Volime II of II Mechanical Piping-GAIL

p
GAIL (India) Limited

(A Govt. of India Undertaking)
PIPELINE FROM HANUMAN JUNCTION TO VCL
BID DOCUMENT FOR PIPELINE LAYING & TERMINAL WORKS
VOLUME II OF II (MECHANICAL/PIPING)
(BID DOCUMENT NO: 110330G/WGI/GAIL/01-R0)
OPEN DOMESTIC COMPETITIVE BIDDING
ISSUED BY
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TABLE OF CONTENT S.No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 DOCUMENT TITLE PIPING MATERIAL SPECIFICATION MECHANICAL DESIGN BASIS ASSORTED VALVES DATA SHEET BALL VALVE QAP BALL VALVE DATA SHEET PLUG VALVE QAP PLUG VALVE DATA SHEET CHECK VALVE QAP CHECK VALVE ASSORTED PIPES TECHNICAL NOTES FOR VALVES TECHNICAL NOTES FOR BUTT WELDED, SOCKET WELDED & SCREWED FITTINGS TECHNICAL NOTES FOR BOLTS & NUTS FLANGES, SPECTACLE BLIND & DRIP RINGS TECHNICAL NOTES FOR GASKETS TECHNICAL SPECIFICATIONS FOR IJ WELDING SPECIFICATION FOR FABRICATION OF PIPING NON DESTRUCTIVE REQUIREMENTS OF PIPING TECHNICAL SPECIFICATION FOR PAINTING FLANGES & FITTINGS UPTO 16 DOCUMENT NUMBER 11-0330G01-01-08-02-001 Rev 0 11-0330G01-01-09-02-001Rev 0 11-0330G01-01-08-02-008Rev 0 11-0330G01-01-08-03-002 Rev 0 11-0330G01-01-08-10-002 Rev 0 11-0330G01-01-08-03-008 Rev 0 11-0330G01-01-08-10-004 Rev 0 11-0330G01-01-08-03-005 Rev 0 11-0330G01-01-08-10-005 Rev 0 11-0330G01-01-08-02-011Rev 0 11-0330G01-01-08-02-016 Rev 0 Page No 4 22 33 69 75 78 86 89 95 98 106
11-0330G01-01-08-02-017 Rev 0
117
13.0 14.0 15.0 16.0. 17.0
11-0330G01-01-09-02-010 Rev. 0 11-0330G01-01-09-02-009 Rev 0 11-0330G01-01-08-02-018 Rev 0 11-0330G01-01-09-02-003 Rev 0
122 126 130 134
11-0330G01-01-09-02-011Rev 0
142
18.0
11-0330G01-01-08-02-019 Rev 0
168
19.0 20.0
11-0330G01-01-09-02-007Rev. 0 11-0330G01-01-08-02-006 Rev
176 203
Document No. TABLE OF CONTENTS 11 / 0330G01 / WGI/ GAIL / 01 SHEET 1 of 2

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21.0
INSPECTION, FLUSHING AND TESTING OF PIPING SYSTEM STANDARD PIPING DRAWINGS
11-0330G01-01-08-02-009 Rev 0
208
22.0
1-08-007 TO 10, 1-08-017, 1-08026, 1-08-027, 1-08-028
216
23.0
TECHNICAL SPECIFICATION FOR PIG SIGNALLER DATA SHEET FOR PIG SIGNALLER DATA SHEET FOR IJ LIST OF VENDORS PIPING GENERAL ARRANGEMENT DIAGRAMS PIPING GAD FOR DISPATCH STATION(HANUMAN JUNCTION) PIPING GAD FOR SV-1 PIPING GAD FOR SV-2 PIPING GAD FOR RECIEVING STATION
11-0330G01-01-11-02-006 Rev 0
224
24.0 25.0 26.0 27.0
11-0330G01-01-11-03-006 Rev 0 11-0330G01-01-09-03-003 Rev 0 11-0330G01-01-11-06-01 Rev 0
229 231 233
27.1
11-0330G01-01-02-01-001 Rev B
242
27.2 27.3 27.4
11-0330G01-01-02-01-002 Rev B 11-0330G01-01-02-01-003 Rev B 11-0330G01-01-02-01-004 Rev B
243 244 245
Document No. TABLE OF CONTENTS 11 / 0330G01 / WGI/ GAIL / 01 SHEET 2 of 2

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CLIENT JOB NO.
18 001
PIPING MATERIAL SPECIFICATION

TOTAL SHEETS
DOCUMENT NO
11
0330G01
01
08
02
0 A REV
28-06-11 24-06-11 DATE
ISSUED FOR TENDER ISSUED FOR IDC DESCRIPTION
MH MH PREP
ASD ASD CHK
AD AD APPR
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TABLE OF CONTENT
CONTENT GENERAL NOTES DEFINITIONS CODES AND STANDARDS ABBREVIATIONS PIPING CLASS DESCRIPTION PIPING CLASS 1A1 PIPING CLASS 3A1 PIPING CLASS 6A1
PAGE No. 3 3 3 4 6 7 11 15
Document No. PIPING MATERIAL SPECIFICATION 11-0330G01-01-08-02-001 SHEET 2 of 18

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1.0
GENERAL NOTES This specification describes the minimum requirements for the design, furnishing of materials, fabrication, and inspection and testing of pipes, fittings and valves. All material shall confirm to ASTM, API or BS standards. Design and fabrication shall confirm to ANSI / ASME for pressure piping, ANSI B 31.3 Chemical Plant and petroleum Refinery Piping, and ANSI B 31.8 Gas transmission and Distribution piping system.
2.0
DEFINITIONS Shall : This verbal form indicates requirements strictly to be followed in order to confirm to the standards and from which no deviation is permitted. : This verbal form indicates that among several possibilities one is particularly suitable without mentioning or excluding others or that a certain course of action is preferred but not necessarily required. : This verbal form indicates a course of action permissible within the limits of this standard. : This verbal form is used for statements of possibility & capability, whether material, physical or casual.
Should
May
Can
3.0
CODES AND STANDARDS The latest revision of the following shall be considered as part of this specification. ASME B 16.5 ASME B 16.9 ASME B 16.11 ASME B 16.20 ASME B 16.21 ASME B 16.47 ASME B 31.3 ASME B 31.4 ASME B 31.8 ASME B 36.10 ASME B 46.1 API 5L API 6D API 590 Steel Pipe Flanges and Flanged Fittings Factory made Wrought Steel Buttwelding Fittings Forged Steel Fittings, Socket Welding and Threaded Metallic Gaskets for Pipe Flanges. Non-Metallic Flat Gasket for Pipe Flanges Large Diameter Steel Flanges (26 throu 60) Process Piping Pipeline Transportation system for Liquid hydrocarbons & other Liquids Gas Transmissions and Distribution Piping System Welded and Seamless Wrought Steel Pipe Surface Texture Line Pipe Pipeline Valves Steel Line Blank Document No. PIPING MATERIAL SPECIFICATION 11-0330G01-01-08-02-001 SHEET 3 of 18
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API 600 API 602 MSS SP 44 MSS SP 75 MSS SP 97
Steel Gate Valves Flanges and Buttwelding Ends Compact Steel Gate Valves Steel Pipe line Flanges Specification for High Test Wrought Butt Welding Fittings Integrally Reinforced Forged Branch Outlet Fitting Socket Welding, Threaded and Buttwelding Ends Forging, Carbon Steel for Piping Components Alloy Steel and Stainless Steel bolting Materials for High temp Service. Carbon and Alloy Steel Nuts for Bolts for High Pressure and High Temperature Service Standard Specification for Alloy Steel and Stainless Steel Bolting Materials Steel Casting, Carbon, Suitable for Fusion Welding, for High Temperature Service. Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperature Pressure Vessel Plates, Carbon Steel, Low and Intermediate Tensile Strength. Forging, Carbon and Alloy Steel, for Pipe Flanges, Fitting, Valves and Parts for High Pressure Transmission Service. Low temperature service seamless pipe. Forged Carbon and Low Alloy Steel requiring Notch Toughness Testing for Piping Components Piping Fittings of Wrought Carbon Steel and Alloy Steel for Low Temperature Service. Standard Specification for Wrought High Strength Low Alloy Steel Butt Welding Fittings
ASTM A 105 ASTM A 193 ASTM A 194
ASTM A 320
ASTM A 216
ASTM A 234
ASTM A 285
ASTM A 694
ASTM A 333 ASTM A 350
ASTM A 420
ASTM A 860
4.0 4.1
ABBREVIATIONS Flange Facing RTJ FF RF Ring Type Joint Flat Face Raised Face

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4.2
Fittings PE BE BW PBE POE TBE TOE LR SR Plain End Bevel End Butt Weld Plain Both End Plain One End Threaded Both End Threaded One End Long Radius Short Radius
4.3
Connections BW FLGD SCRD SO SW THRD WN Butt-Weld Flanged Screwed Slip-On Socket Weld Threaded Weld Neck
4.4
Wall Thickness SCH STD XS XXS Schedule in accordance with ANSI B 36.10 or B 36.19 Standard Weight Wall Thickness Extra Strong Wall Thickness Double Extra Strong Wall Thickness
4.5
Valve Description BC BB ES FB MO GO NRS OS&Y RB RS SC UB UC WB Bolted Cap Bolted Bonnet Extension Stem Full Bore Motor Operated Gear Operated Non-Rising Stem (with inside screw) Outside Screw and Yoke Reducer Bore Rising Stem Screwed Cap Union Bonnet Union Cap Welded Bonnet
4.6
Pipes Description BE CS ERW EFW FS HFI KCS KFS OH Beveled End Carbon Steel Electric Resistance Welded Electric Fusion Welded Forged Steel High Frequency Induction Killed Carbon Steel Killed Forged Steel Open Hearth Document No. PIPING MATERIAL SPECIFICATION 11-0330G01-01-08-02-001 SHEET 5 of 18
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SAW SMLS 5.0
Submerged Arc Welded Seamless
PIPING CLASSES DESCRIPTION Piping Classes assigned for the project are based on the following 2-digit system.
First Digit Numerical, denoting the basic system rating or flange class i.e. 1 = ASME Class 150 3 = ASME Class 300 6 = ASME Class 600 9 = ASME Class 900 Second Digit Letter, denoting the material A Carbon Steel C Stainless Steel F Fiberglass Reinforced plastic/epoxy (FRP) G Galvanized P Plastic (PEHD) S Stainless Steel V PVC Third Digit Sequential number to differentiate two or more piping classes of the same rating and same material but presenting some difference related to the handled fluid. Fourth Digit Letter, denoting the aboveground and underground U = Underground

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PIPING SPECIFICATION
RATING
150# ANSI B 31.8
1A1
TEMPERATURE PRESSURE
ITEM
( 0 TO 60 C) (18.75 bar g)
CODE
BASIC MATERIAL
SHORT CODE
SIZE FROMTHRU
DESCRIPTION
RATING AND/OR SCHED.
DIMENSION STANDARD
MATERIAL
REMARKS
PIPELINE
PL
4" 6" 8"
BE BE BE PE, SEAMLESS BE, SEAMLESS BE, SEAMLESS SW BW, 1.5D, 3D SW BW, 1.5D, 3D BW, 3D BW, 3D BW - ASME B16-25
6.4 mm 6.4 mm 6.4 mm S160 XS S40 3000# M 3000# M M M MXM
API 5L API 5L API 5L ASME B36-10 ASME B36-10 ASME B36-10 ASME B16.11
API 5L Gr. X42 API 5L Gr. X52 API 5L Gr. X56 ASTM A 106 Gr.B ASTM A 106 Gr.B ASTM A 106 Gr.B ASTM A105
PIPES
0.50" - 1.50" 2" 3" - 16"
ELBOWS 90 LR
0.50" - 1.50" 2" - 16"
ASME B16.9 ASTM A 234 Gr WPB ASME B16.11 ASTM A105
ELBOWS 45 LR
E45
0.50" - 1.50" 2" - 16"
ASME B16.9 ASTM A 234 Gr WPB ASME B16.9 ASTM A 234 Gr WPB ASME B16.9 ASTM A 234 Gr WPB ASME B16-9 ASTM A 234 Gr WPB
LR Bends 90 LR Bends 45 REDUCERS CONCENTRIC REDUCERS ECCENTRIC TEES EQUAL
LR B LR B 45 RC
4-16" 4-16" 2" - 16"
RE
2" - 16"
BW - ASME B16-25
MXM
ASME B16-9 ASTM A 234 Gr WPB
0.50" - 1.50" 2" - 16"
SW BW SW BW SW BW - ASME B16-25 SCRF BW PBE, SEAMLESS SW SW
3000# M 3000# MXM 3000# MXM 3000# M M 3000# 3000#
ASME B16.11
ASTM A105
ASME B16.9 ASTM A 234 Gr WPB ASME B16.11 ASTM A105
TEES RED
TR
0.50" - 1.50" 2" - 16"
ASME B16.9 ASTM A 234 Gr WPB MSS-SP 75 MSS-SP 75 ASME B16.11 ASTM A105 ASTM A105 ASTM A105
SOCKOLET WELDOLETS CAPS
S W C
0.50" - 1.50" 2" - 16" 0.50" - 1.50" 2" - 16"
ASME B16-9 ASTM A 234 Gr WPB ASME B36-10 ASME B16-11 ASTM A 106 Gr.B ASTM A105
NIPPLES FULL COUPLINGS HALF COUPLINGS
NA FC HC
0.50" - 1.50" 0.50" - 1.50" 0.50" - 1.50"
ASME B16-11
ASTM A105
NOTE: M=THICKNESS TO MATCH PIPE WALL THICKNESS Document No. PIPING MATERIAL SPECIFICATION 11- 0330G01-01-08-02-001 Sheet 7 of 18 Rev 0
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RATING
150# ANSI B 31.8
1A1
ITEM

