standardisation Society for the Fitting Industry, Inc. (MSS) MSS SP 25 MSS SP 44 MSS SP 75

Standard Marking System for Valves, Fittings, Flanges Steel Pipeline Flanges Specification for High Test Wrought Butt Welding Fittings

American Society of Non-Destructive Testing (ASNT) RPSNT-TC-IA

Personnel Qualification Destructive Testing


and

Certification

in

Non-

Page 5 of 20


International Standards Organisation (ISO) ISO 9000 EN 10204 2.2

Quality Management and Quality Assurance Standards Guidelines for Selection and Use Inspection Documents for the Delivery of Metallic Products

Reference Documents The following general specification shall be used in conjunction with this specification where applicable: Project Specifications

2.3

0435-JH0902-00-PL-SPC-0011

Specification for Pipeline Welding

0435-JH0902-00-PL-SPC0002/0003/0004 0435-JH0902-00-PL-SPC-0021


0435-JH0902-00-PI-SPC-0003

Specification Coatings

Specification for Pipeline Barred Tees for

External

Painting

&

Protective

Document Precedence The CONTRACTOR shall notify the OWNER of any conflict between this specification, the related Data Sheets, the Codes, Standards and any other Specifications referenced herein. Resolution and/or interpretation precedence shall be obtained from the OWNER in writing before proceeding with the Design or Manufacture. In case of conflict, the order of Precedence shall be: • • • • •

2.4

Purchase Order Equipment Data Sheet(s) Equipment Narrative Specification Project Specifications and Standards Referenced Industry Codes and Standards

Specification Deviation/Concession Control Any technical deviations to this specification and its attachments including, but not limited to, the Data Sheets and Narrative Specifications shall be obtained by the CONTRACTOR only through the Concession Request Procedure. CONCESSION REQUESTS require OWNER review/approval prior to implementation of the proposed


Page 6 of 20


changes. Technical changes implemented prior to OWNER approval are subject to rejection. 3.0

SCOPE OF SUPPLY The Pig Launchers & Receivers shall be designed and manufactured as per this specification and data sheets attached with the Material Requisition for pig Launchers and Receivers. The CONTRACTOR shall be fully and solely responsible for the mechanical design, procurement of raw material, fabrication, assembly, inspection and testing, external coating/painting, documentation and preparation for shipment and supply of the equipment as described in this specification. The CONTRACTOR shall also be responsible for the performance of all equipment covered under this specification. The CONTRACTOR shall furnish all components and ancillary equipment necessary to meet the requirements of data sheets, codes and standards in this specification. Each Pig Trap shall be complete with the following: 1.1.1. 1.1.2. 1.1.3. 1.1.4. 1.1.5. 1.1.6. 1.1.7. 1.1.8. 1.1.9.

Pig trap quick opening end closure as described in the data sheet Saddle supports (with PTFE Gaskets for sliding support) Appurtenances as per the data sheet Pig handling system comprising of a jib crane and Pig handling trolley Name plate and earthing lug (2 Nos.) Painting & Coating of equipment as specified Special tools and tackles Documentation as specified Spares

Exclusions: • • 4.0

Civil Foundation design and construction Earthing

QUALITY ASSURANCE / QUALITY CONTROL The CONTRACTOR shall have in effect at all times a QA/QC program which clearly establishes the authority and responsibility of those incharge of the quality system. Persons performing quality functions shall have sufficient and well defined authority to enforce quality requirements that initiate, identify, recommend and provide solutions to quality problems and verify the effectiveness of the corrective action.


Page 7 of 20


A copy of the CONTRACTOR’S QA/QC program shall be submitted to the OWNER with its quotation for OWNER’S review and concurrence prior to award. If CONTRACTOR’s QA/QC program and facility, where the work is to be performed, is ISO 9000 certified, then only a copy of the CONTRACTOR’s ISO 9000 certificate is required. The CONTRACTOR shall identify in purchase documents to its SUBCONTRACTOR all applicable QA/QC requirements imposed by the CONTRACTOR, and shall ensure compliance thereto. On request, CONTRACTOR shall provide objective evidence of its QA/QC surveillance of its Subcontractor’s activities. The CONTRACTOR shall submit certified reports of production tests as soon as the tests are completed satisfactorily. The OWNER reserves the right to inspect materials and workmanship at all stages of manufacture and to witness any or all tests. The CONTRACTOR shall provide the OWNER with a copy of its Manufacturing and Inspection Plan for review and inclusion of any mandatory OWNER witness points 30 days after award but prior to the preinspection meeting. 5.0

DESIGN REQUIREMENTS Compliance with the provisions of this specification does not relieve CONTRACTOR of his responsibility to furnish equipment and accessories of a proper mechanical design in accordance with good working practices to meet the design conditions specified in this document. The design and completed fabrication dimensions of the Pig Launchers and Receivers shall enable safe and effective pipeline Scraping (pigging) operations to be performed using either spheres, Scraper cleaning Scrapers (pigs) and specialist intelligent type Scrapers through liquid, gas and multi-phase hydrocarbon pipelines. Quick Opening Device of the pig launcher and Receiver shall be design as per ASME Sec. VIII Div.I. And supplied by authorized supplier from Pigging Product & services, authorized suppliers are listed below. • • • • • •

G D Closer System USA, Houston, Texas P J Services Singapore PSI Pipeline Services International GmbH & Co. T D Williamson UK Vee Kay Vikram & Co. Ahmadabad, India Multi Tech Faridabad, Delhi


Page 8 of 20


The Pig Launchers and Receivers shall be designed in accordance with the design parameters of this specification, to accommodate intelligent Pig from any of the reputed Indian and International suppliers following are the Indian/International suppliers: • • • • • • • 5.1

TD Williamson Linalog-Tuboscope Pipetronix British Gas H. Rosen Vetco Vee Kay Vikram & Co.

(USA) (USA) (Germany) (UK) (Netherlands) (USA) (India)

System Components The Scraper Launchers and Receivers shall have an appurtenance for by-pass or kicker line that is approximately one third of the pipeline size, as shown in the P & IDs and Data Sheet. The kicker line nozzle shall be provided with bars according to the Specification for pipeline barred tee (0435-JH0902-00-PL-SPC-0021). For kicker line nozzle the joint shall be set-in type and for other nozzles (weldolets) the joints shall be set-on type. Further system components shall include: • • • • • • •

Quick opening end closure Utility connections Kicker connections Vent / drains Pressure instrument connections Any other component / connection required as per P&ID. For Pig signaler, Signal to be taken from Control Room.

The Scraper Launchers and Receivers (including all components) shall be designed and suitable for service in hot, unshaded environment with climatic conditions. 5.1.1

Material of Construction The Scraper Traps shall be manufactured with materials fully compatible with the connecting line pipe. The minor barrel shall be manufactured from material to the same Specification as the connecting line pipe. The major barrel and eccentric reducer may be manufactured from alternative materials that are completely weldable to the pipeline material. Any alternative materials shall be subject to Owner’s approval. All permanent materials and fabrication welds shall meet the requirements of the connecting Line Pipe Specification.


Page 9 of 20


All permanent materials and fabrication welds shall meet the requirements of Project Specifications listed under Section 2.2. Scraper Trap material shall be subject to the same Charpy V-notch tests as required in the specification for the connecting line pipe. 5.2

Barrels For pipelines less than 20" diameter, the major barrel diameter shall be 2" greater than the pipeline diameter. For pipelines with a diameter of 20" and up to and including 46”, the oversize shall be 4", For this project specific barrels sizes are given below 18” Pig Launcher – Barrel 22” 18” Pig Receiver – Barrel 24” 10” Pig Launcher – Barrel 12” 10” Pig Receiver – Barrel 14” The wall thickness and internal diameter of the minor barrel shall match that of the connecting line pipe. The barrel shall be designed to accommodate the longest Scraper that may be used (i.e. an intelligent Scraper) plus a margin of 10 percent. The reducer connecting the major and minor barrels shall be the eccentric type for horizontal Scraper Traps and manufactured with dimensions in accordance with MSS SP75. The eccentric reducer will maintain the Scraper Trap bottom at the same level over its entire length. The barrel on horizontal Receivers shall be sloped (typically 1 in 100) towards the quick opening end closure to improve draining of liquids from the barrel when removing Scrapers. The barrel on horizontal Launchers shall be sloped (typically 1 in 100) towards the pipeline. All nozzle and branch fittings shall be manufactured from material conforming to the same requirements as those for the pressure containing components. All nozzle and branch fittings (except for kickerline connection) shall be "Set on type" weldolet and shall be adequately reinforced in accordance with the requirements of ASME B31.4. The kicker line connection shall be set-in type. Nozzle and branch fittings including kicker line connection shall not be placed on or within the Heat Affected Zone of any weld. Dimensional and out of roundness tolerances for the Scraper Traps shall be in accordance with the requirements of the connecting Line Pipe Specification. Circumferential tolerance for all diameters shall be +0.25% -0% of circumference.


Page 10 of 20


The maximum straight line deviation, measured from the outside surface of the barrel using a straight line running parallel to the vessel axis shall not exceed 1.5mm over any 1000mm of the barrel length. The main vessel nozzle tolerances for the approved fabrication drawings shall conform to the following requirements: • • •

Position Projection Alignment

: : :

•

Bolt hole

:

measured from the neck end +/- 6mm measured from the outer surface +/- 3mm measured from the reference centre line to centre line of nozzle +/- 2mm maximum total indicated run-out shall be 2mm from the true position

Quick opening end closure change axis to be aligned vertically notwithstanding any slope in the barrel section. Maximum misalignment of quick opening end closure flange face shall be +/- 1° in any direction. 5.3

Quick Opening End Closures The Launcher and Receivers shall be equipped with a quick opening end closure fitted with a pressure interlock to prevent opening whilst the barrel is pressurised. The quick opening end closure shall be designed in accordance with ASME Section VIII, Division I Paragraph UG-35. The quick opening end closure shall be Clamp ring/Band lock type or equivalent and shall be consist of safety system allowing the opening only when there is a no pressure in Launcher and receiver. End closure shall be hand operated and operable by one operator. End closure of size 24” NB 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 without sagging screwed type or plug in type of end closure are not permitted The fully closed position shall be clearly marked to assist subsequent closing operations. The quick opening end closure shall use a double edge lip seal as the sealing element. There shall be no leakage of contents prior to disengagement of the locking element and release of the quick opening end closure door. The quick opening end closure shall be reputed vender only (Listed above in 5.0). Material for the quick opening end closure double edge lip seal shall be VITON A, Grade


Page 11 of 20


A (Vender to Advice), shore hardness 90 however the CONTRACTOR shall confirm suitability of this material for the applicable service conditions. The surface under the lip seal shall be corrosion resistant, hard coated surface. The seals shall be explosive decompression resistant. The quick opening end closure shall be girth welded to the major barrel. The welded hub material shall be compatible with the material of the major barrel. 5.3.1

Quick Opening End Closure Safety The quick opening end closure locking mechanism shall be provided with a pressure warning safety interlock device which must be opened before the quick opening end closure mechanism can be unlocked. Closing of the pressure warning safety interlock shall not be possible until the quick opening end closure locking mechanism is fully engaged and locked.

5.4

Supports Permanent supports shall be used to support and restrain the Scraper Traps. The supports shall be designed to carry the weight of the Scraper Trap system filled with water together with the weight of intelligent Scrapers. Structural Steel used for non pressure containing parts shall be as per ASTM specifications. The barrel supports shall be sliding type supports to accommodate expansion of the unrestrained pipeline section. The PTFE gasket between the sliding support and the grouted baseplate shall be supplied by CONTRACTOR. The CONTRACTOR shall provide the loading data on each saddle to be transferred on to each foundation support. The CONTRACTOR drawings shall also mention the location plan. Earthing lugs / clips shall be provided on each saddle support. Scraper Trap supports shall be positioned such that the ancillary trim valves and equipment can be removed for maintenance or replacement without removal of the barrel.

5.5

Design Code The entire Pig Trap except the quick opening end closure shall be designed in accordance with ASME B31.4, with a design factor of 0.72. The quick opening end closure shall be designed to ASME Sec. VIII, Div 1.


Page 12 of 20


5.6

Design Pressure The design pressure for each Pig Trap system shall be as specified in the relevant Data Sheets.

5.7

Design Temperature The maximum and minimum mechanical design temperatures shall be as specified on the applicable data sheets and correspond to the temperatures specified for the connecting pipeline system. The CONTRACTOR shall ensure the minimum design temperature includes operational conditions such as blow-down, where the Pig Trap could be exposed to sub-zero temperatures. Minimum and maximum ambient temperatures shall be as specified in data sheet. CONTRACTOR shall verify the climatic conditions and include any local extremes for the proposed Pig Trap locations.

5.8

Auxiliary Equipment Each Pig Receiver and Launcher shall be supplied with a safe and properly designed Pig handling facility. CONTRACTOR shall provide suitable equipment for the safe loading, unloading and handling of Scraping equipment. Scraper Traps in excess of 12” diameter shall be provided with a permanent jib crane and chain block pulley system. All moving and mating parts of the jib crane system shall be provided with non-sparking materials. The design capacity of jib cranes and lifting systems shall be minimum 1000 kg Safe Work Load (SWL) or more as suggested by the intelligent Scraper suppliers. All Scrapers handling equipment shall be suitable for operation in the climatic conditions as specified in Basis of Design, document no. 0435-JH0902-00-PL-BOD-0001 Pig trap (Launching and Receiving) handling facilities including portable trolley are to be provided at Pig Launcher and Receiver ends. All the time the quick opening end closure is open, a potential hazard/safety concern is present regarding the leak and operator safety. Therefore the pig handling system should be designed to minimise the duration that the door is open. Hence CONTRACTOR should detail fully offered pig handling system in the bid.


Page 13 of 20


The Pig handling system shall be designed to handle all types of intelligent pigs in terms of weight, length and dia, etc. Bidder shall indicate the same at the time of bidding. In addition to above following shall be taken care while designing the pig handling system. 1) Connecting rod (pushing rod) shall not sag when it is in retracted position. 2) Two supports with two handles and gear arrangements shall be provided for operating connecting rod and avoid sagging of same 3) Capacity of chain pulley block shall be suitable to handle all type of intelligent puigs. 4) Enough care shall be taken in designing of trolley so that it should more freely on rails. 5) All bearings shall have weather proof hoods with grease nipples. Final selection of the pig handling equipment shall be subject to OWNER approval. 5.9

Welding All Welding Procedures, Welder Qualification, and Weld Procedure Qualifications, Design and Preparation of Joints, Inspection and Testing, Weld Acceptance Criteria, Repairs and Radiography shall be in strict accordance with ASME V, ASME IX, and the pipeline welding Specification. CONTRACTOR shall ensure all welding procedures and documentation have been reviewed and approved before fabrication commences. Tapering of transition of internal dia., where internal offset is greater than 2.4mm, transition shall be made by a taper angle of maximum 14° for smooth passage of Scraper. Single-welded butt joints are permitted for circumferential joints and shall be subject to 100% radiography. CONTRACTOR shall provide ultrasonic testing where radiography produces questionable results. In the event that welds performed on any forging cannot be 100% radiographed, ultrasonic or wet MPI shall be implemented. Where locally reinforced fittings are to be welded to the Scraper Trap body, the surrounding material shall be subject to ultrasonic inspection to confirm the absence of material defects. All weld ends shall be subject to ultrasonic inspection prior to commencement of welding.

5.10

Inspection and Testing The OWNER reserves the right to inspect the material, manufacturing process and testing during the course of the Work. Such inspection does not relieve the CONTRACTOR of his responsibility for provision of a suitable design and good workmanship.


Page 14 of 20


CONTRACTOR shall offer inspection schedule plan to WorleyParsons for Scraper trap as per requirements stipulated in the specification / data sheet and purchase specification. Base on this WP arrange Inspection visit to vender shop. The CONTRACTOR shall submit for OWNER approval, a detailed inspection and test plan (ITP) containing scheduled activities and intended acceptance criteria, prior to commencement of manufacture. 5.10.1 Inspection, Testing and Acceptance Criteria Inspection, testing and acceptance criteria shall be as follows: Non-Destructive Testing Ultrasonic testing Radiography Magnetic Particle (MPI)

: : :

ASME Code Section V, Articles 5 & 23. ASME Code Section V, Articles 2 & 22. Wet Method to ASME Code Section V, Article 7 & 25.

Acceptance Criteria Results shall be reviewed, interpreted and evaluated in accordance with the following criteria Ultrasonic testing Welds Forgings

: :

Radiography

:

MPI

:

ASME Section VIII Div. 1 Appendix 12. ASME Section VIII Div. 2 Section AM 203.2 (c). ASME Code Section VIII Div. 1 Section UW51. ASME Section VIII Div. 1 Appendix 6.

5.10.2 Air Tests All welded reinforcement pads shall be provided with weep holes to facilitate a low pressure air test. Prior to the final hydrostatic pressure test, the reinforcement pad shall be subject to a 7 bar (g) pressure test using clean dry air and the fillet weld checked for leaks using a foaming agent. 5.10.3 Hydrostatic Pressure Test CONTRACTOR shall submit a detailed hydrostatic pressure test procedure for review and approval by the OWNER before commencement of the works.


Page 15 of 20


Hydrostatic pressure tests shall be performed at the manufacturer’s premises prior to any painting operations being carried out. The test pressure shall be based on a fibre stress of 95% of the Specified Minimum Yield Strength, based on nominal wall thickness of the connecting line pipe section. The Hydrostatic Pressure Test shall not be performed when the temperature of either the material or water may fall below 10°C during the test. The Hydrostatic Pressure Test shall be recorded using as a minimum, two calibrated pressure gauges and a calibrated pressure/temperature recorder. The test pressure shall be held for a minimum period of 4 hours following rectification of any leaks. The graph shall clearly show the history of the test including pressurisation, the 4 hour hold period and de-pressurisation. The graph shall be marked with the Scraper Trap identification, test instrumentation serial numbers, the date and the Manufacturer, CONTRACTOR and where applicable, WorleyParsons / WP nominated Third Party witnessing signatures. The completed pressure test chart, together with all applicable calibration certificates shall be included in the final Manufacturing Dossier. The pressure test shall be performed after completion of all welding, heat treatment if any and installation of any specified instrumentation connections, vessel trim and ancillary equipment. 5.10.4 Functional Tests Functional testing shall be performed following completion of the Hydrostatic Pressure Test. The quick opening end closure shall be fully operable without the use of excessive force to operate the mechanism. The pressure locking device shall operate correctly in both positions. Bleed bolt shall operate correctly. Dimensional inspection shall ensure compliance with fabrication tolerances and the approved drawings. 6.0

SURFACE PREPARATION AND PAINTING All sharp edges shall be ground smooth, surface protrusions and weld spatter shall be ground flush and removed prior to blasting and painting.