( 0 TO 60 C)
CODE BASIC MATERIAL
(18.75 bar g)
SHORT CODE SIZE FROMTHRU DESCRIPTION RATING AND/OR SCHED. RF,125 AARH 150# ASME B16-5 ASTM A105 DIMENSION STANDARD MATERIAL REMARKS
WN FLANGES
FW
0.50"-16"
BLIND FLANGE
FB
0.50"-16"
RF,125 AARH
150#
ASMEB16-5
ASTM A105
FLANGES FIG 8
FF
0.5" - 16"
RF,125 AARH
150#
ASME B16-48
ASTM A105
SPCR & BLND
FSB
16"
RF,125 AARH
150#
ASME B16-48
ASTM A105
STUD BOLTS
0.5" - 16"
ASME B18-2
Bolt: A193 B7 Nut: A194 Gr.2H
GASKETS SPIRAL WOUND GATE
0.5" - 16"
150#, SPIRAL
B-16.20 ASME B16.5
SP. WND metallic with Graphite Filler (5 mm thick)
VG
0.50 - 1.50
SW , B16.11 FLG, B16.5, RF/125 AARH SW,BS-5353
800#
API 602
ASTM A105
VALVE
2''-16'' 0.50 - 1.50
150# 800#
API 600 ASME B16.10
ASTM A 216 Gr WCB ASTM A105
PLUG VALVE
PV 2''-16'' FLG/BW,API6D 150# ASME B16.10 ASTM A 216 Gr WCB
NOTE: M=THICKNESS TO MATCH PIPE WALL THICKNESS
Document No. PIPING MATERIAL SPECIFICATION 11-0330G01-01-08-02-001 Sheet 8 of 18
Rev. 0
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RATING
150# ANSI B 31.8
1A1
ITEM

( 0 TO 60 C)
CODE BASIC MATERIAL
(18.75 bar g)
SHORT CODE SIZE FROMTHRU DESCRIPTION RATING AND/OR SCHED. 800# ASME B16-10 BODY: ASTM A105 BALL: SS 316 FULL BORE FIRE SAFE WRENCH OPERATED. DIMENSION STANDARD MATERIAL
REMARKS
BALL VALVES
VBA
0.50'' - 1.50'' SW:ASME B16-11
2"-3"
BW:ASME B16-5
150#
ASME B16-10
BODY: ASTM A216 Gr. WCB BALL: (A 216 Gr. WCB) + 0.003" ENP
FULL BORE FIRE SAFE WRENCH OPERATED.
4"-16"
BW:ASME B16-5
150 #
ASME B16-10
BODY: ASTM A216 Gr. WCB BALL: (A 216 Gr. WCB) + 0.003" ENP
FULL BORE FIRE SAFE GEAR OPERATED.
GLOBE VALVES
VGL
0.50'' - 1.50''
SW ASME B16-11
800#
ASME B16-10
BODY: ASTM A 105 TRIM: ASTM A182 F6
HANDWHEEL FIRE SAFE
2" - 16"
FLGD RF ASME B16-5
150#
ASME B16-10
BODY: ASTM A 216 Gr. WCB TRIM: ASTM A182 F6
HANDWHEEL FIRE SAFE
LIFT CHECK VALVES
0.50'' - 1.50''
SW ASME B16-11
800#
ASME B16-10
BODY: ASTM A 105 TRIM:
HORIZONTAL INSTALLATION
VCH 2"-16" SWING CHECK VALVE FLGD RF ASME B16-5 150# ASME B16-10
ASTM A182 F6 BODY: ASTM A 216 Gr. WCB TRIM: ASTM A182 F6 HORIZONTAL INSTALLATION VERTICAL INSTALLATION FLOW UPWARDS
Rev. 0
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RATING
150#
1A1
TEMPERATURE ( 0 TO 60 C) PRESSURE (18.75 bar g)
PIPELINE FROM HANUMAN JUNCTION CODE ANSI B 31.8 TO VCL BASIC MATERIAL
BRANCH TABLE
B 1/2" 3/4" 1/2" 3/4" T T T T T T T S S S S S S S S T T T S S S S S S S S T T S S S S S S S S 1" 1.1/2"
R 2"
A 3"
N 4"
C 6"
H 8" 10"
S I 12"
Z 14"
E 16"
H E A D E R
1"
1.1/2" T 2" 3" 4" 6" 8" S S S S S S S S S
T T T W W W W W W T T T W W W W W T T T T W W W T T T T T T T T T T T T T T T T T T T T T
S I Z E
10" 12" 14" 16"
LEGEND T : TEE S: SOCKOLET - SW W : WELDOLET - BW
Rev. 0
13 of 245
RATING
300# ANSI B 31.8
3A1
ITEM SHORT CODE

( 0 TO 60 C) (49 bar g)
SIZE FROMTHRU DESCRIPTION RATING AND/OR SCHED. BE BE BE PE, SEAMLESS PE, SEAMLESS BE, SEAMLESS BE, SEAMLESS SW BW, 1.5D, 3D SW BW, 1.5D, 3D BW, 3D BW, 3D BW - ASME B16-25 6.4 mm 6.4 mm 6.4 mm XXS XS XS S40 3000# M 3000# M M M MXM API 5L API 5L API 5L ASME B36-10 ASME B36-10 ASME B36-10 ASME B36-10 ASME B16.11 ASME B16.9 ASME B16.11 ASME B16.9 ASME B16.9 ASME B16.9 ASME B16-9 API 5L Gr. X42 API 5L Gr. X52 API 5L Gr. X56 ASTM A 106 Gr.B ASTM A 106 Gr.B ASTM A 106 Gr.B ASTM A 106 Gr.B ASTM A105 ASTM A 234 Gr WPB ASTM A105 ASTM A 234 Gr WPB ASTM A 234 Gr WPB ASTM A 234 Gr WPB ASTM A 234 Gr WPB DIMENSION STANDARD MATERIAL
CODE
BASIC MATERIAL
REMARKS
PIPELINE
PL
4" 6" 8"
PIPES
0.50" - 1." 1.5" 2" 3" - 16"
ELBOWS 90 LR
0.50" - 1.50" 2" - 16"
ELBOWS 45 LR
E45
0.50" - 1.50" 2" - 16"
LR Bends 90 LR Bends 45 REDUCERS CONCENTRIC REDUCERS ECCENTRIC
LR B LR B 45 RC
4-16" 4-16" 2" - 16"
RE
2" - 16"
BW - ASME B16-25
MXM
ASME B16-9
ASTM A 234 Gr WPB
TEES EQUAL
0.50" - 1.50" 2" - 16"
SW BW SW BW SW
3000# MXM 3000# MXM 3000#
ASME B16.11 ASME B16.9 ASME B16.11 ASME B16.9 MSS-SP 75
ASTM A105 ASTM A 234 Gr WPB ASTM A105 ASTM A 234 Gr WPB ASTM A105
TEES RED
TR
0.50" - 1.50" 2" - 16"
SOCKOLET
0.50" - 1.50"
WELDOLETS
2" - 16"
BW - ASME B16-25
MXM
MSS-SP 75
ASTM A105
CAPS
2" - 16"
BW
ASME B16-9
ASTM A 234 Gr WPB
NIPPLES
NA
0.50" - 1.50"
PBE, SEAMLESS
ASME B36-10
ASTM A 106 Gr.B
FULL COUPLINGS HALF COUPLINGS
FC
0.50" - 1.50"
SW
3000#
ASME B16-11
ASTM A105
HC
0.50" - 1.50"
SW
3000#
ASME B16-11
ASTM A105
Document No. PIPING MATERIAL SPECIFICATION 11- 0330G01-01-08-02-001 Sheet 11 of 18
Rev. 0
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RATING
300# ANSI B 31.8
3A1
ITEM
CODE BASIC MATERIAL
( 0 TO 60 C) (49 bar g)
SHORT CODE SIZE FROMTHRU DESCRIPTION RATING AND/OR SCHED. RF, 125 AARH 300# ASME B16-5 ASTM A105 DIMENSION STANDARD MATERIAL
REMARKS
WN FLANGES
FW
2"-16"
FLG SW
FS
0.50 - 1.50
RF, 125 AARH
300#
ASME B16-5
ASTM A105
BLIND FLANGE
FB
0.50"-16"
RF, 125 AARH
300#
ASME B16-5
ASTM A105
FLANGES FIG 8
FF
0.5" - 16"
FF, 125 AARH
300#
ASME B16-48
ASTM A105
SPCR & BLND
FSB
16"
FF, 125 AARH
300#
ASMEB16-48
ASTM A105
STUD BOLTS
0.50" - 16''
ASME B18-2
GASKETS SPIRAL WOUND
0.5" - 16"
SPIRAL, 300#
B-16.20 ASME B16.5
GATE VALVE
VG
0.50 - 1.50
SW B16.11
800#
API 602
ASTM A105
2" - 16"
FLGD, B-16.5, RF/125 AARH
300#
API 600
ASTM A 216 Gr WCB
PLUG VALVE
VP
0.50" - 1.50" 2" - 16"
SW, BS -5353 FLG/ BW, API 6D
800# 300#
ASME B16-10 ASME B16-10
ASTM A105 ASTM A 216 Gr WCB
Rev. 0
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RATING
300# ANSI B 31.8
3A1
TEMPERATURE ( 0 TO 60 C) PRESSURE
ITEM

(49 bar g)
CODE BASIC MATERIAL
SHORT CODE
SIZE FROMTHRU
DESCRIPTION
DIMENSION STANDARD
MATERIAL
REMARKS
BALL VALVES
VBA
0.50 - 1.50
SW, ASME B16-11
300#
ASME B16-10 BS 5351
BODY: ASTM A105 BALL:SS 316 BODY SEAT: RPTFE
2"
FLGD RF:ASME B16-5 or BW :ASME B16-5
300#
ASME B16-10 BS 5351
BODY: ASTM A216 Gr. WCB BALL: (A 216 Gr. WCB) + 0.003" ENP BODY SEAT: RPTFE
FULL BORE, FIRE SAFE, WRENCH OPERATED
3" - 4"
300#
ASME B16-10 BS 5351
BODY: ASTM A216 Gr. WCB (A 216 Gr. WCB) + 0.003" ENP BODY SEAT: RPTFE
DOUBLE BLOCK AND BLEED FULL BORE FIRE SAFE WRENCH OPERATED. DOUBLE BLOCK AND BLEED FULL BORE FIRE SAFE GEAR OPERATED. HANDWHEEL FIRE SAFE
6"-16''
300#
ASME B16-10 BS 5351
GLOBE VALVES
VGL
0.50 - 1.50
SW, ASME B16-11
300#
ASME B16-10 BS 5352
2" - 4"
FLGD RF:ASME B16-5
300#
ASMEB16-10 BS 1873
HANDWHEEL FIRE SAFE
6" - 16"
FLGD RF:ASME B16-5
300#
ASME B16-10 BS 1873
GEAR OPERATED FIRE SAFE
LIFT CHECK VALVES
0.50 - 1.50
SW, ASME B16-11
300#
ASME B16-10 BS 5352
VCH SWING CHECK VALVE
2"-16''
FLGD RF:ASME B16-5
300#
ASME B16-10 BS 1868
HORIZONTAL INSTALLATION VERTICAL INSTALLATION FLOW UPWARDS
Rev. 0
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RATING
300# ANSI B 31.8
3A1
TEMPERATURE ( 0 TO 60 C) PRESSURE (49 bar g)
CODE
BASIC MATERIAL
BRANCH TABLE
B
1/2" 3/4" 1" 1.1/2" 2" 3"
R
4"
A
6"
N
8"
C
10"
H
12" 14"
S
16"
H E A D E R S I Z E
1/2" 3/4" 1" 1.1/2" 2" 3" 4" 6" 8" 10" 12" 14" 16"
T T T T S S S S S S S S S T T T T S S S S S S S S T T T S S S S S S S S T T S S S S S S S S T T T W W W W W W T T T W W W W W T T T T W W W T T T T T T T T T T T T T T T T T T T T T
LEGEND T : TEE S: SOCKOLET -SW W : WELDOLET- BW
Rev. 0
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RATING
600# ANSI B 31.8
6A1
ITEM SHORT CODE

( 0 TO 60 C) (92 bar g)
SIZE FROMTHRU DESCRIPTION RATING AND/OR SCHED. BE BE BE PE, SEAMLESS BE, SEAMLESS BE, SEAMLESS SW BW, 1.5D, 3D SW BW, 1.5D, 3D BW, 3D BW, 3D BW - ASME B16-25 6.4 mm 6.4 mm 6.4 mm XXS XS S60 6000# M 6000# M M M MXM API 5L API 5L API 5L ASME B36-10 ASME B36-10 ASME B36-10 ASME B16.11 ASME B16.9 ASME B16.11 ASME B16.9 ASME B16.9 ASME B16.9 ASME B16-9 API 5L Gr. X42 API 5L Gr. X52 API 5L Gr. X56 ASTM A 106 Gr.B ASTM A 106 Gr.B ASTM A 106 Gr.B ASTM A105 ASTM A 234 Gr WPB ASTM A105 ASTM A 234 Gr WPB ASTM A 234 Gr WPB ASTM A 234 Gr WPB ASTM A 234 Gr WPB DIMENSION STANDARD MATERIAL
CODE
BASIC MATERIAL
REMARKS
PIPELINE
PL
4" 6" 8"
PIPES
0.50" - 1.5" 2"-10" 12" - 16"
ELBOWS 90 LR
0.50" - 1.50" 2" - 16"
ELBOWS 45 LR
E45
0.50" - 1.50" 2" - 16"
LR Bends 90 LR Bends 45 REDUCERS CONCENTRIC
LR B LR B 45 RC
4-16" 4-16" 2" - 16"
REDUCERS ECCENTRIC
RE
2" - 16"
BW - ASME B16-25
MXM
ASME B16-9
ASTM A 234 Gr WPB
TEES EQUAL
0.50" - 1.50" 2" - 16"
SW BW SW BW SW
6000# MXM 6000# MXM 6000#
ASME B16.11 ASME B16.9 ASME B16.11 ASME B16.9 MSS-SP 97
ASTM A105 ASTM A 234 Gr WPB ASTM A105 ASTM A 234 Gr WPB ASTM A105
TEES RED
TR
0.50" - 1.50" 2" - 16"
SOCKOLET
0.50" - 1.50"
WELDOLETS
2" - 16"
BW - ASME B16-25
MXM
MSS-SP 97
ASTM A105
CAPS
2" - 16"
BW
ASME B16-9
ASTM A 234 Gr WPB
NIPPLES
NA
0.50" - 1.50"
PBE, SEAMLESS
ASME B36-10
ASTM A 106 Gr.B
FULL COUPLINGS HALF COUPLINGS
FC
0.50" - 1.50"
SW
6000#
ASME B16-11
ASTM A105
HC
0.50" - 1.50"
SW
6000#
ASME B16-11
ASTM A105
NOTE:1. M=THICKNESS TO MATCH PIPE WALL THICKNESS
Rev. 0
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RATING
600# ANSI B 31.8
6A1
ITEM
CODE BASIC MATERIAL
( 0 TO 60 C) (92 bar g)
SHORT CODE SIZE FROMTHRU DESCRIPTION RATING AND/OR SCHED. RF, 125 AARH 600# ASME B16-5 ASTM A105 DIMENSION STANDARD MATERIAL
REMARKS
WN FLANGES
FW
2"-16"
FLG SW
FS
0.50 - 1.50
RF, 125 AARH
600#
ASME B16-5
ASTM A105
BLIND FLANGE
FB
0.50"-16"
RF, 125 AARH
600#
ASME B16-5
ASTM A105
FLANGES FIG 8
FF
0.5" - 16"
FF, 125 AARH
600#
ASME B16-48
ASTM A105
SPCR & BLND
FSB
16"
FF, 125 AARH
600#
ASMEB16-48
ASTM A105
STUD BOLTS
0.50" - 16''
ASME B18-2
GASKETS SPIRAL WOUND
0.5" - 16"
SPIRAL, 600#
B-16.20 ASME B16.5
GATE VALVE
VG
0.50 - 1.50
SW B16.11
800#
API 602
ASTM A105
2" - 16"
FLGD, B-16.5, RF/125 AARH
600#
API 600
ASTM A 216 Gr WCB
PLUG VALVE
VP
0.50" - 1.50" 2" - 16"
SW, BS -5353 FLG/ BW, API 6D
800# 600#
ASME B16-10 ASME B16-10
ASTM A105 ASTM A 216 Gr WCB
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19 of 245
RATING
600# ANSI B 31.8
6A1
TEMPERATURE ( 0 TO 60 C) PRESSURE
ITEM

(92 bar g)
CODE BASIC MATERIAL
SHORT CODE
SIZE FROMTHRU
DESCRIPTION
DIMENSION STANDARD
MATERIAL
REMARKS
BALL VALVES
VBA
0.50 - 1.50
SW, ASME B16-11
600#
ASME B16-10 BS 5351
BODY: ASTM A105 BALL:SS 316 BODY SEAT: RPTFE
2"
600#
ASME B16-10 BS 5351
BODY: ASTM A216 Gr. WCB BALL: (A 216 Gr. WCB) + 0.003" ENP BODY SEAT: RPTFE
FULL BORE, FIRE SAFE, WRENCH OPERATED
3" - 4"
600#
ASME B16-10 BS 5351
DOUBLE BLOCK AND BLEED FULL BORE FIRE SAFE WRENCH OPERATED. DOUBLE BLOCK AND BLEED FULL BORE FIRE SAFE GEAR OPERATED. HANDWHEEL FIRE SAFE
6"-16''
600#
ASME B16-10 BS 5351
GLOBE VALVES
VGL
0.50 - 1.50
SW, ASME B16-11
600#
ASME B16-10 BS 5352
2" - 4"
FLGD RF:ASME B16-5
600#
ASMEB16-10 BS 1873
HANDWHEEL FIRE SAFE
6" - 16"
FLGD RF:ASME B16-5
600#
ASME B16-10 BS 1873
GEAR OPERATED FIRE SAFE
LIFT CHECK VALVES
0.50 - 1.50
SW, ASME B16-11
600#
ASME B16-10 BS 5352
VCH SWING CHECK VALVE
2"-16''
FLGD RF:ASME B16-5
600#
ASME B16-10 BS 1868
HORIZONTAL INSTALLATION VERTICAL INSTALLATION FLOW UPWARDS
Rev. 0
20 of 245
RATING
600# ANSI B 31.8
6A1
TEMPERATURE ( 0 TO 60 C) PRESSURE (92 bar g)
CODE BASIC MATERIAL
BRANCH TABLE
B
1/2" 3/4" 1" 1.1/2" 2" 3"
R
4"
A
6"
N
8"
C
10"
H
12" 14"
S
16"
H E A D E R S I Z E
1/2" 3/4" 1" 1.1/2" 2" 3" 4" 6" 8" 10" 12" 14" 16"
T T T T S S S S S S S S S T T T T S S S S S S S S T T T S S S S S S S S T T S S S S S S S S T T T W W W W W W T T T W W W W W T T T T W W W T T T T T T T T T T T T T T T T T T T T T
LEGEND T : TEE S: SOCKOLET -SW W : WELDOLET- BW
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GAIL (India) Limited PIPELINE FROM HANUMAN JUNCTION TO VCL
CLIENT JOB NO.
MECHANICAL DESIGN BASIS

TOTAL SHEETS
11 001
DOCUMENT NO
11
0330G01
01
09
02
0 A REV
28.06.11 24.06.11 DATE
MH MH PREP
ASD ASD CHK
AD AD APPR
22 of 245
TABLE OF CONTENTS
Sl.No.
DESCRIPTION
PAGE NO.
1.0
INTRODUCTION
2.0
APPLICATION OF THIS DOCUMENT
3.0
DESIGN CODES AND STANDARDS
4.0
DESIGN BASIS
5.0
COLOUR CODING
6.0
GUARANTEE TEST
7.0
ENVIRONMENTAL DESIGN CRITERIA AND UTILITIES
8.0
DESIGN REQUIREMENTS
9.0
FLEXIBILITY ANALYSIS CRITERIA & GUIDELINES
11
10.0
OTHER TECHNICAL REQUIREMENTS
11
Document No. MECHANICAL DESIGN BASIS 11-0330G01-01-09-02-001 SHEET 2 of 11

23 of 245
Rev 0
1.
INTRODUCTION
1.1
This document outlines the design requirements & provides information pertinent to mechanical engineering work, including process & piping. These criteria shall be read in conjunction with project specifications, data sheets and standards attached elsewhere in the bid package.
1.2
The salient features of the project are: Pipeline from Hanuman Junction to CMS at VCL:-
i) Hot Tap Off point is considered at Hanuman Junction point (Chainage 154 Km) on Tatipaka-Lanco
pipeline (18 X 204 Km). ii) Laying of 8 X 45 Km (approx) long pipeline from Hanuman Junction (Tap off point) to VCL where Check Metering Station(CMS) is proposed.CMS will consist of 2-Stage Pressure Reduction system, and metering skid (PRMS) including scrubber, Wet Gas and Dry Gas filters & Gas Chromatograph, PRV with necessary relief valves, and associated piping. iii) Provision of pig launcher/receiver facilities at Hanuman Junction (Dispatch Station) and CMS at VCL has been envisaged (Receiving Station). iv) 6 spare tap-off at Hanuman Junction (Dispatch station) has been considered. v) 2 Numbers Sectionalizing valve stations (SVs) are proposed along 8 45 Km pipeline. vi) Station works including Piping, Civil, Mechanical, Instrumentation, fire fighting and all associated jobs at Hanuman Junction, SV stations and Receiving station ( VCL ). In addition SCADA, Telecom at SV1 and CMS (at VCL) is considered. vii) Condensate recovery, storage & handling system has been envisaged at CMS (Receiving Station). An underground Condensate storage tank of working capacity of 10 KL has been envisaged to store the condensate obtained from manual draining of Gas Scrubber and wet gas filters. The loading of condensate in tanker shall be carried out by motor driven pumps. The peak condensate recovery is expected to be 1.5KL/day at CMS. viii) 6 tap-off for connectivity to customers from first stage PRMS at VCL (Receiving Station) has been considered. ix) Battery limit is from 8 hot Tap off with one ball valve at CH-154 at Hanuman Junction on Tatipaka Lanco Pipeline. The other side of the battery limit is 8 inlet flange of Gas scrubber of pressure reduction and metering skid at CMS. Refer respective P & Ids. x) Condensate storage tank and handling system at CMS shall be hooked up with the metering skid as indicated in P & Id.
1.3
DESIGN BASIS S.No. 1 Parameter Flow Rates Flow rate at Hanuman Junction point 303500SCMD at 30.79 Kg/Cm2 g (pressure at Tatipaka has been considered 42 Kg/Cm2g) Document No. MECHANICAL DESIGN BASIS 11-0330G01-01-09-02-001 SHEET 3 of 11
24 of 245
Rev 0
Details
of
PRS,CMS
(near
existing VCL Terminal) Pressure Temperature 3 Design Pressure Section: Hanuman Junction to PRS CMS Delivery Pressure at customer end 4 Operating Pressure Considering a pressure of 42.5Kg/Sq.cm(g) at Tatipaka Pressure at Hanuman Junction Ist Stage pressure reduction at CMS U/S of PRMS D/S of PRMS 2
nd
26-27 Kg/cm2g to 6 Kg/cm2g 18 C
72 Kg/cm2 g
1-4 Kg/cm2 g
31 Kg/Sq.cm(g)
25-72 Kg/Sq.cm(g) 14-19 Kg/Sq.cm(g)
Stage pressure reduction
at CMS U/S of PRMS D/S of PRMS 14-19 Kg/Sq.cm(g) 2 -4 Kg/Sq.cm(g)
2.
APPLICATION OF THIS DOCUMENT This document applies to this project. This document shall not be used for any other purpose.
3.
DESIGN CODES AND STANDARDS Design, engineering, fabrication, testing etc.shall be as per the latest edition of codes and standards. Indicated below the following codes and standards:
3.1 x x x x x x x x x
CODES AND STANDARDS: ASME Section V Non-Destructive examination Unfired Pressure Vessels. Qualification Standard for welding and brazing procedures. Process Piping Pipe line transportation systems for liquid hydro carbons and other liquids. ASME B 31.8 API 5L API 1104 MSS-SP-53 Gas Transmission and Distribution piping Systems. Specificafication for line pipe. Specification for welding pipeline and related facilities. Quality Standard for steel casting and forging for valves, Document No. MECHANICAL DESIGN BASIS 11-0330G01-01-09-02-001 SHEET 4 of 11
25 of 245
ASME Section VIII, Div 1 ASME Section IX ASME B 31.3 ASME B 31.4 -
Rev 0
flanges and fittings and other piping components magnetic particle Examination method. x x x x MSS-SP-75 NACE RP 0286 Specification for High test Wrought butt welding Fittings. The Electrical Isolation of Cathodically Protected Pipelines. SSPC-VIS-I OISD-STD-18 Steel Structures Painting Council-Visual Standard. Layouts for Oil & Gas Installation
In case of contradiction, the most stringent shall apply.
3.2 x x x x x x x x x x x x x x x x
MATERIALS: ASTM A 105 ASTM A 106 Forgings, Carbon Steel for piping Components Seamless Carbon Steel pipe for High Temperature Service. ASTM A 153 ASTM A 181 ASTM A 182 Zinc coating (hot dip) on iron and steel hardware. Forging, Carbon steel for general purpose piping. Forged or rolled alloy steel pipe flanges, forged fittings, valves and parts for high temperature service. ASTM A 193 Alloy Steel and stainless steel bolting materials for high temperature service. ASTM A 194 Carbon and Alloy steel nuts for bolting for high pressure and high temperature services. ASTM A 216 Steel casting, carbon suitable for fusion welding for high temperature. ASTM A 217 Steel casting, martensitic Stainless and alloy for pressure containing parts suitable for high temperature services. ASTM A 234 ASTM A 312 ASTM A 320 Piping Fittings of wrought carbon Steel and Alloy. Seamless and welded austenitic stainless steel pipe. Alloy steel and SS bolting.
ASTM A 333
Seamless and welded steel pipe for low temperature services.
ASTM A 350
Forging, carbon & low alloy steel, requiring Notch toughness testing for piping components.
ASTM A 352
Steel casting, Ferritic & Martensitic, for pressure containing parts, suitable for low temperature service.
ASTM A 335
Seamless Ferritic Alloy Steel Pipe for high temperature services. Document No. MECHANICAL DESIGN BASIS 11-0330G01-01-09-02-001 SHEET 5 of 11
26 of 245
Rev 0
x x x x x
ASTM A-370
Standard Test Methods and Definitions for Mechanical Testing of Steel products.
ASTM A 403 ASTM A 420
Wrought austenitic Stainless Steel piping fittings. Piping fittings of wrought carbon steel and alloy steel for low temperature services.
ASTM A 694
Forging, carbon and alloy steel for pipe flanges, valves and parts for high pressure transmission services.
ASTM A 860
Standard Specification for Wrought High Strength Low Alloy Steel Butt Welding Fittings.
3.3 x x x x x x x x x x x x x x x x x x x x
DIMENSIONAL / DESIGN STANDARDS ASME B 1.20.1 ASME B 16.5 Pipe threads, general purpose (inch). Pipe Flanges and flanged fittings (NPS1/2 through NPS 24"). ASME B 16.9 ASME B 16.10 ASME B 16.11 ASME B 16.20 Factory made wrought steel butt welding fittings. Face to face and end to end dimensions of valves. Forged fittings, socket-welding and threaded. Metallic gasket for pipe flanges - ring joint, spiral wound and jacketed. ASME B 16.21 ASME B 16.25 ASME B 16.34 ASME B 16.36 ASME B 16.38 Non-metallic gasket for pipe flanges. Butt welding ends. Valves-flanges, threaded and welding ends. Orifice flanges. Large metallic valves for gas distribution) manually operated, NPS 2 1/2 to 1212,125 psig maximum). ASME B 16.47 ASME B 36.10 ASME B 36.19 API 6D API 6FA/API 607 API 590 API 600 API 602 MSS SP 97 Large diameter steel flanges (NPS 26 through NPS 60). Welded seamless wrought steel pipe. Stainless steel pipe. Pipeline valves Fire Safe Design Valve Steel line blank Steel gate valves flanges and buttwelding ends. Compact steel gate valves. Integrally reinforced forged branch outlet fitting - socket welding, threaded and buttwelding ends.
3.4
ORDER OF PRECEDENCE