Page 16 of 20


Surface preparation and painting shall be carried out in accordance with the Project Painting Specification 0435-JH0902-00-PI-SPC-0003

7.0

FINAL INSPECTION Following completion of all painting and de-masking operations, the CONTRACTOR shall perform a final inspection prior to preparation for shipment. The final inspection shall include the functional tests detailed in Section 5.10.4 of this specification, supplemented with the following:

8.0

•

All machined surfaces shall be clean and free from overspray and blast media.

•

All moving components, including valve spindles, shall operate smoothly, without excessive force and be free from paint and blast media contamination.

•

All threaded components shall operate smoothly and be free from paint and blast media contamination.

•

The quick opening end closure sealing surfaces, closure seals surface and locking mechanism are free from paint and blast media contamination.

•

All instrumentations where fitted, are free from overspray and blast media contamination.

PREPARATION FOR SHIPMENT One complete set of installation, operating and maintenance instructions shall be packed and shipped with each individual item of equipment. The Scraper Traps shall be completely drained of the test liquid, cleaned and thoroughly dried prior to shipment. Surfaces subject to atmospheric corrosion or rusting shall be coated with a rust preventive designed for storage periods of at least six months. External non-painted surfaces including bolting and flange faces shall also be coated with the rust preventive. All components shall be securely anchored to the skid and package supports. All openings, flange facings, etc., shall be sealed with waterproof coverings for shipping. Threaded couplings shall be coated with the rust preventive and protected with steel plugs. Two extra closure seals and the quick opening end closure actuation tool shall be taped to the inside of the barrel to prevent loss. The Scraper Traps shall be handled in such a manner as to prevent damage, including damage to the weld bevel or distortion of quick


Page 17 of 20


opening end closure. Service bolting and gaskets shall be suitably rated and properly marked. Flanged openings shall be protected with a ‘one piece’ plywood cover and rubber gasket. The plywood covers shall be 3/8" thick, for flanges up to 6", 1/2" thick for flanges 8" through to 12" and 3/4" thick for larger sizes. A minimum of four (4) 3/8" bolts shall be used for flanges up to 12" and eight (8) 3/8" bolts for larger flanges. Large washers shall be used on the flange side of the bolt. Suitable plate washers shall be used against the plywood side of all such covers. Each equipment item having a nameplate as specified by the Purchase Order and/or Equipment Data Sheet shall have the nameplate permanently protected during welding, painting and shipping. The following information shall be stamped on the nameplate: • • • • • • • • • • • •

Owner Name Purchase Order Number: Item Name and Equipment No.: Manufacturer: Serial Number: Hydrostatic Test Pressure: (required on nameplate) Year Built: Maximum Working Pressure: Maximum Temperature: Maximum Test Pressure: Design Code: TPIA Stamp:

All Scraper Trap nozzle connections shall be tagged stating the connection reference and intended use in accordance with the data sheet and approved drawings.

9.0

CONTRACTOR (VENDOR) DATA REQUIREMENT LIST (VDRL) The VENDOR shall supply three (3) copies of the Manufacturing Dossier, which shall contain as a minimum the following: (i)

Certified mill test certification showing the chemical and physical properties for each item of material used to manufacture the Scraper Traps.

(ii)

Weld Procedures for all welding performed on the Scraper Traps.


Page 18 of 20


(iii)

Weld Procedure Qualification for all welding performed on the Scraper Traps, including Non-Destructive and Mechanical Test Results.

(iv)

Welder Qualification Certificates.

(v)

Fabrication weld map drawings identifying each weld with a unique weld number and the welder’s identification clearly marked against it.

(vi)

Inspection and testing reports carried out for each weld including identified defects and disposition of all repairs. The reports shall contain, where applicable, the following : • • • • •

Ultrasonic Testing Results Radiography Results Visual Inspection Reports Magnetic Particle Inspection Reports Weld Repair Reports

A Certified Copy of all Hydrostatic Pressure Test Charts. Recommended two years Operational Spare Parts List Assembly drawings complete with keyed parts lists for all valves, quick opening end closures and ancillary equipment supplied as part of the Scraper Trap packages. Installation, operation and maintenance instructions/manuals covering the quick opening end closure and ancillary equipment supplied as part of the Scraper Trap packages. Inspection Documentation and Material Certification shall conform to EN 10204 for the following pressure ratings: Type “B” Certificates (ISO 10474, 3.1B). All original radiographs shall be available to the OWNER for review upon request. All final “As-Built” VENDOR data shall be supplied in electronic copy, in addition to hard copies. Refer to VENDOR Data Requirement List included in the requisition for the schedule and number of prints required at various phases. 10.0

SPARES


Page 19 of 20


Spares are required for all mechanical equipment. The three basic categories of spare parts are as follows: • • •

Construction or pre-commissioning Spare Parts Commissioning Spare Parts Two Year Operating Spare Parts

Delivery of the spare parts ordered with the Original equipment such as construction and commissioning spares are required concurrent with the original equipment. Two year operating spare parts shall be delivered prior to equipment commissioning. All spare parts shall meet all specifications and quality standards as the original parts and shall be packaged for shipment and storage in accordance with requirements of OWNER. Spare Parts requirements are defined in the Material Requisition.


Page 20 of 20

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) SPECIFICATION FOR PIG SIGNALER (INTRUSIVE TYPE)


SPECIFICATION FOR PIG SIGNALER (INTRUSIVE TYPE)

0435-JH0902-00-PL-SPC-0032 26 June 09



Page 1 of 9


SYNOPSIS



DESCRIPTION

0

Issued for Design

PREPARED BY

D. Hemnathan

CHECKED BY

S. Ishwad


APPROVED BY

J. Wallace

DATE

26 June 09

CLIENT APPROVAL

DATE

YES A.K.Jain

23/06/09

Page 2 of 9


TABLE OF CONTENTS

1.0

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

2.0

MATERIAL .............................................................................................................................................. 4

3.0

DESIGN AND CONSTRUCTION REQUIREMENT .......................................................................... 4

4.0

INSPECTION AND TESTS ................................................................................................................... 5

5.0

TEST CERTIFICATES........................................................................................................................... 5

6.0

PAINTING, MARKING AND SHIPMENT ........................................................................................... 6

7.0

SPARES AND ACCESSORIES........................................................................................................... 6

8.0

DOCUMENTATION................................................................................................................................ 6


Page 3 of 9


1.0

SCOPE This specification covers the minimum requirements for the design, manufacture, testing and supply of Pig Signalers(INTRSIVE TYPE), used for the detection of passage of pig and instrumented gauging pigs, to be installed in pipeline systems handling hydrocarbons in liquid. Requirement of Pig Signaler one is on the barrel of pig at 12o’Clock position of each Pig launcher and receiver supplied along with each Pig launcher & Receiver and one on pipeline top at12 o’clock position supplied extra and fitted by pipe laying Contractor This specification does not cover pig signalers for sour hydrocarbons (liquid / gas) service as defined in NACE Standard MR0175-98.

2.0 2.1

MATERIAL The material used in manufacture of the main components of the Pig Signaller shall be as under: a. All metallic parts except scarfed welding based b. Scarfed welding base c. Soft Seats

: : :

SS316 CS, ASTM A105 PTFE / VITON

Other components shall be as per Manufacturer’s Standard, suitable for the service conditions indicated in Data Sheet, which will be subject to approval by Purchaser. 2.2

Scarfed welding base shall have Carbon Equivalent (CE) not greater than 0.45 on check analysis, calculated as per the following formula: CE= C + Mn + Cr + Mo + V + Ni + Cu 6 5 15

3.0

DESIGN AND CONSTRUCTION REQUIREMENT

3.1

Pig Signallers shall be designed to meet the requirements of pipeline material, diameter, wall thickness and service conditions indicated in the Data Sheet.

3.2

Pig Signallers shall be bi-directional type, having pivot-less tumbler mechanism and laminated trigger blades.

3.3

Design of Pig Signallers shall be such that any possibility of Signaller being operated by line pressure is eliminated. Also design of Pig Signallers shall be such that repair and installation of internal / accessories are possible under pressure, without removing the unit from the line.


Page 4 of 9


3.4

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 manuals reset.

3.5

Pig Signalers shall be fitted with sealed, weather proof and explosion proof Transmitter for remote signal indication. The area classification and rating of transmitter shall be as indicated in Data Sheet.

3.6

Pig signaler shall be fitted with transmitter (24 V DC, 4-20 mA, loop powered). The transmitter shall be suitable for IEC Zone 1, Gr. IIA, IIB and temp, T3. The transmitter shall be housed in weather proof to IP65 min. and shall be EEx’d’ certified. (COE certificate for the same shall be provided)

3.7

Pig signaler shall have local indicator through LED for pig indicator.

3.7

All welds shall be made by welders and welding procedures qualified in accordance with the provisions of ASME Section IX.

3.8

Whenever specified in the Data Sheet, Pig Signallers shall be provided with extension suitable for installation on underground pipeline.

4.0

INSPECTION AND TESTS

4.1

Manufacturer shall perform all inspection and tests required to supply the Pig Signallers as per the requirements of this specification.

4.2

Hydrostatic tests shall be conducted at a pressure equal to 1.5 times the design pressure Hydrotest duration shall be 15 minutes.

4.3

All welds shall be nondestructively examined.

4.4

The welding end shall be inspected ultrasonically over the entire circumference for lamination type defects. Any lamination larger than 6.35 mm shall not be acceptable.

4.5

Manufacturers shall perform functional tests to establish satisfactory performance of both manual and electrical indications.

5.0

TEST CERTIFICATES Manufacturer shall submit the following test certificates:

5.1

Test certificates for material compliance as per the relevant material standards.

5.2

Certificate for hydrostatic test and functional tests.


Page 5 of 9


6.0

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. In case of Pig Signallers with 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.

Manufacturer’s name. Suitable for installation in ________ mm in dia, pipeline ANSI Rating Tag No.

6.3

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 corrosions shall be well protected by a coat of grease or other suitable materials.

7.0

SPARES AND ACCESSORIES Manufacturer shall furnish list of recommended spares and accessories for Pig Signallers required during start up and commissioning. Cost of such spares shall be included by the Manufacturer in the item rates indicated in Purchase Requisition. Manufacturer shall furnish separately a list of recommended spares and accessories required for two years of normal operation and maintenance of Pig Signallers.

8.0

DOCUMENTATION

8.1

At the time of bidding, Manufacturer shall submit the following documents: a. General arrangement drawings with overall dimensions. b. Reference list of similar supplies of Pig Signaller shall be furnished including Project, Year of supply, Client, Size, Rating and Service for the last five years. c. Clause wise list of deviations from this specification, if any.

8.2

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.


Page 6 of 9


a. Fabrication drawings / sectional arrangement drawings showing all parts with reference numbers and material specification. b. Assembly drawing with overall dimensions. 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 Purchaser whose approval in writing of all such changes shall be obtained before Pig Signallers are manufactured. 8.3

Within four weeks from approval date, Manufacturer shall submit one reproducible and six copies of the drawings, documents and specifications as listed in clause 8.2 of this specification.

8.4

Prior to shipment, Manufacturer shall submit one reproducible and six copies of the following: a. Test Certificate as per clause 5.0 of this specification. b. Manual for installation, erection instructors, maintenance and operation instructions.

8.5

All documents shall be in English language.


Page 7 of 9



Page 8 of 9



Page 9 of 9

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) BASIS OF DESIGN - PIPING


BASIS OF DESIGN - PIPING 0435-JH0902-00-PI-BOD-0001 16 July 09


DOC.NO. – 0435-JH0902-PE-BOD-0001 Rev.1

Page 1 of 30


SYNOPSIS



DESCRIPTION

PREPARED BY

CHECKED BY

APPROVED BY

A

Issued for IDC

D. Hemnathan

S. Ishwad

A. Kumar

B

Issued for Review

D. Hemnathan

S. Ishwad

A. Kumar

C

Issued for Approval

D. Hemnathan

S. Ishwad

A. Kumar

0

Issued for Design

D. Hemnathan

S. Ishwad

A. Kumar


DATE

22 April 09

CLIENT APPROVAL

DATE

N/A

06 May 09

Page 2 of 30



SCOPE ............................................................................................................................................. 6

2.0

CODES, REGULATIONS AND STANDARDS .......................................................................... 6

3.0

GENERAL....................................................................................................................................... 8

4.0

MATERIALS .................................................................................................................................. 9

5.0

LINE DESIGNATIONS AND LINE LISTS ................................................................................ 9

5.1

Line Designation ............................................................................................................9

5.2

Line Lists ......................................................................................................................10

6.0

DESIGN CONDITIONS............................................................................................................... 11

6.1

Operating Conditions...................................................................................................11

6.2

Design Temperature.....................................................................................................11

6.3

Design Pressure ...........................................................................................................11

6.4

Other Conditions ..........................................................................................................12

7.0

Other Limitations..........................................................................................................12

8.0

PIPING ARRANGEMENT ......................................................................................................... 12

8.1

General..........................................................................................................................12

8.2

Maintenance..................................................................................................................12

8.3

Clearance and Accessibility ........................................................................................13

8.4

Access for Maintenance ..............................................................................................13

8.5

Platforms, Ladders and Stairways ..............................................................................14

8.6

Pipe Routing .................................................................................................................14

9.0

EQUIPMENT PIPING ................................................................................................................. 14

9.1

Static Equipment Piping ..............................................................................................15

9.2

Pump Piping .................................................................................................................15

9.3

Emergency Shutdown Valves......................................................................................19

10.0

VALVES, VENTS AND DRAINS ............................................................................................... 20


Page 3 of 30


10.1

Valve Location ..............................................................................................................20

10.2

Vents and Drains ..........................................................................................................20

11.0

PRESSURE RELIEF SYSTEMS ................................................................................................ 21

11.1

General..........................................................................................................................21

11.2

Inlet Piping....................................................................................................................21

11.3

Discharge Piping ..........................................................................................................21

12.0

WALL THICKNESS AND CORROSION ALLOWANCE ..................................................... 22

12.1

General..........................................................................................................................22

12.2

Minimum Wall Thickness .............................................................................................22

13.0

UNDERGROUND PIPING.......................................................................................................... 22

13.1

General..........................................................................................................................22

13.2

Painting and Protective Coating..................................................................................22

14.0

TANK PIPING .............................................................................................................................. 22

14.1

General..........................................................................................................................22

14.2

Tank Valves and Vents.................................................................................................22

14.3

Above Ground Piping...................................................................................................23

14.4

Piping Below Ground ...................................................................................................23

14.5

Internal Tank Heater Piping .........................................................................................23

15.0

BRANCH CONNECTIONS......................................................................................................... 23

15.1

General..........................................................................................................................23

15.2

Gussets .........................................................................................................................23

15.3

Hot Tapping ..................................................................................................................24

16.0

UTILITY STATIONS .................................................................................................................. 24

16.1

General..........................................................................................................................24

16.2

Locations ......................................................................................................................24

17.0

PIPE SUPPORTS.......................................................................................................................... 24

17.1

General..........................................................................................................................24

17.2

Pipe Racks/Pipe Ways .................................................................................................25

17.3

Pipe Support Layout ....................................................................................................25

17.4

Pipe Support Spacing ..................................................................................................26


Page 4 of 30


17.5

Support Shoes..............................................................................................................26

17.6

Anchors.........................................................................................................................26

17.7

Guides ...........................................................................................................................27

17.8

Pipe Hangers ................................................................................................................27

17.9

Auxiliary Supports........................................................................................................28

18.0

PIPING FOR INSTRUMENTS................................................................................................... 28

19.0

SAMPLE CONNECTIONS ......................................................................................................... 29

20.0

NON-CODE PIPING.................................................................................................................... 29

21.0

FIREWATER LINES ................................................................................................................... 29

22.0

GUARANTEE ............................................................................................................................... 30


Page 5 of 30


1.0

SCOPE This Document describes the basis for the overall design of process and utility piping, the requirements governing the arrangement of equipment and piping, mechanical design and drafting, and shall apply to all piping systems and parts of such systems.

2.0


2.1

Piping systems shall meet or exceed the requirements of the latest edition of the following codes, regulations and standards, as applicable, except as superseded herein. In cases where more than one code, regulation or standard apply to the same condition, the most stringent shall be followed. In the event of a conflict between this specification and other specifications or correspondence, the OWNER shall be consulted and a ruling, in writing, shall be obtained before any work is started. •

ASME Boiler and Pressure Vessel Code, all applicable sections.

•

ANSI/ASME B31.3, Process Piping

•

ANSI/ASME B31.4, Liquid Transportation Systems for Hydrocarbons

•

OISD 118

•

OISD 141

•

NFPA / OISD 117 / TAC

•

API 650

RevC

•

ASME section IX, Welding and brazing qualifications

•

ASME B1.1, Unified inch screw threads

•

ASME B1.20.1, Pipe threads, general purpose (inch)

•

ASME B16.48, Steel line blanks

•

ASME B16.5, Pipe flanges and flanged fittings

•

ASME B16.9, Factory-made wrought steel butt welding fittings

•

ASME B16.10, Face-to-face and End-to-end dimensions of valves

•

ASME B16.11, Forged fittings, socket-welding and threaded

•

ASME B16.14, Ferrous pipe plugs, bushings, and locknuts with pipe threads

•

ASME B16.20, Metallic gaskets for pipe flanges - ring joint, spiral wound and jacketed


Page 6 of 30


•

ASME B16.21, Nonmetallic flat gaskets for pipe flanges

•

ASME B16.25, Butt welding ends

•

ASME B16.28, Wrought steel butt welding short radius elbows and returns

•

ASME B16.34, Valves - flanged, threaded and butt welding end

•

ASME B16.36, Orifice flanges

•

ASME B16.47, Large diameter steel flanges

•

ASME B18.2.1, Square and hexagonal bolts and screws

•

ASME B18.2.2, Square and hexagonal nuts

•

ASME B 36.10, Welded and seamless wrought steel pipe

•

ASME B36.19, Stainless steel pipe

•

ASME B46.1, Surface texture

•

API 5L, Specification for Line Pipe

•

API 594, Check valves: wafer and wafer-lug, and double flanged type.

•

API 598, Valve Inspection and Testing

•

API 6FA, Specification for Fire test for valves

•

API 600, Steel Gate Valves - Flanged and Butt-welding ends, Bolted and Pressure seal bonnets

•

API 602, Compact Steel Gate Valves – Flanged, Threaded, Welding and Extended-body ends

•

API 607, Fire test for Soft-Seated quarter-turn valves

•

API 609, Lug and wafer type butterfly valves

•

API 6D, Specification for pipe line valves (Gate, Plug, Ball and Check valves)

•

API 1104, Welding of Pipelines and Related Facilities

•

Annual book of ASTM standards

•

BS 1868, Steel Check valves (Flanged and Butt-welding ends) for the petroleum, petrochemical and allied industries

•

BS 1873, Steel Globe and Globe stop and Check valves (Flanged and Buttwelding ends) for the petroleum, petrochemical and allied industries

•

ISO 17292, Steel Ball valves for petroleum, petrochemical and allied Industries

•

ISO 15761, Steel wedge Gate, Globe and Check valves – 50mm and smaller for the petroleum and petrochemical and allied industries


Page 7 of 30


2.2

•

BS 6755 Part1, Testing of valves Part 1: Production pressure testing requirements

•

BS 6755 Part2, Testing of valves Part 2: Specification for Fire-type testing requirements

•

MSS SP-6, Standard finishes for contact faces of pipe flanges and connecting – end flanges of valves and fittings

•

MSS SP-25, Standard marking system for valves, fittings, flanges and unions

•

MSS SP-44, Steel pipeline flanges

•

MSS SP-97, Integrally reinforced forged branch outlet fittings – socket welding, threaded and butt welding ends

•

NACE MR0175, Sulfide stress cracking resistant metallic materials for Oil-field equipment

•

BS EN 10204, Metallic products – Types of inspection documents

•

ISO 10474, Steel and steel products – inspection documents


0435-JH0902-00-PE-SPC-0005

Welding Spec, for Fab, of Piping

•

0435-JH0902-00-PE-SPC-0002

Piping Materials Specification

•

0435-JH0902-00-PE-SPC-0003

Valve Specifications

2.3

Some requirements in this specification may be modified by specific requirements in the purchase or contract specification. In case of conflict, the specific requirements supersede this specification.

3.0

GENERAL

3.1

Battery limits in this specification refer to the area designated by HPCL/WP.

3.2

Measurement units employed in this specification are based on the International System of Units (SI) except for pipe sizes which shall be in Imperial units. As a reference the following table lists "equivalent" standard pipe sizes in millimeters and inches. mm O.D.

NPS inches

mm O.D.

NPS inches

21.3 26.7

1/2 3/4

323.9 355.6

12 14


Page 8 of 30


33.4 48.3 60.3 88.9 114.3 168.3 219.1 273.1

1 1 1/2 2 3 4 6 8 10

406.4 457 508 559 610 660 711 762

16 18 20 22 24 26 28 30

4.0

MATERIALS

4.1

Refer Piping Material Specification 0435-JH0902-00-PE-SPC-0002

4.2

The maximum hardness of pipe with longitudinal weld seams, made by a welding process using filler metal, shall not exceed 200 BHN.

4.3

Valves shall conform to the requirements of Valve Specification 0435-JH0902-00-PESPC-0003

5.0

LINE DESIGNATIONS AND LINE LISTS

5.1

Line Designation

5.1.1

All lines on mechanical flow and piping drawings shall be designated by a descriptive number consisting of the following identifiers: 1. 2. 3. 4. 5. 6.

Nominal Line Size (inches NPS) Service Area Code Line Number Piping Classification Insulation

The line designation shall take the following form: 00”-XXX-XXX-0000-00XX 1 2 3 4 5 e.g.

RevC

1. 2. 3. 4. 5.

10” P 10 001 A

10”-P-10-001-A specifies: RevC -

Nominal Line Size Service Area Code Line No. Classification (Refer to Piping Material Specifications)


Page 9 of 30


5.1.2

Line Service Designation Service

Designation

Hydrocarbon Liquids

P

Water

UW FW PW

- Utility Water - Fire Water - Potable Water

VENT

V

Drains

5.1.3

- Closed Drain - Open Drain

CD OD

Chemical Injection

CI

Instrument Air Utility Air

IA UA

Piping Classification Refer to the Appendix A of specification for Piping Materials 0435-JH0902-00-PESPC-0002

5.1.4

Equipment, Valve and Line Number Philosophy Refer attachment 1, 2 and 3

5.1.5

Insulation and Heat Tracing Modifiers a)

The first of these modifiers describes the thickness in millimeters and type of insulation. Insulation types are: H C PP

5.2

= = =

Hot Cold Personnel Protection

Line Lists All lines shown on the mechanical flow diagrams and piping drawings shall be listed on a line list which includes, as a minimum, the following basic design data:


Page 10 of 30


a)

Line number

b)

Line size

c)

Piping classification

d)

Pipe wall thickness or schedule

e)

Service description

f)

Origin and termination of the line

g)

Operating and design temperature

h)

Operating and design pressure

i)

Insulation requirements

j)

Test Pressures/Test Media

6.0

DESIGN CONDITIONS

6.1

Operating Conditions

6.1.1

Normal design conditions of pressure and temperature shall be the most severe conditions expected to co-exist under usual long-time operating conditions. These normal operations include all manipulation and control functions such as throttling, blocking, bypassing and recirculation likely to be used for operation and control.

6.1.2

Normal operating conditions do not include more severe temporary conditions, such as those incidental to start up, shutdown, and abnormal operation. Temporary conditions govern as design conditions only when there is clear evidence they definitely exceed time and severity limits defined in the applicable code.

6.2

Design Temperature

6.2.1

Design temperature is the most severe sustained fluid temperature, subject to conditions of Section 6.1 above.

6.3

Design Pressure

6.3.1

Design pressure shall be the most severe condition of internal or external fluid pressure, subject to conditions of Section 6.1 above.


Page 11 of 30


6.3.2

Design pressure for unrelieved piping systems to pump discharge pressure, shall be pump differential pressure at shutoff or stalling conditions, plus normal pump suction pressure and hydrostatic head.

6.3.3

Design pressure for piping systems operating under vacuum shall be full vacuum. Exception may be taken where suitable protection against vacuum failure is provided.

6.3.4

For piping system protected by relief valves, the relief valve set pressure shall be equal to the design pressure minus the hydrostatic head below the relief valve.

6.4

Other Conditions Allowable stress values apply to total loads imposed on piping materials. Design shall provide for all loading significantly affecting pipe material stresses. Refer to the appropriate code for loading in addition to fluid pressure, which may affect piping stress.

7.0

Other Limitations

7.1

1-1/4", 2-1/2", 3-1/2", 5" NPS OD pipe sizes shall not be used. Reducers are to be utilized to connect to equipment with these size nozzles. Minimum pipe size run shall be 3/4", except for connections to equipment, instruments, the discharge end of a sample line or steam tracing.

7.2

7.3

The minimum size for process and utility piping running on pipeways shall be 1 1/2".

8.0

PIPING ARRANGEMENT

8.1

General The primary consideration in arrangement of units and equipment shall be to provide an economical plant, safe and easy to operate and maintain. The arrangement shall favour compactness and integrated disposition of units and equipment. Space shall be provided around equipment for convenient operation and maintenance access. Within the units, space for future needs shall be provided only where specifically designated.

8.2

Maintenance

8.2.1

Plant design and arrangement are based on assumption that mobile equipment will be used where practical. Built-in maintenance facilities generally will not be provided for grade-mounted or near-grade equipment accessible to mobile equipment.


Page 12 of 30


8.2.2

Monorail structures shall be provided to assist in servicing exchangers over 15 meters (50 feet) above grade or otherwise not accessible to mobile equipment. Suitable cranes, monorails, or davits shall be provided to handle equipment components, necessary portable tools and the like at maintenance stations over 9 meters (30 feet) above grade or otherwise not accessible to mobile equipment.

8.3

Clearance and Accessibility

8.3.1

Overhead Clearance Equipment, structures, platforms, piping and piping supports shall be arranged to provide the following overhead clearances: Over railroads, top of rail to bottom of any obstructions 6.7 meters (22 feet)

8.3.2

Over plant roads

5.2 meters (17 feet)

Over accessways in process unit

4.3 meters (14 feet)

Over pumps, from grade Over walkways, passageways and platforms to nearest obstruction

2.5 meters (8 feet) 2.1 meters (7 feet)

Horizontal Clearances Equipment, structures, platforms, piping and its supports shall be arranged to provide the following horizontal clearances: At driver end of pumps, where truck access is required

3 meters (10 feet)

At driver end of pumps, where truck access is not required

1.5 meters (5 feet)

In front of manways

0.75 meters (2’ 6”)

For passageways at grade

1.2 meters (4 feet)

Between extremities, including piping, of adjacent pumps

0.75 meters (2’ 6“)

8.4

Access for Maintenance

8.4.1

Equipment, structures and piping shall be arranged to permit crane access to process pumps and major equipment parts not provided with built-in maintenance facilities.


Page 13 of 30


8.4.2

Clear areas shall be provided at grade for lowering external and internal fittings of tall or elevated equipment.

8.4.3

Truck access shall be provided to driver ends of pumps under pipeways and to areas where elevated fittings are lowered.

8.5

Platforms, Ladders and Stairways

8.5.1

Platforms, ladders and stairways shall be the minimum consistent with access and safety requirements. Certain elevated stations requiring frequent operator attention shall be designated as operation stations requiring stairway access.

8.6

Pipe Routing

8.6.1

Piping shall be arranged in an orderly manner and routed as directly as practical, preferably in established banks or pipeways or sleeper.

8.6.2

Arrangement shall provide for thermal expansion and contraction of lines. Reactions or moments causing excessive stresses in piping or equipment shall be avoided by proper design.

8.6.3

Where dynamic loading, limited pressure drop, or other severe service conditions apply, particular care shall be used in routing the piping.

8.6.4

Limited allowable pressure drop conditions may be expected in large vapor lines, pump suctions and gravity flow lines. Such piping shall be routed as directly as practical.

8.6.5

Other severe services include erosive, corrosive and high or low temperature or pressure conditions. Many such services require alloy or other special materials. Piping in these services shall be routed to minimize the effects of service severity and make most practical use of required special materials.

8.6.6

As far as practical, piping shall run at different elevations in north-south and eastwest banks, and shall change elevation when changing direction. Combined changes of direction and elevation in pipeways ordinarily shall be made with 90o elbows. Where necessary, a 90° and a 45°elbow may be used. Inside tie point piping may run in vertical banks and flat turns may be used.

8.6.7

Drain lines shall be sloped a minimum of 1:200. RevC

8.6.8

Flexible piping connections to be provided at the nozzles of the equipment subject to movement due to soil heaving.

9.0

EQUIPMENT PIPING


Page 14 of 30


9.1

Static Equipment Piping

9.1.1

This specification shall apply to vessel piping within the plant or facility Tie point. It is not mandatory that this specification apply to packaged facility units, when the manufacturer of the unit guarantees the performance and that the fabrication complies with the generally accepted codes. Oil field tank batteries are specifically excluded from the provisions of this specification. Vents, draining and utility connections shall be arranged to prevent unintentional or undetected leakage. Davits or other suitable means shall be provided to lower pressure vessel relief valves larger than 2" inlet size when not within reach of mobile equipment. Flanged valves shall be installed immediately adjacent to flanged connections on vessels except when:

9.1.2 9.1.3 9.1.4

a)

The vessel can be isolated by other flanged valves.

b)

Lines connect to the bottom head of vessels supported on skirts, in which case the flanged valve shall be installed outside the skirt. Do not install valves or flanges inside a vessel skirt.

c)

The connecting piping for gauge glass connections is screwed and gauge cocks are not provided, in which case screwed valves may be used.

9.1.5

Screwed valves shall be installed immediately adjacent to screwed connections on vessels except when gauge glass connections with gauge cocks are used in a clean service with pressure service ratings below Class 300 ANSI.

9.1.6

Gauge glasses installed in a dirty service shall be installed with block valves in addition to gauge cocks regardless of the pressure.

9.2

Pump Piping

9.2.1

This specification shall apply to pump piping within the plant or facility Tie Point. It is not mandatory that this specification apply to packaged facility units, when the manufacturer of the unit guarantees the performance and that the fabrication complies with the generally accepted codes.

9.2.2

The piping shall permit an equipment layout arrangement in accordance with the requirements of the applicable equipment installation specification.

9.2.3

Pump suction and discharge piping shall be designed, fabricated, and supported to prevent: a)

Excessive nozzle loads on the pump due to weight of piping or inaccurate flange facings.


Page 15 of 30


b)

Excessive nozzle loads on the pump due to thermal expansion of piping.

c)

Resonance caused by pulsation frequencies generated by the pump.

d)

Transmittal of mechanical vibrations to adjoining equipment or structures.

9.2.4

Piping loads shall be smaller than that stipulated by the Equipment Supplier’s recommendations or follow API 610 guidelines.

9.2.5

In order to meet the requirements of Paragraph 9.3.4, particularly close attention must be given the piping design in the following situations: a)

The pumping temperature is hot or cold.

b)

The pump is physically small and light in comparison to the connected pipe.

c)

The pump is piped in a complex manner so that more than one service can be handled, as in the case of a pump used as a common spare.

9.2.6

If the pump service is not hazardous and the pressures are sufficiently low, flexible piping elements such as flexible couplings may be employed to meet the requirements of Paragraph 9.3.6.

9.2.7

Short radius elbows shall not be used at, or near, the pump suction and discharge connections. RevC Each pump shall have a motor operated suction and a discharge valve as close to the pump nozzle as practical. Block valves shall be line size.

9.2.8

9.2.9

Connections for pressure gauges or pressure instruments at pumps shall be made between the pumps and the first valve including the check valve. 3/4 inch or 1/2 inch nominal pipe size connections in pump nozzles shall be used if provided. Block valve sizes for such connections may correspond to connection size.

9.2.10

Removable spool pieces shall be provided at pump and driver piping nozzles if required to permit the removal of the pump or driver without removing the block valves. A check valve or reducer located against the piping nozzle may be considered as the spool piece.

9.2.11

Eccentric reducers shall be investigated as a means of obtaining clearance between lines on top suction, top discharge pumps.

9.2.12

Piping shall be arranged to permit access for maintenance of pump and driver.

9.2.13

Suction System: a)

Overhead suction lines shall drain toward the pumps wherever practical.


Page 16 of 30


b)

Suction line shall be arranged so that there are no sections of air pocket. RevC

c)

If the pump installation does not require the installation of a permanent full flow filter ahead of the pump, then the pump suction piping shall be designed to include a temporary conical strainer in the pump suction piping. The included angle of the strainer cone shall not exceed 45 degrees. The strainer shall be designed to fit between flanges. It shall be readily removable and equipped with a handle extension which extends outside of the flange. Reduction in line size at pumps with horizontal suction connections shall be made with eccentric reducers, flat side up, if the suction line comes from below the pump centerline. If the suction line comes from above the pump, use concentric reducers.

d)

9.2.14

Discharge System: a) RevC

9.2.15

9.2.16

Each centrifugal and positive displacement rotary pump shall have a Duel plate Type check valve installed in the main liquid discharge flow line if reverse flow through the pump upon shutdown is a possibility. The check valve shall be line size and shall be located between the pump discharge connection and the first discharge stop valve. Check valves are not required in the discharge of pumps where the piping is to drain back into a tank or pit through the pump.

Vents: a)

Manually operated priming vents shall be provided in the pump suction piping, pump suction bay, and pump casing to permit priming the pump before starting.

b)

Indoor pumps which handle toxic fluids, light hydrocarbons (i.e., rich oil or lighter) or hydrocarbons above bubble point shall be provided with a pump venting system running to a vent pot which, in turn, is vented to a safe location, or shall be vented to a flare or pressure system which can handle both liquids and gas.

c)

Vent systems for outdoor pumps handling light hydrocarbons shall be a matter of individual design considering the hazards which would be involved with open vents. Pumps handling toxic fluids shall be vented into a flare or closed drain system.

Minimum Flow Bypass: a)

Each multistage centrifugal pump and any other centrifugal pump handling a bubble point liquid which may at any time be caused to operate against a closed discharge control valve shall be provided with a minimum flow bypass sized to permit a minimum safe flow through the pump as specified by the pump manufacturer. The bypass must originate in the discharge line between


Page 17 of 30


the pump discharge flange and the check valve, and must be arranged to return the bypassed liquid back into the suction vessel. Flow shall be controlled by a restriction orifice up to 345 kPa (50 psi) differential. Above 345 kPa (50 psi) differential, use a drilled barstock restriction tube. b)

The minimum flow bypass specified in Paragraph 9.3.16.a is not required if the pump is provided with an automatic low flow shutdown device.

c)

The minimum flow bypass may either operate continuously or be controlled by instrumentation to insure the required minimum flow through each individual pump in the following cases: 1) 2)

d)

9.2.17

Electric motor driven multistage process pumps, having their capacity regulated by automatic flow control valves intended to maintain a manually set and essentially constant flow rate substantially greater than the pump manufacturer's safe minimum flow rate, shall have manually operated minimum flow bypasses for starting and switching pumps.

Balancing Bleed-off: a)

Each multistage centrifugal pump handling a liquid close to its bubble point, and depending for hydraulic balance upon a balancing drum or similar device, shall be provided with a balancing drum bleed-off pipe arranged to return the bleed-off stream back to the suction vessel.

b)

The bleed-off stream may serve as a minimum flow bypass when permitted by the pump manufacturer.

c)

If the liquid handled is substantially below its bubble point and a separate minimum flow bypass is provided, the balancing line may be returned to the pump suction.

9.2.18 9.2.19

If two or more multistage pumps are to be operated in parallel and at least one of the pumps is turbine driven. If two or more dissimilar multistage pumps are to be operated in parallel.

DELETED

RevC

Waste Disposal Drains: a)

Provision shall be made at each pump installation to carry away leakage wastes to some acceptable disposal area. This is especially important if the pump has one or more packed stuffing boxes

b)

When the pump is installed in a plant or facility which has a conventional waste disposal system, then the following shall be provided:


Page 18 of 30


Pumps handling light hydrocarbons shall have the drains plugged. Drains from pumps handling toxic fluids shall be valved and piped directly into a closed drain system. 9.2.20

Pump suction piping shall be arranged with particular care to avoid unnecessary pressure drop and vapour pockets. Reducing elbows or concentric reducers are preferred where size changes are necessary in pump suction lines. Eccentric reducers shall be used only where unvented pockets otherwise cannot be avoided.

9.2.21

Piping at pumps shall be arranged to avoid interference with access around the pumps, or with maintenance. Removable spool pieces shall be provided as appropriate, such as at end suction pump inlets, to permit maintenance without major piping disassembly.

9.2.22

Suitable supports or anchors shall be provided for piping to pumps so that excessive weight and thermal stresses are not applied to the casings.Careful design consideration shall be given to piping configuration to minimize these stresses.

9.2.23

If required, Conical type temporary strainers shall be provided at all pump suctions

9.2.24

Check valves shall be installed at the discharge nozzles of pumps.

9.3

Emergency Shutdown Valves

9.3.1

These valves are activated by the shutdown devices, or by the applicable local or remote shutdown pushbuttons.