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3.4.1
Incase of conflict the order of precedence shall be as follows: 3.4.1.1 P & ID 3.4.1.2 Data Sheets 3.4.1.3 Drawings 3.4.1.4 This Specification 3.4.1.5 Other referenced project specifications 3.4.1.6 Codes and standards
4. 4.1
DESIGN BASIS The equipment proposed to meet the specification shall be designed and manufactured to achieve the highest possible reliability for design life of 30 years. All design calculations for pressure requirements, vibrations, considering seismic factors etc. shall be made in accordance with code requirements and submitted to the OWNER for approval. Design and fabrication shall conform to this specification. In case, any other applicable codes are proposed/referred the same shall be complied with sufficient information /justification. Scrapper Launcher/Receiver interface shall be designed as a minimum of ASME B31.4/ASME B31.8 as applicable. The Scrapper Launcher/Receiver shall be supplied along with hinged closure, pig detector and accessories like trolley, jib crane and other pig handling devices. Launcher/Receiver shall be bidirectional type. The material specification shall be governed by the design conditions of pressure, temperature, corrosion allowance and compatibility with contained media. Thickness/schedule against each size shall be calculated. Pipe internal diameter from Launcher/Receiver shall be critically checked for the safe passage of pig. There should not be any negative tolerance in internal diameter of Launcher/Receiver barrel. Both Scraper Launcher and Receiver are supplied with GD Band lock type hinged closure and shall be provided for easy and safe access during pig loading and unloading. Such closure shall be as per data sheets. The hinged closure including the mating flange shall be designed as per latest edition of ASME Sec VIII Div 1. Launcher/Receiver dimensions shall be suitable for intelligent pigging. The design pressure and temperature for all parts shall be 98 barg and 0 to 65 deg.C respectively. Pipes, fittings, flanges of size 3/8", 1 1/4", 2 1/2", 3 1/2", 4 1/2", 5", 7" and 9" shall not be used. However, where equipment is regular supplied by the manufacturer with piping connections of the above odd sizes, connection shall be made to approve nominal sizes using reducers. Material of construction of all piping except Trunk line shall be SA 106 Gr B. The basic material of construction for Launchers and Receivers shall be API 5L Gr. X 70/equivalent. The basic material of construction for hinged closure shall be ASTM A694 Gr. F65. Spectacle blind at the flanged end of Launcher/Receiver to be provided along with other spectacle on kicker line and by-pass line. The venting arrangement in station should have ball and plug valve combination. ASME B31.8 and ASME B16.9 shall be followed for designing of flow tee.
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9 4.10
4.11 4.12 4.13 4.14
4.15 4.16

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Rev 0
4.17 4.18 4.19 4.20 4.21 4.22 4.23
The size of the flow tee shall be such that it will not restrict the path of pig. The jib crane shall have antifriction bearing. Jib crane shall be self balancing type during operation. Jib crane must be spark proof. Cantilever of Jib crane shall not bend during operation. Insulating joint shall not restrict the pipeline bore and shall allow free passage of instrumented pigs. Two cleats shall be provided on the pups on either side of the insulating joint for connecting cables for measurement/shorting purposes. Cleats shall be attached to the insulating joint by welding. All the main line valves shall be double block and bleed type for low temperature application. As a requirement specific to the purpose which the valve is intended to be used, Pneumatic test of valve is to be witnessed by TPIA in both fully closed/open condition and passing/leakage is to checked. All under ground valves vent/drain/greasing points etc, shall be extended above ground along with isolation valves. The vent/drain connection shall have two valve assembly, one under ground and one above ground and suitable plug to be provided. Fully welded valves shall be used for main line aboveground/underground services with two piece construction only. Other aboveground valves may be of welded or bolted type with 2 piece/3 piece construction. Valve stem height shall be provided during detail engineering stage, which shall be at normal operating height up to chest level from Finish Ground level. All the first isolation valves connected to the mainline shall be welded types. All vent isolation valves shall be equipped with spectacle blind at downstream of the valve. All valves on mainline shall be Top Entry type only. Other Valves shall be either Top entry or Side entry. All valves to be full bore type only, irrespective of their location. All Ball valves 6 - 12 shall be Gear operated and above 12 shall be hand Operated & Hydraulically Actuated Manual Valves. COLOUR CODING:
4.24
4.25
4.26
4.27
4.28 4.29 4.30 4.31 4.32
5. 5.1
5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 5.2 5.3
Ball Valve (Above Ground) Globe valve (Above Ground) Check Valve (Above Ground) Pipelines (Above Ground) Launcher/Receiver Jib Crane/Trolley
: : : : : :
Off White Oxford Blue Oxford Blue Yellow Golden Yellow Golden Red & White Straps
All under ground valves shall have epoxy base coating after surface finish of SA 2.5. Valves and above ground pipes need to be properly blasted to achieve surface Finish of SA 2.5 before the application of paints.
6.
GUARANTEE TEST Document No. MECHANICAL DESIGN BASIS 11-0330G01-01-09-02-001 SHEET 8 of 11

29 of 245
Rev 0
In addition to the routine tests and guarantees by the manufacturers for the items being procured and installed, the PMC to demonstrate, as called for by the OWNER / OWNERs representative, by carrying out additional tests viz Hydro testing, NDT etc. at pressure and temperatures as specified by the OWNER in order to ensure that the entire system is safe and meeting the parameters specified in the bid documents. 7. 7.1 ENVIRONMENTAL DESIGN CRITERIA AND UTILITIES SEISMIC AND TRANSPORTATION LOADS Temporary braces shall be designed to withstand seismic loads applicable to the present location. Refer to the Structural Basis of Design for seismic design considerations. 7.2 DESIGN LIFE The process facilities design life requirement is 30 years. 7.3 DIMENSIONS SI units shall be used. Dimensions shall be in mm. 8. 8.1 DESIGN REQUIREMENTS All materials shall conform to project Specification and the identified API, ASME, ASTM, BS and NACE codes and Standards. Design and fabrication shall conform to this Specification and ASME B31.3, In case, any other applicable codes are proposed/referred the same shall be complied with sufficient information/justification after approval by owner/consultant. For smooth pigging operation, attempts shall be made to keep the ID of the piping from reducer of pigBarrel to pipelinepiping interface as close as possible to the ID of the pipe line. In case, ID of the terminal piping is more than the ID of the pipe line, thickness of the Terminal piping shall be increased to match the IDs. If the ID of the Terminal piping is less than that pipeline, thickness of the Terminal piping may be adjusted to match the IDs by: 8.5.1 Considering the actual design conditions of the line in place of class conditions for pipe wall thickness calculations. Reducing the corrosion allowance for Terminal piping but not less than the internal corrosion allowance in corresponding pipeline.
8.2
8.3
8.4
8.5
8.5.2
8.6
In case, the difference in IDs still exists, ID of the terminal piping shall be checked for the passage of gauge plate without interference. The gauge plate diameter shall be calculated by the formula given in the specification of pipelines. Wherever dissimilar metals are in contact, insulating gasket or sacrificial spool piece of 600 mm shall be provided to avoid galvanic corrosion. Piping general arrangement drawings/isometrics/support drawings etc. shall be prepared using good engineering practices and as per guidelines furnished in project Specifications. Thermal Insulation shall be provided wherever required during detail Engineering and as per relevant project specification attached elsewhere in the bid package. Also, wherever necessary, acoustic
8.7
8.8
8.9

30 of 245
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insulation shall be provided to limit the piping emitted noise to the permissible values as per API standards. 8.10 Piping schedule/thickness shall be calculated for each size, service & piping class including corrosion allowance indicated in material of construction of piping specification as per ASME B- 31.3 for various services based on piping class conditions upto class 900 & actual design conditions for 1500 class of the system. The same shall be submitted to the Company for review & approval. The piping connected to equipment shall be analyzed by the PMC for flexibility and maximum stresses developed, along with nozzle reaction on equipment, and these shall not exceed the permissible limits/values as specified in relevant codes & standards. Vendor data for maximum permissible nozzle loadings shall be obtained while analyzing piping for flexibility analysis. The above permissible limits shall not be exceeded in any case. The analysis shall be furnished to the Company for review & approval. Piping shall be suitably supported, as necessary, to prevent sagging, mechanical stresses and vibrations. In general, piping shall be fastened to pipe racks with appropriate sizes hot dip galvanized or cadmium plated U bolts {3/8 (9.5 mm) minimum} and shall be double nutted. The layout of equipment and piping shall be based on following principles: 8.13.1 To locate all equipments identified on equipment list. 8.13.2 To comply with codes & standards, regulations, P & IDs, project specifications and sound engineering industrial practices. 8.13.3 To maximize safety of personnel, equipment and facilities. 8.13.4 To ensure operability & maintainability of equipment with a provision of adequate clearances all around in horizontal & vertical direction. 8.14 8.15 8.16 8.17 To provide means of escape & access for fire fighting. To satisfy all requirements indicated in process documents. To minimize shutdown duration. To provide neat and economical layout, allowing for easy supporting and adequate flexibility to meet equipment allowable nozzle load. To comply with the requirements of Area classification. To comply with statutory guidelines.
8.11
8.12
8.13
8.18 8.19
9. 9.1
FLEXIBILITY ANALYSIS CRITERIA & GENERAL GUIDELINES Flexibility analysis shall be carried out as per requirements of ASME B 31.3. 9.1.1 In addition to the requirements stated in ASME B31.3, all piping shall be designed for combined effect of pressure & temperature during operating conditions without over stressing the piping, valves and equipments. All piping shall be adequately supported, guided or anchored so as to prevent undue vibration, deflection or loads on connected equipments. Piping stress analysis shall be carried out to determine allowable pipe movement and support requirements. Provision for expansion shall normally be made with bends, expansion loops and offsets.
9.1.2
10.
Other Technical Requirements Document No. MECHANICAL DESIGN BASIS 11-0330G01-01-09-02-001 SHEET 10 of 11
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10.1
Station Facilities 10.1.1 Equipment/valves requiring periodical maintenance shall be supported in such a way that the valves & equipment can be removed with a minimum temporary pipe supports. 10.1.2 Blow down facilities shall be provided at each station for any emergency evacuation of the pipeline. Vent line shall be fitted with a flapper type quick opening end closure, rated at the pipeline design pressure to prevent gas leaking through the valves & escaping to atmosphere during normal operation.
10.2
Sectionalizing Valve Stations and Tap-Off Stations 10.2.1 SV stations will be located at a readily accessible location near roads and shall be provided with an access RCC road from the nearest all-weather asphalted road. Location shall be clear of overhead power lines. 10.2.2 Pipeline sectionalizing valves/Tap-off valves shall be installed, buried and provided with a stem extension. Valve body vent/drain shall be extended and terminated above ground. 10.2.3 Two number sectionalizing valve stations (SV) will be installed along the pipe route.SV01 shall be remote operated and SV-02 shall be manual operated. The SV stations shall primarily be comprised of: x x x Sectionalizing valve complete with gas actuated valve with remote / local operation facility. Emergency blow down facility with a set of isolation & throttling valves manually actuated, fittings, pressure / temperature instruments etc. SV with remote actuation facilities will have control room housing, electrical, cathodic protection, instrumentation & SCADA / Telecom facilities.
10.3
Metering & Regulation Activities For custody transfer metering, check metering, pressure regulation and related gas conditioning equipment will be provided at receiving station. This will include indication & recording of flow data, pressure, temperature etc. Some metering skids will have online gas chromatograph to provide data related to gas composition & gas properties. This data will form the basis for the monthly energy & accounting of pipeline system w.r.t gas purchasers, billing of sales, internal use & the pipeline gas inventory balance. Metering facilities will have (n+1) runs based on the flow rates. Pressure regulation will include redundant, active & working monitor pressure regulator. All the custody transfer metering facility will have gas filters. The filtration capacity of cartridge filter shall be 100% for above 8, 99% for 5 to 8 & 95% for less than 5. The main requirements of metering & regulating station will be as under: x Filter unit x Metering system x Pressure regulatory system x Fire alarm system x Process instrumentation. x Telecom & SCADA equipment x Utilities supply system x Fire protection system x All other associated facilities.
NOTE: This is a standardized Design Criteria. Relevant portion of this Design Criteria shall be applicable for the respective Scope of Work covered under the Project.
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CLIENT JOB NO.
TECHNICAL SPECIFICATION FOR ASSORTED VALVES