9.3.2

Failsafe automatic ESD valves are required on the inlet line to the export oil lines. These valves will be activated by : a)

Fire detection,

b)

High gas detection,

RevC c) d)

Field building ESD pushbutton, Plant ESD,

e)

back-up power failure, or

f)

Instrument air failure.

g)

High pressure detection

Separate block and vent lines shall be provided if post-lubrication is required. 9.3.3 RevC

Motorized Operated block valves are required on the header of all suction and discharge process lines.


Page 19 of 30


9.3.4

Bypass control valves shall fail open when activated by one of the emergency shutdown conditions.

9.3.5

A failsafe valve must relieve the discharge header to flare.

9.3.6

Emergency valves shall be conspicuously painted or signed.

10.0

VALVES, VENTS AND DRAINS

10.1

Valve Location

10.1.1

All valves requiring attention during operation shall be operable either from grade or platform. Valves 4" and smaller, and instrument connections, may have ladder or platfarm access only.

10.1.2

Preferred elevations for valves above grade or platform are: •

In low-level horizontal runs.

•

In vertical runs, between 0.9 and 1.4 meters (3 and 4-1/2 feet).

•

Overhead, at approximately 2.1 meters (7 feet), with bottom of handwheel at 1.9 meters (6-1/2 feet).

10.1.3

Operating valves with bottom of handwheel over 1.9 meters (6-1/2 feet) above grade or platform shall be provided with chain or gear operators from grade or platforms. In pipeways, access or chain operators shall be provided for operating valves. Little used valves may be located to be accessible from the pipeway, using portable ladders.

10.1.4

Chain operation shall not be used for screwed valves or for any valve smaller than 2".

10.1.5

All valves shall have sufficient clearance to facilitate removal of the bonnet or plug.

10.1.6

All Valves size more then 6”(150 NB) should be Motorized Operated (MOV) unless RevC other wise specified in P & ID

10.2

Vents and Drains

10.2.1

Piping and instrument diagrams shall show connections, valves and piping for equipment filling, draining, venting and pressuring.

10.2.2

The piping and instrument diagrams shall show connections, valves and piping needed for plant start-up, operation and shutdown. Main air lines must have a valve


Page 20 of 30


and bull plug installed at end of each run for blowdown or future extension. All other services shall have vents and drains provided at the piping high and low points, so the system can be completely filled, vented, hydrostactically tested and drained. Piping high point vents shall be 3/4" minimum size, plugged or blinded. Piping low point drains shall be 3/4", minimum size, valved and plugged or blinded. 11.0

PRESSURE RELIEF SYSTEMS

11.1

General

11.1.1

Relief valves shall be installed in an upright position and in a location easily accessible from a platform or grade.

11.1.2

Orient all gate valves and butterfly valves so that the valve stem is in a horizontal position.

11.2

Inlet Piping

11.2.1

Preferably, relief valves shall be mounted directly to the vessel/tank nozzle or on Piping system when appropriate. Inlet piping for remotely mounted relief valves shall be designed to limit thrust and pressure drop in the inlet pipe. The pressure drop between the protected equipment and the pressure relief valve inlet shall not exceed 3% of the valve set pressure.

11.3

Discharge Piping

11.3.1

Relief valves in water or air service may discharge to atmosphere. However, the following requirements shall apply: a)

Discharge piping shall be galvanized;

b)

The outlet of the piping shall be cut at a 45 degree angle to the axis of the pipe and shall be weather and bird protected;

c)

Weep holes shall be provided at the low points of the discharge piping and so placed that the discharge is directed away from operating areas.

11.3.2

Discharge piping shall be sloped and self draining from the relief valves to the flare header and from the header to the knock-out drum. No pockets shall be permitted.

11.3.3

Relief valve discharge piping shall be independently supported and carefully aligned. Piping stresses shall be avoided by proper support, anchoring, or provision for flexibility. Fixed support may cause stresses at the relief valve due to thermal changes and should not be used.

11.3.4

Relief valve discharge piping installation must provide for proper valve performance with due consideration for the effect of back pressure on the particular valve design.


Page 21 of 30


12.0

WALL THICKNESS AND CORROSION ALLOWANCE

12.1

General

12.1.1

The pipe wall design thickness shall be calculated in accordance with the applicable codes or Refer Piping Material specification.

12.2

Minimum Wall Thickness

12.2.1

Wall thickness for specific services shall be as specified in 0435-JH0902-00-PE-SPC0002 Piping Materials specification.

13.0

UNDERGROUND PIPING

13.1

General

13.1.1

Underground piping refers to process and utility lines below grade.

13.1.2

Lines shall be laid along the side of roads and outside of tank walls.

13.1.3

Lines shall not be routed under foundations without written approval of HPCL/WP.

13.2

Painting and Protective Coating As specified in specification 0435-JH0902-00-PE-SPC-0003

14.0

TANK PIPING

14.1

General

14.1.1

A fire walled area is one containing one or more tanks totally surrounded by a firewall.

14.1.2

Piping shall be laid out to ensure sufficient flexibility to provide for settlement between tanks.

14.2

Tank Valves and Vents

14.2.1

Block valves at tanks shall be steel. Other valves shall be installed in accordance with flow plans and line classification.


Page 22 of 30


14.2.2

Suction and filling lines shall be vented to relieve pressure from thermal expansion of line contents.

14.3

Above Ground Piping

14.3.1

Piping extraneous to a group of tanks shall not be located within a firewall.

14.3.2

Where a pipe is routed through an earth firewall the pipe shall be coated and wrapped. Where the firewall is concrete the pipe shall be sleeved.

14.4

Piping Below Ground

14.4.1

Extraneous piping may be routed through firewalled areas only if routing outside the firewall is not possible.

14.5

Internal Tank Heater Piping

14.5.1

Condensate piping shall not be less than extra strong.

14.5.2

Steam or condensate lines inside tanks shall be of welded construction. Flanged joints shall not be used.

15.0

BRANCH CONNECTIONS

15.1

General

15.1.1

Any line taken off from a main line shall be considered as a branch line. Preferred connections shall be at right angles, but 45° connections may be used if required for the piping layout.

15.1.2

Reference shall be made to Appendix A of this specification and the applicable Piping Material Specification in Piping Specification 0435-JH0902-00-PE-SPC-0002 for details specific to branch connections for metallic and non metallic.

15.1.3

All welding of branch connections in highly cyclic service shall be performed in accordance with the recommendations of the applicable ASME code for pressure piping.

15.2

Gussets Gussets shall be installed for all connections 1-1/2 inch and smaller within battery limits, except in the following services: (a)

Yard and instrument air

(b)

Water

(c)

Inert gas


Page 23 of 30


15.3

Hot Tapping

15.3.1

The method of hot tapping for making connections to lines or equipment shall be used only when all conventional methods are impractical.

15.3.2

Hot tapping may be carried out only where permitted by HPCL/WP and strictly in accordance with safety procedures.

16.0

UTILITY STATIONS

16.1

General

16.1.1

A utility station shall consist of air and water connections except that water connections shall not be provided at platforms.

16.1.2

Utility stations shall be piped up so that they remain in operation during a shutdown of any of the process unit systems.

16.2

Locations

16.2.1

Utility stations shall be located so that the entire area to be served may be reached with a 75 meter length of hose.

16.2.2

Utility stations shall be located at loading racks, near Tank Farm and Pump House etc.

17.0

PIPE SUPPORTS

17.1

General

17.1.1

The supports, guides and anchors for all piping shall be engineered and shown on project drawings.

17.1.2

The piping systems and their supports shall be designed to resist the effect of loads imposed by the weight of the pipe, valves, fittings, insulation and fluid in the lines. Lines which will be hydrostatically tested during initial construction shall be permanently supported to sustain such loads.

17.1.3

The additional loads imposed by dynamic effects e.g. earthquake, wind shall be considered in accordance with the appropriate Code.

17.1.4

Other dynamic effects may require special supports and shall be taken into account in the design of piping systems. Examples include impacts caused by relief valves


Page 24 of 30


opening or flow induced vibration caused by large pressure drops across control valves. 17.1.5

The stresses created by the imposed loads shall not exceed the allowable stresses prescribed by the appropriate ASME Code for Pressure Piping, or where applicable, the ASME Boiler and Pressure Vessel Code.

17.1.6

Supports shall be designed and arranged to prevent excessive stresses, deflections, variations of supporting effort, and possible resonance from imposed vibrations such as that caused by reciprocating pumps or compressors.

17.1.7

Supporting members shall be fabricated of structural steel

17.1.8

Where it is probable that adjustment will be required after installation (to compensate for thermal expansion or settlement), an adjustable support shall be used. Supports shall be designed such that vertical expansion of pipe will not render the supports ineffective.

17.1.9 17.2

Pipe Racks/Pipe Ways

17.2.1

Pipeways for new process units or other “grass roots” facilities shall be sized to provide a surplus capacity of 25% at the completion of construction. It is recommended that in addition to this requirement a design allowance of at least 10% be assumed at the outset of design with anticipation that this allowance will be utilized during the course of engineering. New pipeways in existing facilities shall be sized using the same guidelines.

17.2.2

When lines are required to be located close to grade on sleepers, the minimum clearance shall be 300 mm (1 foot) from grade to the bottom of pipe or to the bottom of insulation for insulated lines.

17.3

Pipe Support Layout

17.3.1

Supports shall be installed while affording normal access to piping and equipment.

17.3.2

Isolated small diameter lines in a bank of large diameter lines shall be supported in a manner such that the main support spacing is not governed by the permissible span for the small diameter lines.

17.3.3

Provision for pipe support shall consider grouping in banks carried at established elevations in each plant area.

17.3.4

Lines at vessels and tanks shall be arranged so as to be supported and guided from the vessel/tank shells without support brackets at vessel/tank nozzles. Where this is not feasible, support from structural steel is permissible.


Page 25 of 30


17.4

Pipe Support Spacing

17.4.1

Pipe support spacing shall not exceed 6 meters. Under special circumstances, permission for longer spans will be granted by HPCL/WP provided detailed calculations of stress and deflection are supplied. For these calculations, maximum deflection shall be limited to 9.5 mm (3/8 inch) based on lines full of water. Stress and deflection shall also be calculated where lines are subject to the following conditions: (i)

All lines over 300°C

(ii)

Lines having substantial concentrated loads such as valves and fittings, unsupported vertical risers and branches.

(iii)

Lines having local reduction in strength due to the installation of special fittings.

(v)

Lines connecting to vessels or tanks having appreciable settlement.

17.5

Support Shoes

17.5.1

Support shoes shall be provided for all insulated lines.

17.5.2

For lines equipped with pipe shoes, proper allowance shall be made in the design of piping and pipe supports to adequately provide for abnormal line movements caused by upset or emergency conditions. This design check is to eliminate the possibility of pipe shoes moving completely off the structural pipe supporting members.

17.5.3

Shoes shall be designed to permit installation and sealing of insulation.

17.6

Anchors

17.6.1

Pipe movement shall be properly directed by using the least number of anchors. Anchors shall normally be designed to transmit directly to foundations all thrusts due to pipe movement. Rigid frame pipe supports shall be used as high thrust anchors where multiple anchors are needed. Guided strut anchors shall be used only where lateral piping thrust might be limited. Struts can be used in place of standard anchors and guides where structural steel is not available. Struts can aid in overcoming support friction without putting undue forces on the nozzles of sensitive equipment like compressors and pumps.

17.6.2

Pipe lines shall be anchored where necessary for the purpose of restraining movement and protecting equipment, branch connections, etc. from thrusts due to expansion, contraction or pressure.

17.6.3

Where lines are supported on shoes, the shoes shall be welded to the anchor. For high thrust forces a detailed shoe design is required.


Page 26 of 30


17.6.4

Where lines are not supported on shoes, the line shall be fastened to the anchor by means of brackets, U-clamps, etc. Welding the line directly to the anchor is not acceptable.

17.6.5

Anchors or thrust blocks below grade shall be designed in accordance with good engineering practices.

17.6.6

Anchors shall be provided at the battery limits on all piping leaving a unit, to prevent any stresses from being transmitted to the offsite piping.

17.6.7

Where necessary, anchors shall be provided in conjunction with expansion loops, expansion joints and guides to control excessive movement of the lines.

17.7

Guides

17.7.1

The following table for guide spacing shall be used for control of pipe against thermal and dynamic forces. The guides shall be located at support points nearest to the dimension shown in the table. Guide Spacing Table Line Size (in NPS) 2 & Smaller 3 4 6 8 Thru 12 14 Thru 20 24 & Larger

Across Loops

Straight Pipe Runs

6.0 m 9.0 m 12.2 m 18.3 m 18.3 m 18.3 m 18.3 m

12.2 m 15.2 m 18.3 m 21.3 m 24.4 m 27.4 m 30.5 m

From Changes In Direction 6.0 m 7.6 m 9.0 m 10.7 m 12.2 m 13.7 m 15.2 m

On Columns

7.3 m 7.3 m 9.0 m 9.0 m 12.2 m 12.2 m 12.2 m

Guides on adjacent lines shall be staggered where possible. 17.8

Pipe Hangers

17.8.1

When suspended type supports are necessary, either with or without springs, the rod type is preferred.

17.8.2

In general, spring type supports shall be used only where vertical expansion limits the use of rigid supports. Spring hangers shall be used to relieve the dead load weight on equipment where rigid supports are not practical. All spring hangers shall be sized according to operating conditions.

17.8.3

Spring supports may be either variable or constant load type provided that overstressing of line or nozzles is not produced.


Page 27 of 30


17.8.4

Variable and constant support spring hangers and supports shall be provided with the calibrated load clearly indicated, a scale showing the range of movement and an accurate means of adjustment.

17.8.5

All spring hangers and supports shall be adjusted in the field after unit start up and in accordance with the manufacturer's instructions.

17.9

Auxiliary Supports

17.9.1

In addition to supports required during operation and for hydrostatic testing, auxiliary supports shall be provided to adequately support piping while disconnected from the following: (i)

Flanged connections at safety relief valves when the attached piping weights more than 25 kg

(ii)

Pumps,

(iii)

Locations where removable pipe spools are required.

18.0

PIPING FOR INSTRUMENTS

18.1

Control valve by-pass piping shall provide sufficient clearance for the removal of the control valve from the loop.

18.2

Where control valve failure will result in plant shutdown, all control valves shall be provided with block valves and by-pass valves rated for the same design pressure as the upstream piping. By-pass valves shall be designed for a capacity at least equal to the capacity of the control valve.

18.3 18.4

Flanged end reducers or spools shall be used between flanged control valves and block valves. The length of the reducers or spools shall be sufficient to permit removal of bolts, and the installation of drain or vent connections.

18.5

Valved 1" drains shall be provided on the isolatable spool upstream of control valves.

18.6

All control valves in socket weld piping shall be flanged.

18.7

The only devices which may be mounted on control valves are valve positioners, volume boosters, lock-up relays and pressure controllers. These devices shall be installed so as to be easily accessible for servicing. These devices shall not be mounted on control valves when vibration may cause malfunction.


Page 28 of 30


18.8

Orifice flanges shall be located adjacent to walkways, platforms, or structures and shall be installed in horizontal pipe runs, wherever possible. Orifice flanges shall have socket weld taps except where screwed connections are specifically permitted in Piping Material Specification 0435-JH0902-00-PE-SPC-0002

18.9

Instrument air distribution headers shall be 2" minimum. A block valve shall be provided for each take-off connection from these headers.

18.10

All gauge glasses and instruments in all process services shall be provided with 1/2" minimum drain connections, piped to their respective closed drain system.

18.11

Piping details for instruments shall be as specified in General Specification 0435JH0901-02-00-IN-DBR-0001 Instrumentation and Control Systems.

19.0

SAMPLE CONNECTIONS

19.1

Unless otherwise specified, double valved sample connections (Using a 3/4" main block valve and a 1/2" bar stock needle valve for regulation) shall be provided as required to permit full evaluation without disconnecting piping or instruments during plant performance tests. Every line containing a process flow meter shall be provided with a sample connection. Liquid sample connections shall be taken off the side of the pipe.

20.0

NON-CODE PIPING (Piping not covered by applicable codes) Welding and fabrication on non code piping such as: fire water lines, air lines and plant water piping shall conform to ANSI B31.3.

21.0

FIREWATER LINES

21.1

Firewater installations shall comply with the latest edition of the National Fire Code Volume 2 Standard 24.

21.2

All firewater installations shall be closed loop. The number of hydrants, arrangement of outlets and isolation valves as per applicable code

21.3

Top of firewater lines shall be installed 300 mm (12") below the frost line.

21.4

Fire hydrant mains shall be as per process P & ID. Above ground ring main shall be painted with Anti corrosive paint and under ground with wrapping and Tar Enamel coating RevC


Page 29 of 30


21.5

Self draining hydrants complete with 2-1/2" A.M.A. thread hose connections shall be used.

21.6

Hydrants and post-indicator valves shall be set on flat stones or concrete slabs, and about a barrel of clean gravel placed around the bottom of the hydrant to insure quick drainage.

21.7

Hydrants shall be protected against mechanical damage by installing a protective post barrier around the hydrants.

21.8

Underground valves to be non-rising stem, steel and brass trim type.

22.0

GUARANTEE Contractor shall guarantee the piping against defective materials, poor workmanship and improper design for a period of one year after the piping has been placed in regular operation, the total period not to exceed eighteen months from the date of receipt. Contractor shall repair or make good, at his own expense, any defects noted during the guarantee period.


Page 30 of 30

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) SPECIFICATION FOR EXTERNAL PAINTING AND PROTACTIVE COATING


SPECIFICATION FOR EXTERNAL PAINTING AND PROTACTIVE COATING 0435-JH0902-00-PI-SPC-0003 09 SEP 09


DOC. NO. : 0435-JH0902-00-PE-SPC-0003 Rev. C

Page 1 of 19


SYNOPSIS



DESCRIPTION

PREPARED BY

CHECKED BY

A

Issued for IDC

D. Hemnathan

S. Ishwad

J. Wallace

B

Issued for Review

D. Hemnathan

S. Ishwad

J. Wallace

C

Issued for Tender

D. Hemnathan

S. Ishwad

J. Wallace

D

Reissued for Tender

D. Hemnathan

S. Ishwad

KMNP


APPROVED BY

DATE

CLIENT APPROVAL

10 July 09

N/A

13 July 09

14 July 09

09 Sep 09

Page 2 of 19

DATE



SCOPE.............................................................................................................................5

2.0

CODES, REGULATIONS AND STANDARDS .................................................................5

3.0

GENERAL........................................................................................................................6

3.1

Workmanship ...................................................................................................................6

3.2

Marking Conditions...........................................................................................................6

4.0

MATERIALS ....................................................................................................................6

4.1

Storage of Materials .........................................................................................................6

4.2

Manufacturer's Recommendations ...................................................................................6

5.0

EXTENT OF PAINTING ...................................................................................................6

5.1

Surfaces to be painted......................................................................................................6

5.2

Surfaces NOT to be painted .............................................................................................7

6.0

EXPOSURE CONDITIONS ..............................................................................................7

7.0

AMBIENT LIMITATIONS .................................................................................................8

7.1

Surface Preparation and Material Application ...................................................................8

7.2

Ventilation ........................................................................................................................8

8.0

SURFACE PREPARATION .............................................................................................9

8.1

Abrasive Blast Cleaning ...................................................................................................9

9.0

PRIMING AND FINISHING ..............................................................................................9

9.1

Manufacturer's Recommendations ...................................................................................9

9.2

Application Procedures.....................................................................................................9

9.3

Types of Primer ..............................................................................................................10

9.4

Types of Finish Paint ......................................................................................................11

10.0

INSPECTION .................................................................................................................12

11.0

GUARANTEE.................................................................................................................12

APPENDICES Appendix – 1.0

Color Code


Page 3 of 19


Appendix – 2.0

Exposure Areas


Page 4 of 19


1.0

SCOPE This specification covers the selection of materials and procedures to be followed in the course of surface preparation and the application of protective paint and primer to aboveground and Under-ground piping, vessels, Tanks, structures and other materials, whether they are prepared and protected in the shop or field. However the Contractor’s is fully responsible for supply and apply of all paints materials carrying out all the necessary painting, coating and lining on external and internal surfaces as per this specification and tender requirement These technical specification shall be applicable for work covered by the contract, and without prejudice to the various code of practice, standard specification etc. It is understood that the Contractor shall carry out the work in all respect with the best quality of materials and workmanship and in accordance with the best engineering practice and this specification. Contractor shall carry out work under instructions of Engineer-In-Charge from Consultant/Owner. Consultant also carries out intermediate and final inspection of painting works performed by contractor This specification is to be applicable for GGSR Products evacuation Project by HPCL at Ramanmandi despatch station and Bathinda and Bahadurgarh receipt stations.

2.0


2.1

External painting and protective coating shall meet or exceed the requirements of the latest edition of the following codes, regulations and standards, except as superseded herein. In cases where more than one code, regulation or standard apply to the same condition, the most stringent shall be followed. In the event of a conflict between this specification and other specifications or correspondence, the OWNER shall be consulted and a ruling, in writing, shall be obtained before any work is started. •

Codes, Regulations and Statutes of Authorities having jurisdiction in location of installation.

•

Steel Structures Painting Council Manual SSPC 1 to SSPC10

•

IS 2379 – Colour codes for the identification for pipelines

•

IS 101 - Methods of Tests for ready mixed paints and Enamels

•

ASA A 13.1 – 1981 - Scheme for Identification of piping system ANSI

•

Swedish Standard – SIS-05 5900-1967 / ISO 8501-1 : 1988, for painting Steel Surfaces White Metal Near White Metal Commercial Blast Brush of blast


SA 3 SA 2 ½ SA 2 SA 1

Page 5 of 19


• 2.2

ISO 12944 – A global Corrosion Standard

Some requirements in this specification may be modified by specific requirements in the Purchase Specification. In case of conflict, the specific requirements supersede this specification. The order of precedence of documents is as follows: 1) 2) 3) 4) 5)

Purchase order. Equipment Data sheets This specification. Owner’s Specifications Referenced International Codes and Standards.

2.3


3.0

GENERAL

3.1

Workmanship Work shall be done by qualified and competent craftsmens in a neat and workman like manner conforming to code requirements and industry standards.

3.2

Marking Conditions Where elevated structures require marking for safety consideration, they shall be marked in accordance with the requirements or the Authority having jurisdiction.

4.0

MATERIALS

4.1

Storage of Materials Materials shall be stored in Manufacturer's containers, clearly marked with Manufacturer's labels, under Manufacturer's specified storage condition.

4.2

Manufacturer's Recommendations Materials shall be used and applied in accordance with Manufacturer's recommendations which shall take precedence over this specification.

5.0

EXTENT OF PAINTING

5.1

Surfaces to be painted

5.1.1

All surfaces subject to weathering, rusting or corrosion by exposure to the elements shall be painted. All uninsulated carbon steel surfaces shall be primed and painted.


Page 6 of 19


5.1.2

Carbon steel surfaces which are insulated or fire-proofed shall, as a minimum, be coated with primer.

5.2

Surfaces NOT to be painted

5.2.1

The following are not to be painted and must be protected from painting: •

Porcelain

•

Gauge Glasses

•

Meter Faces

•

Valve Stem and Threads

•

Working Surfaces of Equipment

•

Name Plates

•

Aluminum, Plastic and Stainless Steel

•

Insulation or Fireproofing

•

Galvanized Steel

•

Concrete, Transite, Masonry, Stucco, Etc.

•

Factory Finished Control Panels

•

Factory Finished Instrument Cases and Meters

•

Factory Finished Equipment, Including Filters, Pumps, Control Valves, Etc.

•

Factory Finished Buildings

5.2.2

Masking or compounds used to protect non-painted surface must be removed prior to completion of the job.

6.0

EXPOSURE CONDITIONS

6.1

Coating requirements are primarily determined by exposure conditions. The types and severity of exposures are outlined in the Appendixes 2.0. These Appendices are to be used in selecting a coating system for facilities where conditions are expected to be similar to those shown as per the charts.

6.2

Exposure conditions may overlap in a single location or a change in operation may bring a change of exposure conditions, either more or less severe.

6.3

Exposure Areas selected for this specific project – Definitions

6.3.1

Areas Classification C3 as per ISO 12944 (See Appendix 2.0). This exposure area shall be defined as any area where Urban and industrial atmospheres. Moderate sulphur dioxide levels Production areas with chemical fumes, mist or dust can combine with high humidity and condensed moisture to corrode carbon steel at rates greater than 150 micrometers per year and corrode zinc at rates greater than 25 micrometers per year. Local rates of pitting corrosion may be higher.


Page 7 of 19


Other areas that are having equipment and surfaces operating above 66°C and are subject to spills of corrosive materials Examples of areas where severe exposure conditions exist are sulphur plant areas, sulphur loading areas, chlorination units, areas within 15m radius of cooling towers and areas with high concentrations of solvent and alkaline fumes. 6.3.2

Areas Classification C1/C2 as per ISO 12944. This exposure area shall be defined as Ruler area, Low pollution, heated buildings/Natural atmosphere, normal outdoor weathering and/or light concentrations of chemical fumes that combine with humidity and condensed moisture to corrode carbon steel at rates of 80 micrometers or less per year and zinc is almost free of corrosion. Examples of areas are most tank farms, areas where moderate exposure conditions may be found and equipment operating at a temperature such that condensation forms on equipment externals

6.4

Decide on the design life (durability) of the coating system ISO 12944 Durability ranges (Time to first major maintenance) High Durability Medium Durability Low Durability

> 15 years design life 5 to 15 years design life < 5 years design life

For this Project specific Medium Durability selected 7.0

AMBIENT LIMITATIONS

7.1

Surface Preparation and Material Application Surface Preparation and Material application is advisable when ambient temperature of the atmosphere is at maximum level; Surface preparation and primer shall be in painting Booth. Selected surface preparation standard for this project specific is SA 21/2 No surface preparation or application of material may take place under the following conditions:

7.2

•

Wet or damp atmosphere

•

Noticeable wind

•

Atmosphere contaminated by dirt, dust, oil, product or any other pollutant

Ventilation During all stages of surface preparation and application of material, adequate ventilation must be assured.


Page 8 of 19


8.0

SURFACE PREPARATION The type of surface preparation shall be in accordance with Appendix 2.0

8.1

Abrasive Blast Cleaning

8.1.1

The steel surface shall be cleaned by either abrasive blast cleaning or shot-blasting.

8.1.2

All rough welds, burrs and sharp surface projections shall be ground smooth and all weld splatter shall be removed prior to blasting operations.

8.1.3

Blast cleaning operations shall not be conducted on surfaces that will be wet after blasting and before coating,

8.1.4

The blast cleaned surface shall be coated with one application of specified primer during the same day as blasted, prior to sundown of that day and before any visible rusting occurs. Blast cleaned surfaces allowed to set overnight shall be reblasted prior to priming.

8.1.5

Sandblast sand shall be freshwater washed, controlled particle size, high silica content sand, with sharp angular surfaces and no soft particles to ensure fast, positive cleaning action with a minimum of dusting when used to blast clean metal surfaces. Under no circumstances shall it contain clay particles or any other extraneous matter.

8.1.6

Profile depth of the abrasive blast cleaned surface shall not be less than 25 nor greater than 40 micrometers

8.1.7

The compressed air for blasting shall be free of water and oil.

8.1.8

No coating shall be permitted to be applied over scale, rust, oil, grit or other foreign material. All sand, shot and grit will be removed by brush, air blast or vacuum type cleaner prior to applying primer. Care shall be exercised to assure that the cleaned surface is not contaminated with any foreign material or fingerprints prior to applying primer.

8.1.9

Surface preparation of fabricated items to be painted in the shop shall be done in an area free of dust and contaminants from other shop work.

9.0

PRIMING AND FINISHING

9.1

Manufacturer's Recommendations The finish and primer paint Manufacturer's recommendations on application and surface preparation are to take precedence over these general specifications.

9.2

Application Procedures

9.2.1

The normal method of application shall be airless spraying method.

9.2.2

The gun shall be at right angles to the surface and 20 cm to 25 cm from the surface.

9.2.3

Each pass of the gun shall overlap by 50%.


Page 9 of 19


9.2.4

When a pause in spraying occurs, the material shall be blown back into the pot.

9.2.5

The material in the pot shall be kept thoroughly mixed at all times.

9.2.6

Any material not used in its pot life shall be destroyed and the containers used thoroughly cleaned.

9.2.7

No spraying shall be done within 15 cm of unprepared surfaces.

9.2.8

Prime coating shall be applied soon after preparation - before flash rusting occurs.

9.2.9

Finish coating shall be applied as soon as possible after the underlying coat is in condition to receive it, according to Manufacturer's specifications.

9.2.10

Care must be taken to ensure that "hard to get at" places are properly primed and painted, that there is no bridging, etc.

9.2.11

Thickness gauge shall be used to determine that a complete even coat has been applied for each primer and finish coat.

9.3

Types of Primer See Below Table.

Sr. No.

Description

P01

P02

P03

P04

P05

A

Technical Name

Epoxy Zinc Phosphate Primer

Metallic Zinc Rich Epoxy Primer

Inorganic Zinc Silicate

Tank Mastic or High Build Coal tar Epoxy

Epliux FRE Durabuild Coating

B

Type of Composition

Two Components Low VOC, High Solids, fast Curing, pigmented with zinc phosphate

Two components, Composition and performance requirements of SSPC Paint 20

Two Pack air drying self solvent based inorganic Zinc Silicate coating

Two pack polyamide curred epoxy resin blended with coaltar medium, suitably pigmented

HOLD*

C

Volume of Solids (approx.)

70%

59 %

60%

65%

HOLD*

D

Theoretical covering Capacity in M2/coat/litre (approx.)

4-6

8 - 10

8-9

5-7

HOLD*

E

Loss Factor

40%

45%

35%

45%

HOLD*

F

Thinning

5%

5%

5%

5%

HOLD*

* Hold Point will be clear while detailed Engineering 9.4

Types of Intermediate/Finish Paint


Page 10 of 19


See below table for types of finish paint. Where required coats of finish as per appendix 2.0 are to be applied, the first coat is to be discoloured (1 paint of contrasting shade to every gallon of main colour), so as to aid visual inspection for holidays, coverage and wear, etc. Sr. No.

A

Description

F01

F02

F03

F04

Technical Name

Acrylic Polyurethene finish paint

Epoxy High build finish paint (Polyamide)

Self priming type surface tolerant high build epoxy coating. (complete rust control Coating)

Epliux Super High Build Coating

Two Pack aliphatic isocynate cured acrylic finish paint

Two pack polyamide cured epoxy resin medium suitably pigmented

Two pack epoxy resin based suitable pigmented and capable of adhering to manually prepared surface

HOLD*

B

Type of Composition

C

Volume of Solids (approx.)

57%

62 %

80%

HOLD*

D

Theoretical covering Capacity in M2/coat/litre (approx.)

10-13

5-6

5-7

HOLD*

E

Weight per litre in kgs/litre (approx.)

1.3

1.4

1.4

HOLD*

F

Loss Factor

30%

30%

30%

HOLD*

G

Thinning

5%

5%

5%

HOLD*

* Hold Point will be clear while detailed Engineering 9.6

PAINT SYSTEM For this project specific system selected C3 as per Cl, 6.3.1 the selected paint system is also suitable upto 90 deg C Temperature for specific requirements. Following options, Option 1 for tank outside and Piping, Option 2 for Tank Bottom Plate soil side, Option 3 for Inside Tank Bottom plate and inside shell up to 1mtr. from bottom, Option 4 for Floating Roof tanks Roof. Suggested for this project specific OPTION 1- tank outside and Piping Paint Type DFT(µ) Primer P03 60 Intermediate Coat F02 100 Final Coat F01 2 X40 TOTAL DFT 240 OPTION 2 - for Tank Bottom Plate soil side Paint Type DFT(µ) Primer P04 2 X100 TOTAL DFT 200


Page 11 of 19


OPTION 3- Tank Bottom plate and Inside shell up to 1mtr from bottom Paint Type DFT(µ) Primer P03 75 Final Coat F04 125 TOTAL DFT 200

Paint Primer

OPTION 4- Floating Roof tanks Roof Type DFT(µ) P05 2X150 TOTAL DFT 300

10.0

INSPECTION

10.1

The Owner’s representative shall have access to all work while being performed and shall be given sufficient notification to complete all required inspections.

10.2

All prepared surfaces shall be subject to inspection by Owner’s representative and approval before primer is applied.

10.3

Measurement of paint dry film thickness will be made with a Mikrotest or similar gauge. Failure to meet specified thickness requirement shall cause work to be rejected.

10.4

Paint shall not be thinned beyond Manufacturer's recommendation and if OWNER requires it, a viscosity check shall be made.

10.5

Work will be rejected because of poor workmanship. Poor workmanship is defined as inadequate drying or curing, dirt and dust inclusions, overspray, pin-holes, runs and sags, or inadequate film build.

10.6

Acceptable finish work must be free of abrasions and must be uniform in colour and appearance.

11.0

GUARANTEE Contractor shall guarantee painting against poor workmanship and improper application. This guarantee shall remain in effect for seven (7) years from the date painting is completed or after final inspection release note from consultant. Contractor shall repair at his own expense any defects noted during the guarantee period.


Page 12 of 19


APPENDIX - 1.0 PAINT COLOUR CODE FOR PIPING AND EQUIPMENT: 12.0

SCOPE This specification covers the requirement of colour scheme for the identification of the contents of the pipelines carrying fluids, storage tanks and equipments in refineries, terminals and petrochemical installations The following colour coding system has been made based on international standards like ASME/ANSI, BS and Indian Standard.

13.0

IDENTIFICATION The system of colour coding consists of a ground colour and secondary colour bands superimposed over the ground colour. The ground colour identifies the basic nature of the service and secondary colour band over the ground colour distinguishes the particular service. The ground colour shall be applied over the entire length of the uninsulated pipes. For insulated lines ground colour shall be provided as per specified length to identify the particular service. Above colour code is applicable for both unit and offside pipelines.

13.1

The following ground colour designation for identification of basic classification of various important services shall be followed: Post Office Red

Fire protection materials

Orange

Volatile petroleum products (motor spirit and Lighter)

Oxide Red

Non- Volatile Petroleum Products (SKO and heavier, Including HSD)

Black

Slop Oils

Sky Blue

Water (All purities and temperature)

Sea Green

Air and its components

13.2

Secondary colours: the narrow bands presenting the secondary colour which identifies the specific service may be applied by painting or preferably by use of adhesive plastic tapes of the specific colour.

14.0

COLOUR BANDS AND IDENTIFICATION LETTERING

14.1

The following specifications of colour bands shall be followed For identifying the piping contents, size of letters in legends will depend to some extent upon the pipe diameter. Either white or black letters are selected to provide


Page 13 of 19


max. contrast to the band colour. Bands usually are 50mm wide and regardless of band width, are spaced 25 mm apart when two bands are employed. Colour Bands and sizing of lettering for piping as per IS 2379: Size of Pipe or Covering in inch

Width of Colour Bands in mm

Size of Legend Letters in mm

¾” to 1”

200

10

11/2” to 2”

200

20

3” to 6”

300

30

8” to 10”

600

63

Over 10”

800

90

Size of the letters stencilled / written for equipments shall be as given below: Vessel Pump, and other machinery 14.2

Colour Bands: The location and size of the Bands, as recommended, when used, shall be applied to the pipe. -

14.3

150mm (Height) 50 mm (Height)

On both side of the Valves, tees and other fittings of importance. Where the pipe enters and emerges from wall and where it emerges from road and walkway overpasses, unit battery limits. At uniform intervals along long section of pipe. Adjacent to Tanks, Vessels and Pumps.

For piping, writing of name of service and direction of flow for all the lines shall be done at following location - The letters will be on Black on pipes painted with light shade colours and white on pipes painted with dark shade colour to give good contrast - On stainless steel line precaution should be taken while painting by using low chloride content

14.4

Colour Band Specification: a) b) c) d)

Unit area; bands at intervals of 6.0 Mtrs. Offsite area: Bands at intervals of 10.0 Mtrs. Each pipe segment will have min. one band indication, irrespective of length. The band shall be displayed near walkway, both side of culverts, tank dykes, tanks, Vessels, suction and discharge of Pumps, unit battery limit, near valves of line, etc.


Page 14 of 19


e) In case of camouflaging requirements of civil defence or any other location requirement, the same shall be followed accordingly. The specification for application of the complete piping identification colour code, including base and bands colours, are presented in the enclosed table

Sr. No.

Service

1

Recommended color Code Hydrocarbon Lines (Uninsulated)

2

M.S.