TOTAL SHEETS
36 008
DOCUMENT NO
11
0330G01
01
08
02
0 A REV
28.06.11 24.06.11 DATE
MH MH PREP
ASD ASD CHK
AD AD APPR
33 of 245
TABLE OF CONTENT
BALL VALVE CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 10.0 11.0 SCOPE REFERENCEE DOCUMENTS DEFINITIONS INSPECTION MATERIALS DESIGN AND CONSTRUCTION INSPECTION AND TESTS TEST CERTIFICATES PAINTING, MARKING & SHIPMENT SPARES AND ACCESSORIES DOCUMENTATION REFERENCE DRAWINGS PAGE NO. 5 5 6 7 7 8 12 14 14 15 15 17
PLUG VALVE
CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 SCOPE REFERENCEE DOCUMENTS DEFINITIONS MATERIALS DESIGN AND CONSTRUCTION INSPECTION AND TESTS TEST CERTIFICATES PAINTING, MARKING & EQUIPMENT SPARES AND ACCESSORIES
PAGE NO. 20 20 21 21 22 24 26 27 27 Document No. 11-0330G01-01-08-02-008 SHEET 2 of 36

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10.0 11.0
DOCUMENTATION REFERENCE DRAWINGS CHECK VALVES CONTENTS
28 30
PAGE NO. 32 32 32 32 33 34 34 35 35 36
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
SCOPE REFERENCEE DOCUMENTS MATERIALS DESIGN AND CONSTRUCTION INSPECTION AND TESTS TEST CERTIFICATES PAINTING, MARKING & SHIPMENT SPARES AND ACCESSORIES DOCUMENTATION GUARANTEE
Document No. 11-0330G01-01-08-02-008 SHEET 3 of 36
Rev 0
35 of 245
BALL VALVE
Rev 0
36 of 245
1.0
SCOPE This specification provides minimum requirement for design, manufacturing, Inspection, Testing and supply of Carbon steel Ball Valves covering sizes NB through 36NB( 900mm) for ANSI pressure classes # 150 through # 900 to be used in cross country Gas pipeline(onshore) and City Gas distribution for handling non-sour hydrocarbon in liquid or gaseous phase.
2.0
REFERENCE DOCUMENTS The following Standard includes provision which, through reference in this text constitute provision of this Standard. Latest revision of this standard shall be used unless otherwise specified.
API 6D API 605 API 6FA API 5L API 1104 ASME 16.10 ASME 16.20
: : : : : : :
Specification for Pipeline Valves. Large Diameter Carbon steel Flanges. Specification for Fire Test for Valves. Specification for Line Pipe. Specification for Welding Pipelines and related facilities. Face to Face and End to End Dimensions of Valves Metallic gasket for pipe flanges Ring joint or spiral wounds and jacketed. Non Metallic Gaskets for pipe flanges. Steel Pipe Flanges and Flanged Fittings. Valves - Flanged, Threaded and Welding Ends. Steel Pipe Flanges and Flanged Fittings. Process Piping. Gas Transmission and Distribution Piping Systems. Boiler and Pressure Vessel Code Rules for Construction of Pressure Vessels. Standard Test Methods and Definitions for Mechanical Testing of Steel Products. Auto catalytic Nickel Phosphorous Coating on Metals. Testing of Valves. Specification for production pressure testing requirements. Document No. 11-0330G01-01-08-02-008 SHEET 5 of 36
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ASME 16.21 ASME B 16.5 ASME B 16.34 ASME B 16.5 ASME B 31.3 ASME B 31.8
: : : : : :
ASME Sec VIlI Div.I/Div.II :
ASTM A370
ASTM B 733 BS 6755-1
: :
Rev 0
EN 1004511 BS 6755-2 EN 10204 MSS-SP-6
: : : :
Metallic products: Charpy Impact test test methods (U & V Notches) Testing of Valves. Specification for fire type-testing requirement. Metallic Materials Types of Inspection documents. Standard Finishes for Contact Faces of Pipe Flanges and Connecting end Flanges of Valves and Fittings. Standard marking system for Valves, Fittings, Flanges and Union. Steel Pipeline Flanges. Quality Standard for Steel Casting and Forgings for Valves, Flanges and Fittings and Other Piping Components Magnetic Particle Examination Method. Quality Standard for Steel casting of valves, Flanges, Fittings & other Piping components (Visual Method) Ball Valves with Flanged or Buttwelding ends for General Service. Industrial Valves Pressure Testing of Valves Testing of Valves fire type testing requirements. Petroleum & Natural Gas Industry pipeline transportation system.
MSS-SP-25 MSS-SP-44 MSS-SP-53
: : :
MSS-SP-55
MSS-SP-72 ISO 5208 ISO 10497 ISO 13623
: : : :
ISO 14313
Petroleum & Natural Gas Industry. Pipeline transportation system pipeline Valves Steel Structures Painting Council Visual Standard.
SSPC-VIS-1
In case of contradiction the most stringent shall apply.
3.0 DEFINITIONS Purchaser Manufacturer Shall : The Company which makes purchase order. : Manufacturer who receive the purchase order. : This verbal form indicates requirements strictly to be followed in order to confirm to the standards and from which no deviation is permitted. : This verbal form indicates that among several possibilities one is particularly suitable without mentioning or excluding others or that a certain course of action is preferred but not necessarily required. Document No. 11-0330G01-01-08-02-008 SHEET 6 of 36
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Should
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May
: This verbal form indicates a course of action permissible within the limits of this standard. : This verbal form used for statements of possibility & capability, whether material, physical or casual.
Can
4.0 4.1
INSTRUCTIONS Eventual Interpretations and deviations to this specification by the manufacturer shall be requested by writing in his offer with detailed justification and approved by the purchaser or purchaser representative before the eventual order to the manufacturer. The specifications of the steel used shall be mentioned by the material manufacturer and all potential sub contractors (such as forging plant, casting plant and fabrication unit etc) will be described in the offer. After order no change will be accepted except for justified force majeure. In that case the asked changes shall be supported by a technical file submitted to the purchaser and the purchaser representative for approval. The manufacturer shall provide a technical description of the manufacturing method that might influence the quality of material. The purchaser/ purchasers representative keeps the right to audit the manufacturers and sub contractors manufacturing and control methods. All costs from such an audit shall be borne by the manufacturer except the wages and travel expenditure of the auditors supported by the purchaser/ purchasers representative. The purchaser/ purchasers representative shall have at any time free access to all parts of the manufacturers facilities and to those of all his sub contractors involved in the order manufacturing. A copy of ISO 9001 Certificate shall be included in the offer. An approval of documents can never be considered as acceptance of deviations or relaxation to requirements. A deviation is only possible after specific request to purchaser and purchasers representative. Purchaser/ purchasers representative may verify the control equipment of the manufacturer, its calibration and the points at which it is located. If during the production certain problem arises, the purchaser/ purchasers representative may demand supplementary tests. MATERIALS Material for major components of the valves shall be as indicated in Valve Data Sheet. In addition, the material shall also meet the requirements specified herein. Other components shall be as per Manufacturers standard (suitable for service conditions as indicated in valve data sheet), which shall be subjected to approval by Purchaser.
4.2
4.3
4.4
4.5
4.6 4.7
4.8
5.0 5.1
5.2 5.3
Carbon steel used for the manufacture of valves shall be fully killed. The carbon equivalent (CE) of valve end connections which are subject to further field welding by Purchaser shall not exceed 0.45 on check analysis for each heat of steel used, shall be calculated by the following formula: CE = C + Mn + 6 Cr + Mo + V + Ni + Cu 5 15 Document No. 11-0330G01-01-08-02-008 SHEET 7 of 36
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5.4
The steel used shall be suitable for field welding to pipes, flanges or fittings manufactured under ASTM 53, A 105, A 106, A 234, A 350, A 352, A 694, A 420, A 333, and API 5L etc. When the ball of valve is manufactured out of C.S, it shall be subjected to 75 m/0.003/0.075mm thick Electrolysis nickel plating as per ASTM B733 with following classification SC2, type II, class-2.For Ball made of S.S material, ENP is not mandatory. The hardness of plating shall be minimum 50 RC.
5.5
5.6
For valves specified to be used for Gas service or High Vapor Pressure (HVP) liquid service; Charpy VNotch test on each heat of base material shall be conducted as per API 6D, clause 7.5 for all pressure containing parts such as body, end flanges and welding ends as well as bolting material for pressure containing parts. Unless specified otherwise, the Charpy V-notch test shall be conducted at 0 C. The Charpy V-notch test specimen shall be taken in the direction of principal grain flow and notched perpendicular to the original surface of plate or forging. The minimum average absorbed energy per set of three specimens shall be 27 J with an individual minimum per specimen of 22J. Test procedure shall conform to ASTM A 370 or ISO 148. For valves specified to be used for other hydrocarbon services, the Charpy V-notch requirements stated above are not applicable, unless required by the specified material standard as a mandatory requirement. When Low Temperature Carbon Steel (LTCS) materials are specified in Valve Data Sheet or offered by Manufacturer, the Charpy V-notch test requirements of applicable material standard shall be complied with.
5.7
Valves shall be subjected to hardness test on base material for each heat for pressure containing parts. A full thickness cross section shall be taken for this purpose and the maximum hardness shall not exceed 248 HV10 based on minimum four (4) measurements representing the entire thickness.
6.0 6.1
DESIGN AND CONSTRUCTION a) Valve design shall be as per API 6D and suitable for the process conditions indicated in the Data Sheet. The ASME Boiler & Pressure Vessel Code, Section VIII, Division 1 shall be used to design the valve body. Allowable stress requirements shall comply with the provisions of ASME B31.3 and B31.8. In addition, corrosion allowance indicated in Valve Data Sheet shall be considered in valve design. However, the minimum wall thickness shall not be less than the minimum requirement of ASME B16.34. b) Corrosion Allowance for all valves to be used in sweet gas services shall be considered nil. c) The manufacturer shall have valid license to use API monogram on valves manufactured as per API 6D.
6.2
Valve body design shall be fully welded for underground buried application. For above ground services body design can be either welded or bolted. Threaded body joints shall not be accepted.
6.3
Ball shall be of single piece, solid type construction.
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6.4
Valves shall be Full bore (FB). Full bore valves shall be suitable for the passage of all types of pipeline scraper and inspection pigs on regular basis without causing damage to either the valve component or the pig. The full bore valve shall provide an unobstructed profile for pigging operations in either direction. Full bore valves shall be designed to minimize accumulation of debris in the seat ring region to ensure that valve movement is not impeded. Reduced bore valves shall be provided if specifically mentioned in data sheet. Valve body shall be manufactured by casting or forging. All valves 4NB and above shall be trunion mounting type. Valves below 4 shall be floating type unless specifically mentioned in data sheet otherwise. Valve seats shall be with primary metal to metal contact. O - Rings or other seals if used for drip tight sealing shall be encased in a suitable groove in such a manner that it can not be removed from seat ring and there is no extrusion during opening or closing operation at maximum differential pressure. The seat rings shall be designed so as to ensure sealing at low as well as high differential pressures. Seat design with PTFE inserts is not acceptable. All valves shall have two seating surfaces which in close position blocks the flow from both ends. The cavity between the seating surfaces is vented through a bleed connection provided on the body cavity i.e. the valves shall be Double Block & Bleed (DBB). Valves shall be designed to withstand a sustained internal vacuum of at least 1 (one) milli-bar in both open and closed positions. All valves of nominal valve size 200 mm (8) NB & above shall have provision for secondary sealant injection under full line pressure for seat and stem seals. All sealant injection connections shall be provided with an internal Non-return valve. Valve design shall have a provision to replace the sealant injection fitting under full line pressure. All valves shall be provided with a vent and drain connection. These connections shall be welded type as per Fig. 6.11 A/B. Body vent and drain shall be provided with valves (Ball or Plug type). All these vents & drain connection shall be provided with isolation ball valve as shown in Fig 6.11 A/B. The end connection of vent & drain line to valve body or isolation valves shall be welded type at underground location and threaded type for above ground location. Valve design shall ensure repair of stem seals/packing under full line pressure.
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12 6.13
a) Valve ends shall be either flanged/or butt welded or one end flanged and one end butt welded as indicated in the Valve Data Sheet. Flanges of the flanged end cast/forged body valves shall be integrally cast/ forged with the body of the valve. Face to face/end to end dimensions shall conform to API 6D. b) The length of butt welding ends shall be sufficient to allow welding and heat treatment without damage of the internal parts of the valves. c) Flanged end shall have dimensions as per ASME B 16.5, for valve sizes up to DN 600 mm (24) excluding DN 550 mm (22) MSS-SP-44 shall be referred. ASME B16.47Series A for DN 650 mm (26 inches) and above. Flange face shall be either raised face or ring joint type as indicated in Valve Data Sheet. In case of RTJ flanges, the groove hardness shall be minimum 140 BHN. All flanged face shall have concentric serration with 125 AARH finish d) Butt welding end preparation shall confirm to ASME B 16.25. Incase of difference in thickness of valve body & mating pipelines, the bevel end of valve shall be as per ASME B 31.8 or ASME B 31.4 as applicable. The end preparation shall take care of outside diameter of connecting pipe, wall thickness, material grade, SMYS & Special chemistry of welded material as indicated in the data sheet.
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6.14
The temperature and pressure range of the valves shall be in accordance with the indicated values on the relevant piping specification and valve data sheet.
6.15
Wall thickness of parts used for the welding connection with the line pipe shall meet the following requirements: a) The maximum allowable stress in the material of butt-weld connection for butt welding shall be equal to 50% of the minimum yield strength guaranteed by the specification of steel used. b) The minimum wall thickness for butt welding connection must be greater than or equal to the largest valve of either the calculated minimum thickness of butt welding connections or the nominal thickness of pipe as indicated on data sheet. c) If the butt welding connections has a yield strength lower than the yield strength of the pipe to which it is intended to be welded, the wall thickness in each zone of the butt welding connection is at least equal to the specified pipe wall thickness time the ratio of minimum yield strength guaranteed by the specification of the steel of the pipe & minimum yield strength guaranteed by the specification of the steel of the butt welding connection. d) The specified pipe wall thickness and grade with which the valve is intended to be used is specified in the data sheet. e) All valves under this specification shall be designed to withstand a field hydrostatic test pressure with non corrosive water. After installation during 24 hours when the ball is partially or fully open at a pressure level P = 1.4 X MOP P = hydrostatic test pressure (bar) MOP = Maximum operating pressure at 38deg C