ORANGE WITH 1 DARK AD, GREY

3

HSD

OXIDE RED WITH 1 WHITE BAND

4

SKO

OXIDE RED 1 GREEN BANDS

5

ATF

LIEF BROWN WITH 1 YEIIOW BAND

6

SLOP & WASTE OIL

BLACK WITH ONE ORANGE BAND

7

CORROSION INHIBIBITOR

CANARY YELLOW WITH 1 ALUMINIUM BAND

8

WATER LINES (UNINSULATED)

9

RAW WATER

SKY BLUE WITH 1 BLACK BAND

10

POTABLE WATER

SKY BLUE WITH GREEN RED BAND

11

SERVICE WATER

SKY BLUE WITH 1 SIGNAL RED BAND

12 13 14

FIRE PROTACTION ABOVE GROUND(UNINSULATED) FIRE WATER FOAM AND EXTINGUISHERS

POST OFFICE RED

UNINSULATED EQUIPMENT,TANKS & STRUCTURES

15

VESSELS

ALUMINIUM / OFF WHITE

16

ALL OTHER TANKS

ALUMINIUM / OFF WHITE

17

PUMPS

NEVY BLUE

18

HAND RAILINGS

SIGNAL RED

19

STAIRCASE,LADDER & WALKWAYS

BLACK

20

LOAD LIFTING EQUIPMENTS & MONO RAILS

LEAF BROWN

21

GENERAL STRUCTURES

BLACK


Page 15 of 19


14.5

Colour Scheme in Detail: A) Colour Scheme for Storage Tank (Stored Fluid- MS): The following details should be painted on the tanks : Tank Number Name of Product Tank Capacity ( in KLs) Size of Tank : Dia x Ht. ( in M) Safe Filling Ht. (in M) Date Painted Date Commissioned Date of Calibration Date of Hydro testing Due Date of Cleaning Asset ID No. Beige No. 388 (IS-5) (roof/shell) Leaf Brown No. 489 (IS-5) ( bottom band) Corporate Logo ( Sticker ) on Storage Tanks White Back Ground 3M Vinyl 3650-10 ( white) Blue & Red Gasoline resistant film of 7725 series 7725-63 ( Red) 7725-37 (Blue)

Note : 1. The corporate logo should be positioned at 2/3rd height of tank. 2. The Corporate logo can be painted or sticker can be pasted. 3. The height-width proportion of the Logo should not be compromised. Logo size for tanks up to 12m height – 7.5 feet x 6 feet Logo Size for tanks more than 12m height – 10 feet x 8 feet 4. Visibility of the Logo should be kept in mind while selecting the area on the tank. 5. Specifications of the paint should be in line with HPCL guidelines. Note on Product details : 1. Height of bottom band will be equal to 1.25 m , from bottom of the tank. 2. Details about the product stored in the tank should be painted in black on 2nd streak from the bottom , near the staircase. 3. The sequence of the details should follow as mentioned above.


Page 16 of 19


Lettering Size : For Tank Number For Name of product Other details

9 inches height 6 inches height 3 inches height

B) Colour Scheme for Storage Tank (Stored Fluid- HSD/ SKO/ INTERFACE/SLOP): Satin Blue No. 177 (IS-5) ( Roof / Shell) Oxford Blue No. 105 (IS-5) (Bottom Band)

Notes: 1. The railing at the top of the tank should be painted in Jet Black 2. The platform along the top rim of the tank should be painted in the colour of the roof / shell of the tank ( as per the tank colour scheme). 3. The sprinkler pipe should be painted Fire Red. 4. The railing , rungs and supports of the staircase going up the tank should be painted in Jet Black. 5. The supports of the fire hydrant pipes going up the tank should be painted in Jet Black. 6. “Water drain” & “Manhole” should be painted at the same level on the 1st streak , closer to the valves & manhole. 7. The size of the lettering should be 3”. 8. Contractor shall follow Camouflaging requirements at Bathinda Receiving Depot.


Page 17 of 19


APPENDIX - 2.0

DESCRIPTION

AREA COVER

TEMP DEG. C

Field Paint system for C3 Environment for CS

For Uninsulated Structures, Piping, Equipments, Rotary Eqpt,s etc.

-14 to 80

Field Paint System for CS Storage tanks (External) for C3 Environment

External shell, wind Girders as well as and associated structural works, for all environment for HSD, ATF, SKO,MS, fire water, raw water, potable water etc.

-14 to 80

SURFACE PREPARATION

SA-21/2

SA-21/2

PRIMER

FINISH PAINT

As per Option 1

As per Option 1

Total DFT(µ)

305

305

Roof top of all above ground tank including top side of floating roof of open tank as well as and associated structural works, rolling and stationary ladders, spiral stairway, hand rail for all environment for HSD, ATF, SKO,MS,

-14 to 80

SA-21/2

As per Option 4

Field Paint System for CS Storage tanks (External) for C3 environments

External Surface of bottom plate (Soil Side) for all Storage tank

-14 to 80

SA-21/2

As per Option 2

200

Field Paint System for CS Storage tanks (Internal) for C3 environments

Internal surface of Tanks Bottom plate and Tank shell up to 1 mtr. height from bottom plate

-14 to 80

SA-21/2

As per Option 3

200

Field Paint System for CS Storage tanks roof (External) for C3 Environment

Coating system for External Side of Underground CS Plant Piping &

Yard and Over the ditch coating

25 to 60


SA-21/2

2 Coats of P02 of 75 DFT

4 mm Thk. Coaltar coating Wrappi ng as per AWWA-

REMARKS

300

4 mm

Page 18 of 19

Contractor shall follow Camouflagin g requirements at Bathinda Receiving Depot Contractor shall follow Camouflagin g requirements at Bathinda Receiving Depot

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) SPECIFICATION FOR EXTERNAL PAINTING AND PROTACTIVE COATING Tanks


C-203 in 2 layer of each 2 mm Thk

Page 19 of 19

0435-JH-0902

9/8/2009

VALVE LIST

TITLE PROJECT:

MANUAL VALVE LIST FOR RAMAN MANDI - BATHINDA DOC No. BAHADURGARH PIPE LINE GGSR PRODUCTS EVACUATION PROJECT CLIENT:

0435-JH0902-70-PL-LST-0004 HINDUSTAN PETROLEUM CORPORATION LTD

PROJECT NO: 0435/JH-0902

C

ISSUED FOR TENDERING A KULKARNI

K M N PILLAI

K M N PILLAI

08.09.09

B

CLIENT REVIEW

A KULKARNI

S ISHWAD

J WALLACE

01.07.09

A

IDC

A KULKARNI

S ISHWAD

J WALLACE

24.06.09

N/A

REV

DESCRIPTION

DATE

CLIENT APPROVAL

REF P&ID

LOCATION - LINE NUMBER/EQPT NUMBER

PREPARED BY

CHECKED BY

END

ACTUATOR REF. NO.

APPROVED BY

VALVE Sl. No. SIZE

(inch)

QTY

TYPE

MATL RATING CLASS

INSTALLATION

OPERATOR

VALVE TAG/ SPEC NO.

ACTUATOR OPEN / CLOSING TIME

REMARK

RAMANMANDI - BAHADURGARH PIPELINE 1

18"

1

BALL

C2

600

A/G

MOTORISED WITH MANUAL OPERATION

BUTT WELD

70-MOV-4608

BA - C612FX

120 SEC

435-JH0902-70-PR-PID-7001

18"-P-60-565-C2

2

18"

1

BALL

C2

600

A/G


BUTT WELD

70-MOV-4609

BA - C612FX

120 SEC

435-JH0902-70-PR-PID-7001

18"-P-60-565-C2

3

18"

1

BALL

C2

600

A/G


BUTT WELD

70-MOV-4607

BA - C612FX

120 SEC

435-JH0902-70-PR-PID-7001

18"-P-60-565-C2

4

18"

1

BALL

C2

600

A/G


BUTT WELD

70-MOV-4610

BA - C612FX

120 SEC

435-JH0902-70-PR-PID-7001

18"-P-60-565-C2

5

18"

1

BALL

C2

600

U/G


BUTT WELD

70-MOV-4613

BA - C612FEX

120 SEC

435-JH0902-70-PR-PID-7001

18"-P-60-565-C2

6

18"

1

BALL

C2

600

U/G


BUTT WELD

70-MOV-4614

BA - C612FEX

120 SEC

435-JH0902-70-PR-PID-7001

18"-P-60-565-C2

7

18"

1

BALL

C2

600

U/G


BUTT WELD

70-MOV-4604

BA - C612FEX

120 SEC

435-JH0902-70-PR-PID-7001

18"-P-60-565-C2

8

18"

1

BALL

C2

600

U/G


BUTT WELD

70-MOV-4605

BA - C612FEX

120 SEC

435-JH0902-70-PR-PID-7001

18"-P-60-565-C2

9

18"

1

BALL

C2

600

U/G


BUTT WELD

70-MOV-4606

BA - C612FEX

120 SEC

435-JH0902-70-PR-PID-7001

18"-P-60-565-C2

10

18"

1

BALL

C2

600

U/G


BUTT WELD

70-MOV-4611

BA - C612FEX

120 SEC

435-JH0902-70-PR-PID-7001

18"-P-60-565-C2

11

18"

1

BALL

C2

600

U/G


BUTT WELD

70-MOV-4612

BA - C612FEX

120 SEC

435-JH0902-70-PR-PID-7001

18"-P-60-565-C2

12

18"

1

BALL

C2

600

A/G


BUTT WELD

70-MOV-4564

BA - C612FX

50-70 sec

435-JH0902-10-PR-PID-1504

18"-P-10-565-C2

13

18"

1

BALL

C2

600

U/G


BUTT WELD

70-MOV-4566

BA - C612FEX

120 SEC

435-JH0902-10-PR-PID-1504

18"-P-10-565-C2

14

18"

1

BALL

C2

600

A/G


BUTT WELD

70-MOV-4572

BA - C612FX

50-70 sec

435-JH0902-60-PR-PID-6001

18"-P-60-565-C2

15

18"

1

BALL

C2

600

U/G


BUTT WELD

70-MOV-4570

BA - C612FEX

120 SEC

435-JH0902-60-PR-PID-6001

18"-P-60-565-C2

BOLTED BODY / TRUNNION MOUNTED ( Pigable ) BOLTED BODY / TRUNNION MOUNTED ( Pigable ) BOLTED BODY / TRUNNION MOUNTED ( Pigable ) BOLTED BODY / TRUNNION MOUNTED ( Pigable ) BURRIED WITH EXTENDED STEM ( Pigable ) BURRIED WITH EXTENDED STEM ( Pigable ) BURRIED WITH EXTENDED STEM ( Pigable ) BURRIED WITH EXTENDED STEM ( Pigable ) BURRIED WITH EXTENDED STEM ( Pigable ) BURRIED WITH EXTENDED STEM ( Pigable ) BURRIED WITH EXTENDED STEM ( Pigable ) BOLTED BODY / TRUNNION MOUNTED ( Pigable ) BURRIED WITH EXTENDED STEM ( Pigable ) BOLTED BODY / TRUNNION MOUNTED ( Pigable ) BURRIED WITH EXTENDED STEM ( Pigable )

RAMANMANDI - BATHINDA PIPELINE 16

10"

1

BALL

B2

300

A/G


BUTT WELD

70-MOV-4040

BA - C312FX

50-70 sec

435-JH0902-10-PR-PID-1004

10"-P-10-051-B2

17

10"

1

BALL

B2

300

U/G


BUTT WELD

70-MOV-4042

BA - C312FX

120 SEC

435-JH0902-10-PR-PID-1004

10"-P-10-051-B2

18

10"

1

BALL

B2

300

A/G


BUTT.WELD

70-MOV-4062

BA - C312FX

50-70 sec

435-JH0902-20-PR-PID-2001

10"-P-10-051-B2

19

10"

1

BALL

B2

300

U/G


BUTT.WELD

70-MOV-4060

BA - C312FX

120 SEC

435-JH0902-20-PR-PID-2001

10"-P-10-051-B2

BOLTED BODY/ TRUNNION MOUNTED ( Pigable) BURRIED WITH EXTENDED STEM ( Pigable ) BOLTED BODY/ TRUNNION MOUNTED ( Pigable) BURRIED WITH EXTENDED STEM ( Pigable )

NOTE : ALL BALL VALVES WITH FULL BORE

0435-JH0902-60-PL-LST-0004 / REV-B

1 OF 1

0435-JH-0902

VALVE LIST - 4" and Below

TITLE PROJECT:


0435-JH0902-70-PL-LST-0004A HINDUSTAN PETROLEUM CORPORATION LTD


B


A

IDC

REV

DESCRIPTION

A KULKARNI

S ISHWAD

K M N PILLAI

08.09.09

S ISHWAD

J WALLACE

24.06.09

N/A

DATE

CLIENT APPROVAL

REF P&ID


PREPARED BY

CHECKED BY

END

ACTUATOR REF. NO.

APPROVED BY

VALVE Sl. No. SIZE

(inch)

QTY

TYPE

MATL RATING CLASS

INSTALLATION

OPERATOR

VALVE TAG/ SPEC NO.


REMARK

RAMANMANDI - BAHADURGARH PIPELINE 1

3/4"

1

PLUG

C2

1500

U/G

MANUAL

SOCKET WELDED

NA

PL-C604

NA

435-JH0902-10-PR-PID-1504

3/4"-D-10-567-C2

2

2"

1

BALL

C2

600

A/G

MANUAL

RF

NA

BA-C600F

NA

435-JH0902-10-PR-PID-1504

2"-P-10-569-C2

3

1/2"

1

BALL

C2

600

A/G

MANUAL

RF

NA

BA-C600F

NA

435-JH0902-10-PR-PID-1504

2"-P-10-569-C2

4

2"

2

BALL

C2

600

A/G

MANUAL

RF

NA

BA-C600F

NA

435-JH0902-70-PR-PID-7001

SV-01

5

1/2"

4

BALL

C2

600

A/G

MANUAL

RF

NA

BA-C600F

NA

435-JH0902-70-PR-PID-7001

SV-01

6

2"

2

BALL

C2

600

A/G

MANUAL

RF

NA

BA-C600F

NA

435-JH0902-70-PR-PID-7001

SV-02

7

1/2"

4

BALL

C2

600

A/G

MANUAL

RF

NA

BA-C600F

NA

435-JH0902-70-PR-PID-7001

SV-02

8

2"

2

BALL

C2

600

A/G

MANUAL

RF

NA

BA-C600F

NA

435-JH0902-70-PR-PID-7001

SV-03

9

1/2"

4

BALL

C2

600

A/G

MANUAL

RF

NA

BA-C600F

NA

435-JH0902-70-PR-PID-7001

SV-03

10

2"

2

BALL

C2

600

A/G

MANUAL

RF

NA

BA-C600F

NA

435-JH0902-70-PR-PID-7001

SV-05

11

1/2"

4

BALL

C2

600

A/G

MANUAL

RF

NA

BA-C600F

NA

435-JH0902-70-PR-PID-7001

SV-05

12

2"

2

BALL

C2

600

A/G

MANUAL

RF

NA

BA-C600F

NA

435-JH0902-70-PR-PID-7001

SV-06

13

1/2"

4

BALL

C2

600

A/G

MANUAL

RF

NA

BA-C600F

NA

435-JH0902-70-PR-PID-7001

SV-06

14

2"

1

BALL

C2

600

A/G

MANUAL

RF

NA

BA-C600F

NA

435-JH0902-70-PR-PID-7001

2"-P-65-001-C2

15

1/2"

1

BALL

C2

600

A/G

MANUAL

RF

NA

BA-C600F

NA

435-JH0902-70-PR-PID-7001

2"-P-65-001-C2

16

2"

1

BALL

C2

600

A/G

MANUAL

RF

NA

BA-C600F

NA

435-JH0902-70-PR-PID-7001

2"-P-65-003-C2

17

1/2"

1

BALL

C2

600

A/G

MANUAL

RF

NA

BA-C600F

NA

435-JH0902-70-PR-PID-7001

2"-P-65-003-C2

18

2"

1

BALL

C2

600

A/G

MANUAL

RF

NA

BA-C600F

NA

435-JH0902-60-PR-PID-6001

2"-P-60-505-C1

19

1/2"

1

BALL

C2

600

A/G

MANUAL

RF

NA

BA-C600F

NA

435-JH0902-60-PR-PID-6001

2"-P-60-505-C1

20

2"

1

PLUG

C2

600

A/G

MANUAL

RF

NA

PL - C600

NA

435-JH0902-60-PR-PID-6001

2"-P-60-502-C2

21

2"

1

PLUG

C2

600

A/G

MANUAL

RF

NA

PL - C600

NA

435-JH0902-60-PR-PID-6001

2"-P-60-504-C2

22

2"

1

NRV-SWG

C2

600

A/G

--

RF

NA

CH - C600

NA

435-JH0902-60-PR-PID-6001

2"-P-60-504-C2

0435-JH0902-70-PL-LST-0004A

1 OF 2

0435-JH-0902

VALVE LIST - 4" and Below

TITLE PROJECT:


0435-JH0902-70-PL-LST-0004A HINDUSTAN PETROLEUM CORPORATION LTD


B


A

IDC

REV

DESCRIPTION

A KULKARNI

S ISHWAD

K M N PILLAI

08.09.09

S ISHWAD

J WALLACE

24.06.09

N/A

DATE

CLIENT APPROVAL

APPROVED BY

PREPARED BY

CHECKED BY

VALVE TAG/ SPEC NO.


REF P&ID


VALVE Sl. No. SIZE

(inch)

QTY

TYPE

MATL RATING CLASS

INSTALLATION

OPERATOR

END

ACTUATOR REF. NO.

23

3/4"

1

PLUG

C2

1500

U/G

MANUAL

SOCKET WELDED

NA

PL-C604

NA

435-JH0902-60-PR-PID-6001

3/4"-D-60-530-C2

24

3/4"

1

PLUG

C2

1500

U/G

MANUAL

SOCKET WELDED

NA

PL-C604

NA

435-JH0902-60-PR-PID-6001

3/4"-D-60-534-C2

REMARK

RAMANMANDI - BATHINDA PIPELINE 25

3/4"

1

PLUG

B2

800

A/G

MANUAL

SOCKET WELDED

NA

PL-C804

NA

435-JH0902-10-PR-PID-1004

3/4"-D-10-071-B2

26

2"

1

BALL

B2

300

A/G

MANUAL

RF

NA

BA-C300F

NA

435-JH0902-10-PR-PID-1004

2"-P-10-055-B2

27

1/2"

1

BALL

B2

800

A/G

MANUAL

SOCKET WELDED

NA

BA-C804F

NA

435-JH0902-10-PR-PID-1004

2"-P-10-055-B2

28

2"

1

BALL

B2

300

A/G

MANUAL

RF

NA

BA-C300F

NA

435-JH0902-20-PR-PID-2001

2"-P-20-031-B2

29

1/2"

1

BALL

B2

800

A/G

MANUAL

SOCKET WELDED

NA

BA-C804F

NA

435-JH0902-20-PR-PID-2001

2"-P-20-031-B2

30

2"

1

PLUG

B2

300

A/G

MANUAL

RF

NA

PL - C300

NA

435-JH0902-20-PR-PID-2001

2"-P-10-016-B2

31

2"

1

PLUG

300

A/G

MANUAL

RF

NA

435-JH0902-20-PR-PID-2001

2"-P-10-018-B2

2"

1

NRV-SWG

300

A/G

--

RF

NA

PL - C300 CH - C300

NA

32

B2 B2

2"-P-10-018-B2

33

3/4"

1

PLUG

B2

800

A/G

MANUAL

SOCKET WELDED

NA

PL-C804

NA NA

435-JH0902-20-PR-PID-2001 435-JH0902-20-PR-PID-2001

3/4"-D-20-087-B2

34

3/4"

1

PLUG

B2

800

A/G

MANUAL

SOCKET WELDED

NA

PL-C804

NA

435-JH0902-20-PR-PID-2001

3/4"-D-20-071-B2

NOTE : ALL BALL VALVES WITH FULL BORE

0435-JH0902-70-PL-LST-0004A

2 OF 2

0435-JH0902

VALVE MTO SUMMARY-4" and Below

TITLE CLIENT: DOCUMENT No. PROJECT: PROJECT NO:

SIZE

QTY.