6.16
Valve shall be provided with ball position indicator and stops of rugged construction at the fully open and fully closed positions. Valves of nominal valve size, DN 200 mm (8) and larger, shall be equipped with support foot and lifting lugs. Tapped holes and eyebolts shall not be used for lifting lugs. Height of support foot shall be kept minimum. The lifting lugs shall be stamped with safe working load. In order to avoid stress induced crack and soft seat damage during direct field welding operation to valve body, all valves shall be supplied with welded pups at both ends which shall be considered as an integral part of the valves and also the ID of the pup shall match with pipe ID. The pup piece welding shall be carried out in controlled condition of temperature at manufacturers workshop. Field welding of pup piece shall not be allowed. Material & length of pup piece shall be as per Data sheet. When indicated in Material Requisition, valves shall have locking devices to lock the valve either in full open (LO) or full close (LC) positions. Locking devices shall be permanently attached to the valve operator and shall not interfere with operation of the valve. Locking device shall be such that the valve shall operate when the differential pressure across the valve is 3bar. Valve design shall be such as to avoid bimetallic corrosion between carbon steel and high alloy steel components in the assembly. Accordingly, Suitable insulation shall be provided as required. The valve stem shall be capable of withstanding the maximum operating torque required to operate the valve against the maximum differential pressure as per the appropriate class. The combined stress shall not exceed the maximum allowable stresses specified in ASME Section VIII, Division 1. The design shall take into account a safety factor of 1.5 based on the maximum output torque of the operating mechanism. The valve Manufacturer shall guarantee that the breakaway torque after long periods of non- movement can not exceed the normal short term breakaway torque by a factor more than 1.25, and that the safety factor specified above is not compromised. TECHNICAL SPECIFICATION FOR ASSORTED VALVES Document No. 11-0330G01-01-08-02-008 SHEET 10 of 36
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6.17
6.18
6.19
6.20
6.21
6.22
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6.23 6.24
The valve stem shall have anti-blowout feature with antistatic device conforming to BS 5351 When stem extension requirement is indicated in Valve Data Sheet, the valves shall have the following provisions. a) Valves provided with stem extension shall have water proof outer casing. The Length of stem extension shall be as indicated on the Valve Data Sheet. The length indicated corresponds to the distance between centerline of the valve opening and the centerline of the rim of the hand wheel on a vertical shaft or centerline of the hand wheel on a horizontal shaft. b) Manual override devices shall be provided on all valves c) Vent, drain and sealant connections shall be terminated adjacent to the valve operator by means of suitable piping anchored to the valve body. d) The stem extension shall be self relieving. e) Outer casing of stem extension shall have 3/8 or 1/2 NPT plugs at the top and bottom, for draining and filling with oil to prevent internal corrosion
6.25
Operating Devices a) All valves of size 12 & above shall be manually operated & hydraulically actuated. In case of manual operator, valve sizes, 100 mm (NPS 4) and below shall be wrench/ lever operated for Valves from 6-10 shall be gear operated. Valve design shall be such that damage due to malfunctioning of the operator or its control gear train or power cylinder and other damaged parts can be replaced without the valve cover being removed. b) The power actuator shall be in accordance with the Purchaser Specification issued for the purpose and as indicated in the Valve and Actuator Data Sheet. Operating time shall be as indicated in Valve Data Sheet. Valve operating time shall correspond to full close to full open/full open to full close under maximum differential pressure corresponding to the valve rating. For actuated valves, the actuators rated torque output shall be 1.25 times the break torque required to operate the ball valve under the maximum differential pressure corresponding to the Valve Class Rating. c) For the manual operator of all valves, the diameter of the hand wheel or the length of operating wrench shall be such that under the maximum differential pressure, the total force required to operate the valve does not exceed 350N. Manufacturer shall also indicate the number of turns of hand wheel In case of gear operators) required for operating the valve from full open to full close position. The wrench length or hand wheel diameter shall be in accordance with API 6D requirements. The manufacturer shall indicate the number of turns of the hand wheel (for gear operators), required for operating the valve from fully open to the fully closed position. d) Direction of operation of hand wheel or wrench shall be in clock-wise direction while closing the valve. Hand wheels shall not have protruding spokes. e) Gear operators, when provided, shall have a self-locking provision and shall be fully encased in water proof/splash proof enclosure and shall be filled with suitable grease.
6.26
Welding including repair welding of pressure controlling parts shall be as per welding procedure qualification specified in ASME Section IX. The procedure qualification shall also include impact test and hardness test when required as per Clause 5.5, 5.6, 7.4 and 7.5 of this specification and shall meet the requirements as specified therein. The welders involved in welding shall be qualified in accordance with ASME Section IX.
6.27
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6.28
Repair by welding is not permitted for forged body valves. However repair by welding as per ASME B 16.34 is permitted for cast body valves. Repair shall be carried out before any heat treatment of casting is done. Repair welding procedure qualification shall also include impact test and hardness test when required as per Clause 5.5, 5.6, 7.4 and 7.5 of this specification and shall meet the requirements as specified therein. The tolerance on internal diameter and out of roundness at the ends for welded ends valves shall be as per connected pipe specification as indicated in the Valve Data Sheet. When specified on the Valve Datasheet, ball valves shall be fire safe in accordance with API 6FA, for which qualifying certificates, covering the range of items offered, shall be supplied by the Manufacturer.
6.29
6.30
7.0
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:
7.1
The valve manufacturer must deliver a Certificate EN 10204 3.2 starting the quality, the mechanical properties (yield strength, tensile strength, and impact test at - 20 C), the chemical analysis the process of manufacture and the marking (for ex: - heat number of material) A new chemical analysis (up gradation) shall be done on specimen of valve in presence of TPIA.
7.2
All valves shall be visually inspected. The external and internal surfaces of the valves shall be free from any arc strikes, gouges and other detrimental defects. Dimensional check on all valves shall be carried out as per the Purchaser approved drawings. Chemical composition and mechanical properties shall be checked as per relevant material standards and this specification, for each heat of steel used. Pressure containing parts of all valves such as body, bonnet, flange, welding ends and balls etc shall be subjected to impact test on each heat of base material as per API6D CL.7.5. Notch toughness properties Charpy V: The standard impact test temperature is - 20 C. The average value per series of 3 test specimen shall be equal to 35 J/cm. The minimum value per test specimen shall be equal to 35 J/cm; this value may drop to 28 J/cm per only test specimen per series. Non Destructive Examination a) Non-destructive examination of individual valve material and component consisting of but not limited to castings, forgings, plates and assembly welds shall be carried out by the Manufacturer. All castings shall be wet magnetic particle inspected 100% of the internal surfaces. Method and acceptance shall comply with MSS-SP-53. b) Body castings of all valves shall be radio graphically examined as per ASME B16.34. Procedure and acceptance criteria shall be as per ASME B 16.34. For all sizes body casting shall be subjected to 100% radiography. c) All forgings shall be ultrasonically examined in accordance with the procedure and acceptance standard of Annexure E of ASME B 16.34. All forgings shall be subject to wet magnetic particle inspection on 100% of the internal surfaces. Method and acceptance shall comply with MSS-SP-53 d) Bodies and bonnets made by welded assembly of segments of castings, forgings, combinations thereof shall be examined, as applicable, by methods of 7.7 (b) for cast components or 7.7 (c) for forged components and plates. Document No. 11-0330G01-01-08-02-008 SHEET 12 of 36
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7.3 7.4
7.5
7.6
7.7
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7.8
Full inspection by radiography shall be carried out on all welds of pressure containing parts. Acceptance criteria shall be as per ASME B 31.3 or ASME B31.8 as applicable and API 1104.
7.9
a) All finished weld ends subject to welding in field shall be 100% ultrasonically tested for lamination type defects for a distance of 50 mm from the end. Laminations shall not be acceptable. b) Weld ends of all cast valves subject to welding in field shall be 100% radio graphically examined and acceptance criteria shall be as per ASME B 16.34. c) After final machining, all bevel surfaces shall be inspected by dye penetrate or wet - magnetic particle methods. All defects longer than 6.35 mm are rejected, as are the defects between 6.35 mm and 1.59 mm that are separated by a distance less than 50 times their greatest length. Rejectable defects must be removed. Weld repair of bevel surface is not permitted.
7.10
All valves shall be tested in compliance with the requirements of API 6D. During pressure testing, valves shall not have sealant lines and other cavities filled with sealant, grease or other foreign material. The drain, vent and sealant lines shall be either included in the hydrostatic shell test or tested independently. No leakage is permissible during hydrostatic testing. The body cavity self-relieving feature meeting the requirements of clause 6.8 of this specification shall also be checked. A supplementary air seat test as per API 6D, Appendix C, Para C3.3 Type II shall be carried out for all valves. A bubble tight seal is required without the use of any sealant. No leakage is allowed. Test pressure shall be held for at least 15 minutes. Valves shall be subjected to Operational Torque Test as per Appendix C, Para C.6, API 6D under hydraulic pressure equal to maximum differential pressure corresponding to the valve rating. For manually operated valves, it shall be established that the force required to operate the valve does not exceed the requirements stated in section 6.24 (c) of this specification. Power actuated valves shall be tested after assembly of the valve and actuator, at the valve Manufacturers works. At least five Open-Close-Open cycles without internal pressure and five OpenClose-Open cycles with maximum differential pressure corresponding to the valve rating shall be performed on the valve actuator assembly. The time for Full Open to Full Close shall be recorded during testing. If required, the actuator shall be adjusted to ensure that the opening and closing time is with in the limits stated in Valve Data Sheet. The Hand operator provided on the actuator shall also be checked after the cyclic testing, for satisfactory manual over-ride performance. These tests shall be conducted on minimum one valve out of a lot of five (5) valves of the same size, rating and the actuator model/type. In case, the tests do not meet the requirements, retesting/rejection of the lot shall be decided by the Purchasers Inspector.
7.11
7.12
7.13
7.14
Subsequent to successful testing as specified in clause 7.10, 7.11, 7.12 and 7.13 above, one (1) valve out of the total ordered quantity shall be randomly selected by the Company Representative for cyclic testing as mentioned below:
a) The valve shall be subjected to at least 5 Open-Close-Open cycles with maximum differential pressure corresponding to the valve rating. b) Subsequent to the above, the valve shall be subjected to hydrostatic test and supplementary air seat test in accordance with clause 7.10 and 7.11. In case this valve fails to pass these tests, the valve shall be rejected and two more valves shall be selected randomly and subjected to testing as indicated above. If both valves pass these tests, all valves manufactured for the order (except the valve that failed) shall be deemed acceptable. If either of the two valves fails to pass these tests, all valves shall be rejected or each valve shall be tested at the option of manufacturer. Document No. 11-0330G01-01-08-02-008 SHEET 13 of 36
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Previously carried out prototype test of similar nature shall not be considered acceptable in place of this test. 7.15 Purchaser reserves the right to perform stage wise inspection and witness tests as indicated in clauses 7.1 to 7.14 above at Manufacturers works prior to shipment. Manufacturer shall give reasonable access and facilities required for inspection to the Purchaser. Purchaser or Purchaser representative reserves the right to require additional testing at any time to confirm or further investigate a suspected fault. The cost incurred shall be borne to Manufacturer. In no case shall any action of Purchaser or his inspector shall relieve the Manufacturer of his responsibility for material, design, quality or operation of valves. Inspection and tests performed/witnessed by the Purchasers Inspector shall in no way relieve the Manufacturers obligation to perform the required inspection and tests. 8.0 TEST CERTIFICATES Manufacturer shall submit the following certificates: a) Mill test certificates relevant to the chemical analysis and mechanical properties of the materials used for the valve construction as per the relevant standards. b) Test certificates of hydrostatic and pneumatic tests complete with records of timing and pressure of each test. c) Test reports of radiograph and ultrasonic inspection. d) Test report on operation of valves conforming to clause 7.12, 7.13 and 7.14 of this specification. e) All other test reports and certificates as required by API 6D, this specification and data sheets. The certificates shall be valid only when signed by Purchasers Inspector. Only those valves which have been certified by Purchasers Inspector shall be dispatched from Manufacturers works. 9.0 9.1 PAINTING, MARKING AND SHIPMENT Valve surface shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot blasting to SP-6 in accordance with Steel Structures Painting Council - Visual Standard SSPC-VIS-1. For the valves to be installed underground, when indicated in Valve Data Sheet, the external surfaces of buried portion of the valve shall be painted with three coats of suitable coal tar epoxy resin with a minimum dry film thickness of 300 microns. All valves shall be marked as per API 6D. The units of marking shall be metric except nominal diameter, which shall be in inches. Valve ends shall be suitably protected to avoid any damage during transit. All threaded and machined surfaces subject to corrosion shall be well protected by a coat of grease or other suitable material. All valves shall be provided with suitable protectors for flange faces, securely attached to the valves. Bevel ends shall be protected with metallic or high impact plastic bevel protectors. All sealant lines and other cavities of the valve shall be filled with sealant before shipment. TECHNICAL SPECIFICATION FOR ASSORTED VALVES Document No. 11-0330G01-01-08-02-008 SHEET 14 of 36