TYPE

CLASS

RATING

OPERATION

PIPE LINE BALL VALVES - 4" & Below MTO SUMMARY

HPCL 0435-JH0902-70-PL-MTO-0001A GGSR PRODUCTS EVACUATION PROJECT 0435/JH-0902

REMARK

END CONN.

DESPATCH LOCATION

BALL VALVES - LESS THAN 4 INCH 1/2"

2

BALL

B2

300

MANUAL

SOCKET WELDED

FLOATING TYPE

2"

2

BALL

B2

300

MANUAL

RF

FLOATING TYPE

1/2"

24

BALL

C2

1500

MANUAL

SOCKET WELDED

FLOATING TYPE

2"

14

BALL

C2

600

MANUAL

RF

FLOATING TYPE

2"

1

CHECK

B2

300

--

2"

1

CHECK

C2

600

--

CHECK VALVES RF

SWING TYPE

RF

SWING TYPE

PLUG VALVES 3/4"

3

PLUG

B2

800

MANUAL

SOCKET WELDED

BOLTED BODY LUBRICATED TYPE

2"

2

PLUG

B2

300

MANUAL

RF


3/4"

3

PLUG

C2

1500

MANUAL

SOCKET WELDED


2"

2

PLUG

C2

600

MANUAL

RF


B

ISSUED FOR TENDER

D HEMANATHAN

S ISHWAD

K M N PILLAI

31.08.09

A

SDC

D HEMANATHAN

S ISHWAD

K M N PILLAI

26.08.09

N/A

REV

DESCRIPTION

PREPARED BY

CHECKED BY

DATE

CLIENT APPROVAL

0435-JH0902-70-PL-MTO-0001A

APPROVED BY

1 OF 1

0435-JH0902

LINEWISE BULK MTO - PIPELINE

LINEWISE BULK MTO - PIPE LINE

DOC NO: 0435-JH0902-70-PL-MTO-0002

PROJECT:

GGSR PRODUCTS EVACUATION PROJECT

CLIENT : HINDUSTAN PETROLEUM CORPORATION LTD.

PROJECT NO.:

0435/JH0902

TITLE:

P & ID

Line No.

10

P

10

051

SPEC DESCRIPTION

B2

435-JH0902-10PR-PID-1004

2

P

10

055

B2

435-JH0902-10PR-PID-1004

2

P

20

030

B2

Size-1

B2

PIPE

2

B2

BARRED TEE

10

B2

ISOLATION JOINT

B2

FLANGES

B2

Size-2

Qty

Class / End Ssh./ Thk. Conn.

DIM. STANDARD

Type

A106 GR.B

ASME B36.10

SMLS

0.5

SCH 40

BE

2

300#

BE

10

2

300#

BE

ASTM A694 GRADE F65

MANUFACTURER STD

2

2

300#

A 105

ASME B 16.5

WELDOLET

2

8

SCH 40

A234 GR. WPB

MSS SP97

B2

SOCKOLET

3/4

1

3000#

SW

A105

MSS SP97

B2

SOCKOLET

1/2

2

3000#

SW

A105

MSS SP97

B2

PIPE

2

3m

SCH 40

BE

A106 GR.B

ASME B36.10

B2

PIPE

1/2

1m

SCH 80

PE

A106 GR.B

ASME B36.10

SMLS

B2

FLANGES

2

2

300#

A 105

ASME B 16.5

WNRF

B2

GASKET

2

2

300#

SPW,GRAPHITE FILLER, 4.5 mm SS 316L WINDING WITH 3.2mm INTERNAL & EXTERNAL CENTERING RINGS

ASME B 16.20

SPIRAL WOUND

B2

STUD

M16 X 90 LENGTH

16

300#

ASTM A193 GR.B7 ( FOR STUD ) With 2 Heavy Hex. Nuts of A194 Gr.2H with cadium plating

ASME B18.2

B2

SOCKOLET

1/2

1

3000#

SW

A105

MSS SP97

B2

PIPE

2

2m

SCH 40

BE

A106 GR.B

ASME B36.10

SMLS

ASME B 16.20

SPIRAL WOUND

ASME B18.2

8

B2

GASKET

2

2

300#

B2

STUD

M16 X 90 LENGTH

16

300#


WNRF

SMLS

B2

SOCKOLET

1/2

1

3000#

SW

A105

MSS SP97

3/4 D

20

087

B2

B2

PIPE

3/4

2m

SCH 80

PE

A106 GR.B

ASME B36.10

SMLS

2

20

016

B2

B2 B2

PIPE

2m 2

SCH 40 300#

BE

A106 GR.B

ASME B36.10

FLANGES

2 2

A 105

ASME B 16.5

SMLS WNRF

B2

GASKET

2

2

300#


ASME B 16.20

SPIRAL WOUND

B2

STUD

M16 X 90 LENGTH

16

300#


ASME B18.2

B2

SOCKOLET

1/2

1

3000#

A105

MSS SP97

P

435-JH0902-20PR-PID-2001

0435-JH0902-70-PL-MTO-0002

SW

Remark

ASTM A 860 GRADE WPHY 65 ASME B16.9 / MSS-SP 75


435-JH0902-20PR-PID-2001

435-JH0902-20PR-PID-2001

Material ASTM

1 OF 9

0435-JH0902



DOC NO: 0435-JH0902-70-PL-MTO-0002

PROJECT:



PROJECT NO.:

0435/JH0902

TITLE:

P & ID

Line No. 2

P

20

018

SPEC DESCRIPTION B2

435-JH0902-20PR-PID-2001

18

P

10

565

C2

435-JH0902-10PR-PID-1504 , 0435-JH0909-70PR-PID-7001 , 0435-JH0902-60PR-PID-6001

2

435-JH0902-10PR-PID-1504

0435-JH0902-70-PL-MTO-0002

P

10

569

C2

Size-1

Size-2

Qty

Class / End Ssh./ Thk. Conn. BE

Material ASTM

DIM. STANDARD

Type

B2

PIPE

2

2m

SCH 40

A106 GR.B

ASME B36.10

SMLS

B2

FLANGES

2

2

300#

A 105

ASME B 16.5

WNRF

B2

GASKET

2

3

300#


ASME B 16.20

SPIRAL WOUND

B2

STUD

M16 X 90 LENGTH

16

300#


ASME B18.2

B2

SOCKOLET

1/2

1

3000#

SW

A105

MSS SP97

C2

PIPE

2

50m

SCH 80

BE

A106 GR.B

ASME B36.10

SMLS

C2

PIPE

1/2

15m

SCH 80

PE

A106 GR.B

ASME B36.10

SMLS

C2

BLIND FLANGE

18

2

600 #

A 105

ASME B 16.5

C2

GASKET

18

2

600#

C2

STUD

M42 X 295 LENGTH

40

600#

C2

BARRED TEE

18

18

2

600#

BE


C2

BARRED TEE

18

16

2

600#

BE


C2

ISOLATION JOINT

18

4

600#

BE

ASTM A694 GRADE F65

MANUFACTURER STD

C2

FLANGES

2"

34

600#

A 105

ASME B 16.5

WNRF

ASME B 16.20

SPIRAL WOUND

ASME B18.2

SPW,GRAPHITE FILLER, 4.5 mm SS 316L WINDING WITH 3.2mm INTERNAL & EXTERNAL CENTERING RINGS ASTM A193 GR.B7 ( FOR STUD ) With 2 Heavy Hex. Nuts of A194 Gr.2H with cadium plating

ASME B 16.20

SPIRAL WOUND

ASME B18.2

C2

GASKET

2"

20

600#


C2

STUD

M16 X 110 LENGTH

160

600#


C2

WELDOLET

2

32

SCH 80

C2

SOCKOLET

3/4

1

6000#

SW

C2

SOCKOLET

1/2

20

6000#

SW

A105

MSS SP97

C2

PIPE

2

2m

SCH 80

BE

A106 GR.B

ASME B36.10

SMLS

C2

FLANGES

2

2

600 #

A 105

ASME B 16.5

WNRF

C2

GASKET

2

2

600#

ASME B 16.20

SPIRAL WOUND

C2

STUD

M16 X 110 LENGTH

16

600#

C2

SOCKOLET

1/2

1

6000#

A234 GR. WPB

MSS SP97

A105

MSS SP97


SW

A105

Remark

ASME B18.2 MSS SP97

2 OF 9

0435-JH0902



DOC NO: 0435-JH0902-70-PL-MTO-0002

PROJECT:



PROJECT NO.:

0435/JH0902

TITLE:

P & ID

Line No. 2

P

60

505

SPEC DESCRIPTION C2

435-JH0902-60PR-PID-6001

435-JH0902-60PR-PID-6001

Size-1

Size-2

Qty


Material ASTM

DIM. STANDARD

Type SMLS

C2

PIPE

2

2m

SCH 80

BE

A106 GR.B

ASME B36.10

C2

PIPE

1/2

1m

SCH 80

PE

A106 GR.B

ASME B36.10

SMLS

C2

FLANGES

2

2

600 #

A 105

ASME B 16.5

WNRF

C2

GASKET

2

2

600#

ASME B 16.20

SPIRAL WOUND

C2

STUD

M16 X 110 LENGTH

16

600#

C2

SOCKOLET

1/2

1

6000#


ASME B18.2

SW

A105

MSS SP97

3/4 D

60

530

C1

C1

PIPE

3/4

2m

SCH 80

PE

A106 GR.B

ASME B36.10

2

60

502

C2

C2

PIPE

2

2m

SCH 80

BE

A106 GR.B

ASME B36.10

SMLS

C2

FLANGES

2

2

600 #

A 105

ASME B 16.5

WNRF

C2

GASKET

2

2

600#

ASME B 16.20

SPIRAL WOUND

C2

STUD

M16 X 110 LENGTH

16

600#

C2

SOCKOLET

1/2

1

6000#

SW

A105

MSS SP97

C2

PIPE

2

2m

SCH 80

BE

A106 GR.B

ASME B36.10

SMLS

C2

FLANGES

2

2

600 #

A 105

ASME B 16.5

WNRF

C2

GASKET

2

3

600#

ASME B 16.20

SPIRAL WOUND

C2

STUD

M16 X 110 LENGTH

16

600#

C2

SOCKOLET

1/2

1

6000#

SW

A105

MSS SP97

C2

PIPE

2

2m

SCH 80

BE

A106 GR.B

ASME B36.10

C2

PIPE

1/2

2m

SCH 80

PE

A106 GR.B

ASME B36.10

SMLS

C2

FLANGES

2

2

600 #

A 105

ASME B 16.5

WNRF

C2

GASKET

2

3

600#

ASME B 16.20

SPIRAL WOUND

C2

STUD

M16 X 110 LENGTH

16

600#

C2

SOCKOLET

1/2

1

6000#

P

435-JH0902-60PR-PID-6001

2

P

60

504

C2

435-JH0902-60PR-PID-6001

2

435-JH0902-70PR-PID-7001

0435-JH0902-70-PL-MTO-0002

P

65

001

C2




SW

A105

Remark

SMLS

ASME B18.2

ASME B18.2

SMLS

ASME B18.2 MSS SP97

3 OF 9

0435-JH0902



DOC NO: 0435-JH0902-70-PL-MTO-0002

PROJECT:



PROJECT NO.:

0435/JH0902

TITLE:

P & ID

Line No. 2

P

65

435-JH0902-70PR-PID-7001

ISSUED FOR TENDER B SDC A DESCRIPTION REV

0435-JH0902-70-PL-MTO-0002

003

SPEC DESCRIPTION C2

Size-1

Size-2

Qty


Material ASTM

DIM. STANDARD

Type SMLS

Remark

C2

PIPE

2

2m

SCH 80

BE

A106 GR.B

ASME B36.10

C2

PIPE

1/2

2m

SCH 80

PE

A106 GR.B

ASME B36.10

SMLS

C2

FLANGES

2

2

600 #

A 105

ASME B 16.5

WNRF

C2

GASKET

2

3

600#

ASME B 16.20

SPIRAL WOUND

C2

STUD

M16 X 110 LENGTH

16

600#

C2

SOCKOLET

1/2

1

6000#


SW

ASME B18.2

A105

MSS SP97

A KULKARNI

S ISHWAD

J WALLACE

07.09.09

A KULKARNI

S ISHWAD

J WALLACE

30.08.09

N/A

PREPARED BY

CHECKED BY

APPROVED BY

DATE

CLIENT APPROVAL

4 OF 9

0435-JH0902

BOM SUMMARY - PIPES

TITLE : BILL OF MATERIAL SUMMARY - PIPES ( PIPELINE ) GGSR PRODUCTS EVACUATION PROJECT PROJECT : PROJECT NO.:0435-JH0902 0435-JH0902-70-PL-BOM-0001 DOC. NO: HINDUSTAN PETROLEUM CORPORATION LTD. CLIENT S No.

SPEC DESCRIPTION

Size INCH

Qty CLASS / END METRES SCH./ THK CONN

MATERIAL ASTM

DIM STD ASME

TYPE

1

B2

PIPE

1/2

2m

SCH 80

PE

A106 GR.B

ASME B36.10

SMLS

2

B2

PIPE

3/4

2m

SCH 80

PE

A106 GR.B

ASME B36.10

SMLS

3

B2

PIPE

2

10m

SCH 40

BE

A106 GR.B

ASME B36.10

SMLS

4

C2

PIPE

1/2

20m

SCH 80

PE

A106 GR.B

ASME B36.10

SMLS

5

C1

PIPE

3/4

2m

SCH 80

PE

A106 GR.B

ASME B36.10

SMLS

6

C2

PIPE

2

62m

SCH 80

BE

A106 GR.B

ASME B36.10

SMLS

REMARK

B

ISSUED FOR TENDER

HEMANATHAN D

S ISHWAD

J WALLACE

07.09.09

A

SDC

HEMANATHAN D

S ISHWAD

J WALLACE

30.08.09

N/A

REV

DESCRIPTION

PREPARED BY

CHECKED BY

APPROVED BY

DATE

CLIENT APPROVAL

0435-JH0902-70-PL-BOM-0001

5 OF 9

0435-JH0902

BOM SUMMARY - PIPE FITTINGS

TITLE : PROJECT : PROJECT NO.: DOC. NO: CLIENT S.NO.

SPEC DESCRIPTION

BILL OF MATERIAL SUMMARY - PIPE FITTINGS ( PIPELINE ) GGSR PRODUCTS EVACUATION PROJECT 0435-JH0902 0435-JH0902-70-PL-BOM-0002 HINDUSTAN PETROLEUM CORPORATION LTD.

Size-1

Size-2

Qty


Material ASTM

DIM. STANDARD

1

B2

BARRED TEE

10

8

2

300#

BE

ASTM A 860 GRADE WPHY 65

ASME B16.9 / MSS-SP 75

2

C2

BARRED TEE

18

18

2

300#

BE



3

C2

BARRED TEE

18

16

2

300#

BE



4

B2

ISOLATION JOINT

10

2

300#

BE

ASTM A694 GRADE F65

MANUFACTURER STD

5

C2

ISOLATION JOINT

18

4

300#

BE

ASTM A694 GRADE F65

MANUFACTURER STD

6

B2

SOCKOLET

3/4

1

3000#

SW

A105

MSS SP97

7

B2

SOCKOLET

1/2

8

3000#

SW

A105

MSS SP97

8

C2

SOCKOLET

3/4

1

6000#

SW

A105

MSS SP97

9

C2

SOCKOLET

1/2

26

6000#

SW

A105

MSS SP97

10

B2

WELDOLET

2

7

SCH 40

BW

A234 GR. WPB

MSS SP97

Type

Remark

B A

ISSUED FOR TENDER

HEMANATHAN D HEMANATHAN D

S ISHWAD S ISHWAD

J WALLACE

07.09.09

SDC

J WALLACE

30.08.09

N/A

REV

DESCRIPTION

PREPARED BY

CHECKED BY

APPROVED BY

DATE

CLIENT APPROVAL

0435-JH0902-70-PL-BOM-0002

6 OF 9

0435-JH0902

BOM SUMMARY - FLANGES

TITLE :

BILL OF MATERIAL SUMMARY - FLANGES & BLIND FLANGES ( PIPELINE )

PROJECT : GGSR PRODUCTS EVACUATION PROJECT 0435-JH0902 PROJECT NO.: DOC. NO: CLIENT S. NO SPEC

0435-JH0902-10-PL-BOM-0003 HINDUSTAN PETROLEUM CORPORATION LTD.

DESCRIPTION

Size-1

Qty

Class / Ssh./ Thk.

Material ASTM

DIM. STANDARD

Type

Remark

FLANGES 1

B2

FLANGES

2

10

300#

A 105

ASME B 16.5

WNRF

2

C2

FLANGES

18

2

600 #

A 105

ASME B 16.5

WNRF

3

C2

FLANGES

2

46

600 #

A 105

ASME B 16.5

WNRF

ASME B 16.5

BLIND, RF

BLIND FLANGES 4

C2

BLIND FLANGE

18

2

600 #

A 105

B

ISSUED FOR TENDER

HEMANATHAN D

S ISHWAD

J WALLACE

07.09.09

A REV

SDC

HEMANATHAN D PREPARED BY

S ISHWAD CHECKED BY

J WALLACE

30.08.09

APPROVED BY

DATE

DESCRIPTION

0435-JH0902-70-PL-BOM-0003

N/A CLIENT APPROVAL

7 OF 9

0435-JH0902

S.NO

BOM SUMMARY - GASKETS

TITLE :

BILL OF MATERIAL SUMMARY - GASKETS ( PIPELINE )

PROJECT : PROJECT NO.: DOC. NO: CLIENT

GGSR PRODUCTS EVACUATION PROJECT 0435-JH0902 0435-JH0902-70-PL-BOM-0004 HINDUSTAN PETROLEUM CORPORATION LTD.