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9.2
9.3
9.4
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9.5
Packaging and shipping instructions shall be as per API 6D and procurement documentation. All valves shall be transported with ball in the fully open condition. On packages, following shall be marked legibly with suitable marking ink: a) Order Number b) Manufacturers Name c) Valve size and rating d) Tag Number e) Serial Number
9.6
10.0 10.1
SPARES AND ACCESSORIES Manufacturer shall furnish list of recommended spares and accessories for valves required during startup and commissioning. Manufacturer shall furnish list of recommended spares and accessories required for two years of normal operation and maintenance of valves. Manufacturer shall quote for spares and accessories as per Material Requisition.
10.2
10.3
11.0 11.1
DOCUMENTATION At the time of bidding, Manufacturer shall submit the following documents: a) Filled in Data Sheet b) General arrangement/assembly drawings showing all features and relative positions and sizes of vents, drains, gear operator/ actuator, painting, coating and other external parts together with overall dimension. c) Sectional drawing showing major parts with reference numbers and material specification. In particular a blow up drawing of ball-seat assembly shall be furnished complying with the requirement of Clause 6.7 of this specification. d) Reference list of similar ball valves manufactured and supplied in last five years indicating all relevant details including project, year, client, location, size, rating, service etc. e) Torque curves for the power actuated valves along with the break torque and maximum allowable stem torque. In addition, sizing criteria and torque calculations shall also be submitted for power actuated valves. f) Clause wise list of deviations from this specification, if any.
g) Descriptive technical catalogues of the manufacturer. h) Installation, Operational and Maintenance Manual. i) j) 11.2 Copy of valid API 6D Certificate. Details of support foot including dimensions and distance from valve centerline to bottom of support foot.
With in three weeks of placement of order, the Manufacturer shall submit four copies of, but not limited to, the following drawings, documents and specifications for Purchasers approval: Document No. 11-0330G01-01-08-02-008 SHEET 15 of 36
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a) Detailed sectional drawings showing all parts with reference numbers and material specifications. b) Assembly drawings with overall dimensions and features. Drawing shall also indicate the number of turns of hand wheel (in case of gear operators) required for operating the valve from full open to full close position and the painting scheme. Complete dimensional details of support foot (where applicable) shall be indicated in these drawings. c) Welding, heat treatment and testing procedures. d) Details of corrosion resistant paint to be applied on the valves. Manufacturer of valves shall commence only after approval of the above documents. Once the approval has been given by Purchaser, any changes in design, material and method of manufacture shall be notified to Purchaser whose approval in writing of all changes shall be obtained before the valve is manufactured. 11.3 CD containing all docs in 11.2 & 11.4 shall be submitted within 30 days from the approval date, Manufacturer shall submit to Purchaser one reproducible and six copies of the approved drawings, documents and specifications as listed in clause 11.2 above.
11.4 Prior to shipment, Manufacturer shall submit to Purchaser one reproducible and six copies of the
following: a) Test certificates as per clause 8.0 of this specification. b) Manual for installation, erection, maintenance and operation instructions including a list of recommended spares for the valves. 11.5 All documents shall be in English language only.
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FIG - 6.11 A
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FIG - 6.11 B
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PLUG VALVE
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1. SCOPE This Specification covers the minimum requirements for design, manufacture and supply of carbon steel plug valves of size DN 50 mm (2 inch) and above and ANSI class 150# thru 900# for use in onshore pipeline systems handling non sour hydrocarbons in liquid phase or gaseous phase including Liquefied Petroleum Gas (LPG).This specification does not cover plug valves for sour hydrocarbons (liquid/gas) service as defined in NACE Standard MR-0l-75. 2. REFERENCE DOCUMENTS The following Standard includes provision which, through reference in this text constitute provision of this Standard. Latest revision of this standard shall be used unless otherwise specified. API 1104 ASME 16.10 ASME 16.20 ASME 16.21 ASME B 16.5 ASME B 16.34 ASME B 16.5 ASME B 31.3 ASME B 31.8 : Specification for Welding Pipelines and related facilities. : Face to Face and End to End Dimensions of Valves : Metallic gasket for pipe flanges Ring joint or spiral wounds and jacketed. : Non Metallic Gaskets for pipe flanges. : Steel Pipe Flanges and Flanged Fittings. : Valves - Flanged, Threaded and Welding Ends. : Steel Pipe Flanges and Flanged Fittings. : Process Piping. : Gas Transmission and Distribution Piping Systems.
ASME Sec VIlI Div.I/Div.II : Boiler and Pressure Vessel Code Rules for Construction of Pressure Vessels. ASTM A3 70 : Standard Test Methods and Definitions for Mechanical Testing of Steel Products. : Auto catalytic Nickel Phosphorous Coating on Metals. : Testing of Valves. Specification for production pressure testing requirements. : Testing of Valves. Specification for fire type-testing requirement. : Metallic Materials Types of Inspection documents. : Standard Finishes for Contact Faces of Pipe Flanges and Connecting - end Flanges of Valves and Fittings. : Standard marking system for Valves, Fittings, Flanges and Union.
ASTM B 733 BS 6755-1 BS 6755-2 EN 10204 MSS-SP-6
MSS-SP-25
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MSS-SP-44 MSS-SP-53
: Steel Pipeline Flanges. : Quality Standard for Steel Casting and Forgings for Valves, Flanges and Fittings and Other Piping Components Magnetic Particle Examination Method. : Industrial Valves Pressure Testing of Valves : Testing of Valves fire type testing requirements. : Petroleum & Natural Gas Industry pipeline transportation system. : Petroleum & Natural Gas Industry. Pipeline transportation system Valves. : Steel Structures Painting Council Visual Standard.
ISO 5208 ISO 10497 ISO 13623 ISO 14313 SSPC-VIS-1
3. DEFINITIONS
Shall
: This verbal form indicates requirements strictly to be followed in order to confirm to the standards and from which no deviation is permitted. : This verbal form indicates that among several possibilities one is particularly suitable without mentioning or excluding others or that a certain course of action is preferred but not necessarily required. : This verbal form indicates a course of action permissible within the limits of this standard. : This verbal form used for statements of possibility & capability, whether material, physical or casual.
Should
May
Can
4. MATERIALS 4.1 Material for major components of the valves shall be as indicated in Valve Data Sheet. In addition, the material shall also meet the requirements specified herein other components shall be as per Manufacturers standard, which shall be subject to approval by Purchaser. Carbon steel used for the manufacture of valves shall be-fully killed. The Carbon Equivalent (CE) of valve end connections which are subject to further field welding by Purchaser shall not exceed 0.45 in check analysis for each heat of steel used, as calculated by the following formula: CE = C + Mn + Cr + 6 Mo + V + 5 Ni + Cu 15
4.2 4.3
4.4
For valves specified to be used for Gas service or High Vapor Pressure (HVP) liquid service; Charpy V-Notch test on each heat of base material shall be conducted as per API 6D, clause 3.7 for all pressure containing parts such as body, end flanges and welding ends as well as bolting material for pressure containing parts. Unless specified otherwise, the Charpy V-notch test shall be conducted at 0 C. The Charpy V-notch test specimen shall be taken in the direction of principal grain flow and notched perpendicular to the original surface of plate or forging. The
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minimum average absorbed energy per set of three specimens shall be 27 J with an individual minimum per specimen of 22J. For valves specified to be used for other hydrocarbon services, the Charpy V-notch requirements stated above are not applicable, unless required by the specified material standard as a mandatory requirement. When Low Temperature Carbon Steel (LTCS) materials are specified in Valve Data Sheet or offered by Manufacturer, the Charpy V-notch test requirements of applicable material standard shall be complied with. 4.5 When the ball of valve is manufactured out of C.S, it shall be subjected to 75 m/0.003/0.075mm thick Electroless nickel plating as per ASTM B733 with following classification SC2, type II, class-2 For Ball made of S.S material, ENP is not mandatory. Valves shall be subjected to hardness test on base material for each heat for pressure containing parts. A full thickness cross section shall be taken for this purpose and the maximum hardness shall not exceed 248 HV10 based on minimum four (4) measurements representing the entire thickness.
4.6
5.0 5.1
DESIGN AND CONSTRUCTION a) Valve design shall be as per API 6D and suitable for the process conditions indicated in the Data Sheet. The ASME Boiler & Pressure Vessel Code, Section VIII, Division 1 shall be used to design the valve body. Allowable stress requirements shall comply with the provisions of ASME B31.3. In addition, corrosion allowance indicated in Valve Data Sheet shall be considered in valve design. However, the minimum wall thickness shall not be less than the minimum requirement of ASME B16.34. b) Corrosion Allowance for all valves to be used in sweet gas services shall be considered nil. c) The manufacturer shall have valid license to use API monogram on valves manufactured as per API6D.
5.2
Valve pattern area shall be as specified in the following table: ANSI Rating Size Range, DN mm ( inch ) 50-100 (2-4) 150 150-300 (6-12) 350 (14) & above 50-100 (2-4) 300 150-250 (6-10) 300 (12) & above 600 50-250 (2-10) 300 (12) & above 900 50-250 (2-10) 300 (12) & above Pattern Short Regular Venturi Short Regular Venturi Regular Venturi Regular Venturi
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5.3
Valves shall have an inherent feature using line pressure to ensure that the line pressure cannot cause taper locking of the plug / plug movement into the taper, i.e. valves shall be of pressure balanced design. Cover shall be bolted to the body and screwed connections are not acceptable. Soft seats to achieve a seal between plug and body are not permitted. All valves shall have the provision for secondary sealant injection under full line pressure for seat and stem seals. All sealant injection connections shall be provided with an internal non-return valve. Valve design shall have a provision (e.g. Ball Type Check Valve/Needle Valve) to replace the sealant injector fitting under full line pressure. Location and arrangement of sealant injection points shall be as per Figure-4.6. When specified in the Vale Data Sheet, valves shall be designed to withstand a sustained internal vacuum of at least 1 (one) milli-bar in both open and closed position. Valve design shall ensure repair of gland packing under full line pressure. a) Valve ends shall be either flanged or butt-welded or one end flanged and one end butt-welded as indicated in the Valve Data Sheet. Flanges of the flanged end cast body valves shall be integrally cast with the body of the valve. Face to face/end to end dimensions shall conform to API 6D. b) Flanged end shall have dimensions as per ASME B 16.5. For valve sizes up to DN 600 mm (24) excluding DN 550 mm (22) MSS-SP-44 shall be referred/ ASME B16.47Series A for DN 550 mm (22) and for DN 650 mm (26 inches) and above. Flange face shall be either raised face or ring joint type as indicated in Valve Data Sheet. In case of RTJ flanges, the groove hardness shall be minimum 140 BHN. All flanged face shall have concentric serration with 125 AARH finish c) Butt welding end preparation shall confirm to ASME B 16.25. Incase of difference in thickness of valve body & mating pipelines, the bevel end of valve shall be as per ASME B 31.8. The end preparation shall take care of outside diameter of connecting pipe, wall thickness, material grade, SMYS & Special chemistry of welded material as indicated in the data sheet.
5.4 5.5 5.6
5.7
5.8
5.9
5.10
Valves shall be provided with plug position indicator and stops of rugged construction at the fully open and fully closed positions. When indicated in Material Requisition, valves shall have locking devices to lock the valve either in full open (LO) or full close (LC) position. Locking devices shall be permanently attached to the valve operator and shall not interfere with operation of the valve. Valves shall be suitable for either buried or aboveground installation as indicated in Valve Data Sheet. When stem extension requirement is indicated in Valve Data Sheet, the valves shall have the following provisions: a) Valves provided with stem extension shall have waterproof outer casing. Length of stem extension shall be as indicated in Valve Data Sheet. The length indicated corresponds to the distance between centre line of the valve opening and the centerline of the rim of the hand wheel on a vertical shaft or centerline of the hand wheel on a horizontal shaft. b) Vent, drain and sealant connections shall be terminated adjacent to the valve operator by means of suitable piping anchored to the valve body.
5.11
5.12
5.13