SPEC DESCRIPTION

Size-1

Qty

Class / Ssh./ Thk.

1

B2

GASKET

2

9

300#

2

C2

GASKET

18

2

600#

3

C2

GASKET

2

35

600#

Material ASTM

SPW,GRAPHITE FILLER, 4.5 mm SS 316L WINDING WITH 3.2mm INTERNAL & EXTERNAL CENTERING RINGS SPW,GRAPHITE FILLER, 4.5 mm SS 316L WINDING WITH 3.2mm INTERNAL & EXTERNAL CENTERING RINGS SPW,GRAPHITE FILLER, 4.5 mm SS 316L WINDING WITH 3.2mm INTERNAL & EXTERNAL CENTERING RINGS

DIM. STANDARD

Type

ASME B 16.20

SPIRAL WOUND

ASME B 16.20

SPIRAL WOUND

ASME B 16.20

SPIRAL WOUND

Remark

B A

ISSUED FOR TENDER

HEMANATHAN D

07.09.09

HEMANATHAN D

S ISHWAD S ISHWAD

J WALLACE

SDC

J WALLACE

30.08.09

N/A

REV

DESCRIPTION

PREPARED BY

CHECKED BY

APPROVED BY

DATE

CLIENT APPROVAL

0435-JH0902-70-PL-BOM-0004

8 OF 9

0435-JH0902

BOM SUMMARY - FASTENERS

TITLE :

S.NO.

SPEC DESCRIPTION

BILL OF MATERIAL SUMMARY - FASTENERS ( PIPELINE )

PROJECT :


PROJECT NO.: DOC. NO:

0435-JH0902 0435-JH0902-70-PL-BOM-0005

CLIENT

HINDUSTAN PETROLEUM CORPORATION LTD.

Size-1

Qty


Material ASTM

DIM. STANDARD ASME

1

B2

STUD

M16 X 90 LENGTH

64

300#


B18.2

2

C2

STUD

M42 X 295 LENGTH

40

600#


B18.2

3

C2

STUD

M16 X 110 LENGTH

256

600#


B18.2

B A REV

0435-JH0902-70-PL-BOM-0005

ISSUED FOR TENDER SDC DESCRIPTION

HEMANATHAN D HEMANATHAN D PREPARED BY

S ISHWAD S ISHWAD CHECKED BY

Type

J WALLACE

07.09.09

J WALLACE

30.08.09

APPROVED BY

DATE

Remark

N/A CLIENT APPROVAL

9 OF 9

0435-JH0902

MTO FOR HOT INDUCTION BENDS

MTO FOR HI BEND

RAMAN MANDI - BAHADURGARH HOT INDUCTION BEND (6D) SR. NO.

TP No.s

Degree

1

In Terminal

2

In Terminal

3

In Terminal

4

In Terminal

5

In Terminal

6

In Terminal

7

In Terminal

8

TP-01 TP-03 TP-04 TP-05 TP-06 TP-08 TP-13 TP-15 TP-35 TP-36 TP-37 TP-41 TP-42 TP-43 TP-44 TP-49 TP-50 TP-56 TP-57 TP-58 TP-62 TP-63 TP-72 TP-73 TP-80 TP-106 TP-107 TP-110 TP-114 TP-115 TP-116 TP-117 TP-123 TP-125 TP-131 TP-132 TP-133 TP-134 TP-135 TP-161 TP-166 TP-168

45° 45° 45° 45° 90° 90° 90° 90° 40° 40° 35° 45° 45° 35° 40° 70° 75° 45° 40° 50° 45° 35° 105° 100° 50° 55° 40° 50° 60° 65° 65° 35° 55° 50° 40° 30° 40° 35° 30° 30° 30° 35° 30° 30° 35° 35° 30° 35° 30°

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49

Doc. No.: 0435-JH-0902-00-PL-MTO-0202

Chainage

0+028.6 0+738.2 0+973.0 1+134.6 1+244.2 1+629.2 2+528.3 2+939.1 27+243.4 27+623.4 28+611.4 34+068.8 35+072.9 35+428.3 36+510.0 44+061.2 51+184.6 51+184.6 51+365.7 52+619.6 59+801.6 60+043.8 69+169.4 69+435.2 76+266.0 103+703.6 103+778.0 104+758.8 106+918.7 107+111.9 108+921.2 109+055.4 114+793.5 114+893.7 120+789.6 123+279.5 124+022.8 139+158.9 139+155.8 146+311.2 150+128.7 151+438.4

Required Length for Bend (mm)

4273 4273 4273 4273 7500 7500 7500 7500 4000 4000 3730 4273 4273 3730 4000 5850 6210 4273 4000 4560 4273 3730 9150 8550 4560 4860 4000 4560 2000 5500 5500 3730 4860 4560 4000 3470 4000 3730 3470 3470 3470 3730 3470 3470 3730 3730 3470 3730 3470

ALIGNMENT SHEET NUMBER

0435-JH902-00-PL-DAG-0002-001 0435-JH902-00-PL-DAG-0002-001 0435-JH902-00-PL-DAG-0002-001 0435-JH902-00-PL-DAG-0002-001 0435-JH902-00-PL-DAG-0002-001 0435-JH902-00-PL-DAG-0002-001 0435-JH902-00-PL-DAG-0002-001 0435-JH902-00-PL-DAG-0002-001 0435-JH902-00-PL-DAG-0002-009 0435-JH902-00-PL-DAG-0002-009 0435-JH902-00-PL-DAG-0002-009 0435-JH902-00-PL-DAG-0002-011 0435-JH902-00-PL-DAG-0002-011 0435-JH902-00-PL-DAG-0002-011 0435-JH902-00-PL-DAG-0002-012 0435-JH902-00-PL-DAG-0002-014 0435-JH902-00-PL-DAG-0002-014 0435-JH902-00-PL-DAG-0002-016 0435-JH902-00-PL-DAG-0002-016 0435-JH902-00-PL-DAG-0002-016 0435-JH902-00-PL-DAG-0002-019 0435-JH902-00-PL-DAG-0002-019 0435-JH902-00-PL-DAG-0002-021 0435-JH902-00-PL-DAG-0002-022 0435-JH902-00-PL-DAG-0002-024 0435-JH902-00-PL-DAG-0002-032 0435-JH902-00-PL-DAG-0002-032 0435-JH902-00-PL-DAG-0002-032 0435-JH902-00-PL-DAG-0002-033 0435-JH902-00-PL-DAG-0002-033 0435-JH902-00-PL-DAG-0002-034 0435-JH902-00-PL-DAG-0002-034 0435-JH902-00-PL-DAG-0002-035 0435-JH902-00-PL-DAG-0002-035 0435-JH902-00-PL-DAG-0002-037 0435-JH902-00-PL-DAG-0002-038 0435-JH902-00-PL-DAG-0002-038 0435-JH902-00-PL-DAG-0002-038 0435-JH902-00-PL-DAG-0002-043 0435-JH902-00-PL-DAG-0002-045 0435-JH902-00-PL-DAG-0002-046 0435-JH902-00-PL-DAG-0002-046

1

0435-JH0902

MTO FOR HOT INDUCTION BENDS

MTO FOR HI BEND

RAMAN MANDI - BAHADURGARH HOT INDUCTION BEND (6D) SR. NO.

TP No.s

Degree

Chainage

83

TP-171 TP-175 TP-177 TP-178 TP-180 TP-183 TP-187 TP-189 TP-198 TP-199 TP-200 TP-201 TP-205 TP-207 TP-216 TP-217 TP-219 TP-220 TP-222 TP-223 TP-236 TP-238 TP-239 TP-243 TP-244 TP-245 TP-257 TP-258 TP-259 TP-262 TP-263 TP-269 TP-270 TP-271

152+628.5 155+525.7 157+435.8 157+501.5 158+595.7 616+984.6 163+859.8 165+079.1 177+653.5 178+728.7 178+866.9 180+492.2 184+038.2 184+160.2 187+359.3 187+405.1 188+216.3 188+451.8 190+243.9 201+713.0 205+061.3 210+530.5 210+867.0 214+954.2 215+016.3 217+717.3 228+193.3 223+394.8 230+376.4 233+742.8 233+902.1 239+066.9 239+244.3 240+011.8

84

In Terminal

85

In Terminal

86

In Terminal

40° 35° 60° 55° 40° 30° 50° 40° 30° 60° 55° 30° 35° 40° 55° 55° 30° 40° 60° 30° 30° 35° 30° 50° 50° 60° 75° 70° 40° 45° 45° 60° 90° 95° 90° 45° 45°

50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82

Required Length for Bend (mm)

4000 3730 5170 4860 4000 3470 4560 4000 3470 5170 4860 3470 3730 4000 4860 4860 3470 4000 5170 3470 3470 3730 3470 4560 4560 5170 6210 5850 4000 4273 4273 5170 7500 8000 7500 4273 4273

394836 394.836

B A REV

HD HD

SI SI

NA NA

Preared

checked

approved

Doc. No.: 0435-JH-0902-00-PL-MTO-0202

18-09-2009 14-09-2009 Date

ALIGNMENT SHEET NUMBER

0435-JH902-00-PL-DAG-0002-047 0435-JH902-00-PL-DAG-0002-048 0435-JH902-00-PL-DAG-0002-048 0435-JH902-00-PL-DAG-0002-048 0435-JH902-00-PL-DAG-0002-049 0435-JH902-00-PL-DAG-0002-050 0435-JH902-00-PL-DAG-0002-050 0435-JH902-00-PL-DAG-0002-051 0435-JH902-00-PL-DAG-0002-054 0435-JH902-00-PL-DAG-0002-055 0435-JH902-00-PL-DAG-0002-055 0435-JH902-00-PL-DAG-0002-055 0435-JH902-00-PL-DAG-0002-056 0435-JH902-00-PL-DAG-0002-056 0435-JH902-00-PL-DAG-0002-057 0435-JH902-00-PL-DAG-0002-057 0435-JH902-00-PL-DAG-0002-058 0435-JH902-00-PL-DAG-0002-058 0435-JH902-00-PL-DAG-0002-058 0435-JH902-00-PL-DAG-0002-052 0435-JH902-00-PL-DAG-0002-063 0435-JH902-00-PL-DAG-0002-064 0435-JH902-00-PL-DAG-0002-064 0435-JH902-00-PL-DAG-0002-066 0435-JH902-00-PL-DAG-0002-066 0435-JH902-00-PL-DAG-0002-066 0435-JH902-00-PL-DAG-0002-070 0435-JH902-00-PL-DAG-0002-070 0435-JH902-00-PL-DAG-0002-070 0435-JH902-00-PL-DAG-0002-071 0435-JH902-00-PL-DAG-0002-071 0435-JH902-00-PL-DAG-0002-073 0435-JH902-00-PL-DAG-0002-073 0435-JH902-00-PL-DAG-0002-073

mm m DOC. NO, 0435-JH0902-00-PL-MTO-0202

2

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) TECHNICAL DELIVERY CONDITION FOR PURCHASE OF GASKETS


TECHNICAL DELIVERY CONDITION FOR PURCHASE OF GASKETS 0435-JH0902-00-PI-TEN-0003 09 July 09


Doc. No.: 0435-JH0902-00-PI-TEN-0003 Rev. B

Page 1 of 4


SYNOPSIS



DESCRIPTION

PREPARED BY

CHECKED BY

APPROVED BY

A

Issued for IDC

D. Hemnathan

S. Ishwad

J. Wallace

B

Issued for Review

D. Hemnathan

S. Ishwad

J. Wallace


DATE

08 July 09

CLIENT APPROVAL

DATE

N/A

09 July 09

Page 2 of 4


TECHNICAL DELIVERY CONDITIONS FOR PURCHASE OF GASKETS 1.0

Gaskets shall be provided in accordance with the specification for the applicable Piping Class Rating and Service.

2.0

Materials for use below 32ºF or above the temperature ratings for the applicable Piping Class Rating and Service shall be approved.

3.0

Jackets or double jacketed gaskets shall be Armco Iron or soft carbon steel, Flexitallic or equivalent, unless otherwise specified.

4.0

Spiral wound gaskets shall be Flexitallic or approved equivalent.

5.0

Where required for corrosive conditions, materials other than those listed in this Specification may be used where approved.

6.0

The process of manufacture, dimensions and tolerances not specified herein shall be in accordance with the requirement of the manufacturer’s standards for the flange type, rating and size.

7.0

All gaskets shall conform to the codes / standards and specifications given in the requisition. Deviation (s), if any shall be clearly highlighted in the quotation.

8.0

Full face gaskets shall have bolt holes punched out.

9.0

Manufacturers test certificate for filler material and spiral material shall be given as per the relevant material specifications for spiral wound gaskets.

10.0

Gasket of different types and sizes shall be placed in separate shipping containers and each container clearly marked with the size, rating and material specification.

11.0

All items shall be inspected and approved by company inspector or any other agency authorized by company.

12.0

Any additional requirements specified in the requisition, shall be fully complied with.

13.0

Certificates for Gaskets shall have following applicable information: a. b. c. d. e. f.

Mill or Manufacturer’s name Heat or charge number Material Standard Size, Rating, dimensional standard Chemical analysis The results of visual examination and dimensional check


Page 3 of 4


g. Inspector’s name and signature 14.0

Gasket dimensions shall conform to ASME M16.20 for metallic (spiral wound).


Page 4 of 4

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) TECHNICAL DELIVERY CONDITION FOR PURCHASE OF CS FITTINGS AND FLANGES


TECHNICAL DELIVERY CONDITION FOR PURCHASE OF CS FITTINGS AND FLANGES 0435-JH0902-00-PI-TEN-0004 09 July 09


Doc, No.: 0435-JH0902-00-PI-TEN-0004 Rev. B

Page 1 of 6


SYNOPSIS



DESCRIPTION

PREPARED BY

CHECKED BY

APPROVED BY

A

Issued for IDC

D. Hemnathan

S. Ishwad

J. Wallace

B

Issued for Review

D. Hemnathan

S. Ishwad

J. Wallace


DATE

08 July 09

CLIENT APPROVAL N/A

09 July 09

Page 2 of 6

DATE


INDEX

List of Contents

Page

GENERAL

4

MARKING AND DISPATCH

5


Page 3 of 6


TECHNICAL DELIVERY CONDITIONS FOR PURCHASE OF BUTT WELDED SOCKET WELDED AND SCREWED FITTINGS & WELDING NECK FLANGES 1.0

GENERAL

1.1

Chemical composition, physical properties, Tests, Dimensions and Tolerances, Heat treatment and Marking shall conform to the applicable codes / standards / specifications as specified in the requisition, 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. Material test certificates (Physical property, chemical composition & heat treatment report) shall also be furnished for fittings supplied.

1.3

Material test certificates (Physical properties, chemical composition & Heat treatment report) shall also be furnished for the flanges supplied.

1.4

Fittings shall be provided in accordance with specification for the applicable piping class rating and service. All fittings shall be seamless in construction unless otherwise specified. Flanges and flanged fittings shall comply with ASME B16.5.

1.5

Outside diameters and wall thickness (unless otherwise mentioned) of Butt weld fittings shall be in accordance with ASME B36.10M as applicable.

1.6

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 diameter.

1.7

Bevelled ends for all fittings and welding neck flanges shall conform to ANSI B16.25. Contour of bevel shall be as follows : ---------------------------------------------------------------------------------------------------MATERIAL WALL THICKNESS WELD CONTOUR ---------------------------------------------------------------------------------------------------Carbon Steel

Upto 22 mm > 22 mm

Figure 2 Type A Figure 3 Type A

> 25 mm

Figure 6 Type A

------------------------------------------------------------------------------------------------------------------------

1.8

Thickness / schedule lower or higher than specified shall not be accepted.


Page 4 of 6


1.9

Threaded ends shall have NPT Taper threads in accordance with ANSI B1.20.1 upto 1.5 inch.

1.10

Special fittings like weldolet, sockolet etc., which are not covered in ANSI, MSS-SP shall be as per manufacturer’s standard. Contours of these fittings shall meet the requirements of ANSI B31.3. Manufacturer shall submit drawings / catalogue of these items along with the offer. Branch Connections using welding tees or commercial integrally reinforced fittings such as weldolets, sockolets (forged only) or socket weld couplings are equally acceptable, with the choice of the type of connection based on the criteria provided by the Branch Connection Tables contained in 0435-JH0902-00-PI-SPC-0001(Piping Material Specification).

1.11

All seamless pipes employed for manufacturing of fittings shall be required to have undergone hydrotest to ASTM A 530. Welded pipes employed for manufacture of fittings shall be tested as per addendum.

1.12

Galvanized flanges shall be coated with zinc by hot dip process conforming to IS : 4736 / ASTM A 153 or by electrogalvanizing. Threaded portion shall be suitably protected during galvanizing.

1.13

For 26” and above, flanges of series A in accordance with ASME B16.47 to be considered. Ends of weld neck flanges shall be beveled to suit the schedule / thickness of matching pipe, as specified in the requisition.

1.14

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 THREADES SMALL END THREADED LARGE END

2

MARKING AND DISPATCH

2.1

All items shall be legibly and conspicuously stamped in accordance with the requirements of applicable standards along with special condition like ANSI, API, MSS, etc.


Page 5 of 6


2.2

Steel die marking shall not be permitted on body of Butt weld fittings. The same should be marked by before dispatching.

2.3

Paint or Ink for marking shall not contain any harmful metal or metal salts such as Zinc, Lead or Copper which causes corrosive attack on heating.

2.4

Fittings shall be dry, clean and free of moisture, dirt and loose foreign materials of any kind.

2.5

Fittings shall be protected from rust, corrosion and mechanical damage during transportation, shipment and storage.

2.6

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.

2.7

Each end of fitting shall be protected with a wood, metal or plastic cover.

2.8

Each size of fitting and flanges shall be supplied in separate packaging marked with the Purchase Order No., Material specification, size, and Schedule / Thickness / Rating.

2.9

2.10

Each end of flange shall be protected with the following materials : Flange face : Wood, Metal or Plastic Cover Beveled end

:

Wood, Metal or Plastic Cover

Threaded end

:

Plastic Plug

Socket welding end

:

Plastic Cover or Plug

Certificates for Fittings shall have following applicable information : a. b. c. d. e. f. g. h. i. j. k.

Mill or Manufacturer’s name Heat or charge number Material Standard Size, Rating, dimensional standard Steel making process Chemical analysis The methods, the extent and the results of mechanical testing The methods, the extent and the results of non-destructive testing The results of hydrostatic tests, where applicable The results of visual examination and dimensional check Inspector’s name and signature


Page 6 of 6

VOLUME III TECHNICAL SPECIFICATIONS ANNEXURE-A PIPELINE A - 1.pdf

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