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c) Stem extension and stem housing design shall be such that the complete assembly will form a rigid unit giving positive drive under all conditions with no possibility of free movement between valve body, stem extension or its operator. d) Outer casing of stem extension shall have 3/8 or 1/2 NPT plugs at the top and bottom, for draining and filling with oil to prevent internal corrosion. 5.14 Operating Devices a) Valves shall have a power actuator or manual operator as indicated in the Valve Data Sheet. In case of manual operator, valve sizes < DN 100 mm (4) shall be wrench operated and valve sizes > DN 150 mm (6) shall be gear operated. Each wrench operate valve shall be supplied with wrench. Valve design shall be such that damage due to malfunctioning of the operator or its controls will only occur in the operator gear train or power cylinder and that damaged parts can be replaced without the valve cover being removed. b) The power actuator shall be in accordance with the Purchaser specification issued for the purpose and as indicated in the Valve and Actuator Data Sheet. Operating time shall be as indicated in Valve Data Sheet. Valve operating time shall correspond to full close to full open/full open to full close under maximum differential pressure corresponding to the valve rating. For actuator valves, the actuator rated torque output shall be at least 1.25 times the break torque required to operate the valve under maximum differential pressure corresponding to the valve class rating. c) For the manual operator of all valves, the diameter of the hand wheel or the length of operating wrench shall be such that under the maximum differential pressure, total force required to operate the valve does not exceed 350N. Manufacturer shall also indicate the number of turns of hand wheel (in case of gear operator) required to operate the valve from full open to full close position. d) Direction of operation of hand wheel or wrench shall be in clock-wise direction while closing the valve. e) Gear operators, when provided, shall have a self-locking provision and shall be fully encased in water proof/splash proof enclosure and shall be filled with suitable grease. 5.15 Repair by welding is not permitted for fabricated and forged body valves. However repair by welding as per ASME BI 6.34 is permitted for cast body valves. Repair shall be carried out before any heat treatment of casting is done. Repair welding procedure qualification shall also include impact test and hardness test when required as per Clause 4.6, 6.4 and 6.5 of this specification and shall meet the requirements as specified therein. The tolerance on internal diameter and out of roundness at the ends for welded ends valves shall be as per connected pipe specification as indicated in the Valve Data Sheet. Valve stem shall be capable of withstanding the maximum operating torque required to operate the valve against the maximum differential pressure corresponding to applicable class rating. The combined stress shall not exceed the maximum allowable stresses specified in ASME section VIII, Division 1. For Power Actuated Valves, the valve stem shall be designed for maximum output torque of the selected power actuator (including gear box, if any) at the valve stem.. 6.0 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:
5.16
5.17
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6.1 6.2 6.3
All valves shall be visually inspected. Dimensional check on all valves shall be carried out as per the Purchaser approved drawings. Chemical composition and mechanical properties shall be checked as per relevant material standards and this specification, for each heat of steel used. Pressure containing parts of all valves such as body, bonnet, flange, welding ends and balls etc shall be subjected to impact test on each heat of base material as per API6D CL.3.7. All Valves shall be impact tested at -20qC. The average energy absorbed shall be 35J and min. 28J. Non Destructive Examination a) Non-destructive examination of individual valve material and component consisting of but not limited to castings, forgings, plates and assembly welds shall be carried out by the Manufacturer. All castings shall be wet magnetic particle inspected 100% of the internal surfaces. Method and acceptance shall comply with MSS-SP-53. b) Body castings of all valves shall be radio graphically examined as per ASME B16.34. Procedure and acceptance criteria shall be as per ASME B 16.34. For all sizes body casting shall be subjected to 100% radiography. c) All forgings shall be ultrasonically examined in accordance with the procedure and acceptance standard of Annexure E of ASME B 16.34. All forgings shall be subject to wet magnetic particle inspection on 100% of the internal surfaces. Method and acceptance shall comply with MSS-SP-53 Bodies and bonnets made by welded assembly of segments of castings, forgings, combinations there of shall be examined, as applicable, by methods of 6.6 (b) for cast components or 6.6 (c) for forged components and plates.
6.4
6.5
6.6
6.7
Full inspection by radiography shall be carried out on all welds of pressure containing parts. Acceptance criteria shall be as per ASME B 31.3 or ASME B31.8 as applicable and API 1104.
6.8 a) All finished wrought weld ends subject to welding in field shall be 100% ultrasonically tested for lamination type defects for a distance of 50 mm from the end. Laminations shall not be acceptable. b) Weld ends of all cast valves subject to welding in field shall be 100% radio graphically examined and acceptance criteria shall be as per ASME B 16.34. c) After final machining, all bevel surfaces shall be inspected by dye penetrate or wet - magnetic particle methods. All defects longer than 6.35 mm are rejected, as are the defects between 6.35 mm and 1.59 mm that are separated by a distance less than 50 times their greatest length. Rejectable defects must be removed. Weld repair of bevel surface is not permitted. 6.9 All valves shall be tested in compliance with the requirements of API 6D. During pressure testing, valves shall not have sealant lines and other cavities filled with sealant, grease or other foreign material. The drain, vent and sealant lines shall be either included in the hydrostatic shell test or tested independently. No leakage is permissible during hydrostatic testing. The body cavity self-relieving feature meeting the requirements of clause 5.8 of this specification shall also be checked. A supplementary air seat test as per API 6D shall be carried out for all valves. A bubble tight seal is required without the use of any sealant. No leakage is allowed. Test pressure shall be Document No. 11-0330G01-01-08-02-008 SHEET 25 of 36
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held for at least 15 minutes. 6.11 Valves shall be subjected to Operational Torque Test as per clause C4 of API 6D under hydraulic pressure equal to maximum differential pressure corresponding to the valve rating. For manually operated valves, it shall be established that the force required to operate the valve does not exceed the requirements stated in section 5.22 (c) of this specification. Power actuated valves shall be tested after assembly of the valve and actuator, at the valve Manufacturers works. At least five Open-Close-Open cycles without internal pressure and five Open-Close-Open cycles with maximum differential pressure corresponding to the valve rating shall be performed on the valve actuator assembly. The time for Full Open to Full Close shall be recorded during testing. If required, the actuator shall be adjusted to ensure that the opening and closing time is with in the limits stated in Valve Data Sheet. The Hand operator provided on the actuator shall also be checked after the cyclic testing, for satisfactory manual over-ride performance. These tests shall be conducted on minimum one valve out of a lot of five (5) valves of the same size, rating and the actuator model/type. In case, the tests do not meet the requirements, retesting/rejection of the lot shall be decided by the Purchasers Inspector. 6.13 Subsequent to successful testing as specified in clause 6.9, 6.10, 6.11 and 6.12 above, one (1) valve out of the total ordered quantity shall be randomly selected by the Company Representative for cyclic testing as mentioned below: a) The valve shall be subjected to at least 500 Open-Close-Open cycles with maximum differential pressure corresponding to the valve rating. b) Subsequent to the above, the valve shall be subjected to hydrostatic test and supplementary air seat test in accordance with clause 6.9 and 6.10. In case this valve fails to pass these tests, the valve shall be rejected and two more valves shall be selected randomly and subjected to testing as indicated above. If both valves pass these tests, all valves manufactured for the order (except the valve that failed) shall be deemed acceptable. If either of the two valves fails to pass these tests, all valves shall be rejected or each valve shall be tested at the option of manufacturer. Previously carried out prototype test of similar nature shall not be considered acceptable in place of this test. 6.14 Purchaser reserves the right to perform stage wise inspection and witness tests as indicated in clauses 6.1 to 6.13 above at Manufacturers works prior to shipment. Manufacturer shall give reasonable access and facilities required for inspection to the Purchaser. Purchaser reserves the right to require additional testing at any time to confirm or further investigate a suspected fault. The cost incurred shall be to Manufacturers account. In no case shall any action of Purchaser or his inspector shall relieve the Manufacturer of his responsibility for material, design, quality or operation of valves. Inspection and tests performed/witnessed by the Purchasers Inspector shall in no way relieve the Manufacturers obligation to perform the required inspection and tests. 7.0 TEST CERTIFICATES Manufacturer shall submit the following certificates: a) Mill test certificates relevant to the chemical analysis and mechanical properties of the materials used for the valve construction as per the relevant standards.
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b) Test certificates of hydrostatic and pneumatic tests complete with records of timing and pressure of each test. c) Test reports of radiograph and ultrasonic inspection. d) Test report on operation of valves conforming to clause 6.11, 6.12 and 6.13 of this specification. e) All other test reports and certificates as required by API 6D, this specification and data sheets. The certificates shall be valid only when signed by Purchasers Inspector. Only those valves which have been certified by Purchasers Inspector shall be dispatched from Manufacturers works. 8.0 8.1 PAINTING, MARKING AND SHIPMENT Valve surface shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot blasting to SP-6 in accordance with Steel Structures Painting Council - Visual Standard SSPC-VIS-1. For the valves to be installed underground, when indicated in Valve Data Sheet, the external surfaces of buried portion of the valve shall be painted with three coats of suitable coal tar epoxy resin with a minimum dry film thickness of 300 microns. All valves shall be marked as per API 6D. The units of marking shall be metric except nominal diameter, which shall be in inches. Valve ends shall be suitably protected to avoid any damage during transit. All threaded and machined surfaces subject to corrosion shall be well protected by a coat of grease or other suitable material. All valves shall be provided with suitable protectors for flange faces, securely attached to the valves. Bevel ends shall be protected with metallic or high impact plastic bevel protectors. All sealant lines and other cavities of the valve shall be filled with sealant before shipment. Packaging and shipping instructions shall be as per API 6D and procurement documentation. All valves shall be transported with ball in the fully open condition. On packages, following shall be marked legibly with suitable marking ink: a) Order Number b) Manufacturers Name c) Valve size and rating d) Tag Number e) Serial Number 9.0 9.1 SPARES AND ACCESSORIES Manufacturer shall furnish list of recommended spares and accessories for valves required during start-up and commissioning. Manufacturer shall furnish list of recommended spares and accessories required for two years of normal operation and maintenance of valves. Document No. 11-0330G01-01-08-02-008 SHEET 27 of 36
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8.2
8.3
8.4 8.5
8.6
9.2
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9.3 10.0 10.1
Manufacturer shall quote for spares and accessories as per Material Requisition. DOCUMENTATION At the time of bidding, Manufacturer shall submit the following documents: a) b) Filled Data Sheet General arrangement/assembly drawings showing all features and relative positions and sizes of vents, drains, gear operator/ actuator, painting, coating and other external parts together with overall dimension. Sectional drawing showing major parts with reference numbers and material specification. In particular a blow up drawing of ball-seat assembly shall be furnished complying with the requirement of clause 4.6 of this specification. Reference list of similar ball valves manufactured and supplied in last five years indicating all relevant details including project, year, client, location, size, rating, service etc. Torque curves for the power actuated valves along with the break torque and maximum allowable stem torque. In addition, sizing criteria and torque calculations shall also be submitted for power actuated valves. Clause wise list of deviations from this specification, if any. Descriptive technical catalogues of the manufacturer. Installation, Operational and Maintenance Manual. Copy of valid API 6D Certificate. Details of support foot including dimensions and distance from valve centerline to bottom of support foot.
b)
c)
d)
e) f) g) h) i)
10.2
With in three weeks of placement of order, the Manufacturer shall submit four copies of, but not limited to, the following drawings, documents and specifications for Purchasers approval: a) Detailed sectional drawings showing all parts with reference numbers and material specifications. Assembly drawings with overall dimensions and features. Drawing shall also indicate the number of turns of hand wheel (in case of gear operators) required for operating the valve from full open to full close position and the painting scheme. Complete dimensional details of support foot (where applicable) shall be indicated in these drawings. Welding, heat treatment and testing procedures. Details of corrosion resistant paint to be applied on the valves.
b)
c) d)
Manufacturer of valves shall commence only after approval of the above documents. Once the approval has been given by Purchaser, any changes in design, material and method of manufacture shall be notified to Purchaser whose approval in writing of all changes shall be obtained before the valve is manufactured. Document No. 11-0330G01-01-08-02-008 SHEET 28 of 36
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10.3
CD containing all docs in 10.2 & 10.4 shall be submitted within 30 days from the approval date, Manufacturer shall submit to Purchaser one reproducible and six copies of the approved drawings, documents and specifications as listed in clause 10.2 above. Prior to shipment, Manufacturer shall submit to Purchaser one reproducible and six copies of the following: a) Test certificates as per clause 7.0 of this specification. b) Manual for installation, erection, maintenance and operation instructions including a list of recommended spares for the valves.
10.4
10.5
All documents shall be in English language only.
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CHECK VALVE
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1.0
SCOPE This specification covers the minimum requirements for design, manufacture and supply of carbon steel check valves of size DN 50mm (2) and above and ANSI class 150, 300 and 600, for use in natural gas pipeline system and associated facilities.
2.0 2.1
REFERENCE DOCUMENTS All valves shall be manufactured and supplied in accordance with the latest edition of American Petroleum Institute (API) Specification 6D c-594 or British Standard BS:1868, with additions and modifications as indicated in the following sections of this specification. For Contractual purpose, the edition in force at the time of floating of the enquiry shall be termed as latest edition.
3.0 3.1
MATERIALS Material for major components of the valves shall be as indicated in Valve Data Sheet. Other components shall be as per Manufacturers standards, which will be subject to approval by Purchaser. Carbon steel used for the manufacture of valves shall be fully killed. The Carbon Equivalent (CE) of valve end connections which are subject to further field welding by Purchaser, shall not exceed 0.45% (as calculated by the following formula) on check analysis for each heat of steel used: Mn Cr + Mo + V Ni + Cu CE = C + ---------- + -------------------- + --------------6 5 15
3.2 3.3
3.4
Charpy V-Notch test on each heat of base material shall be conducted as per API 6D, clause 7.5, for all pressure containing parts such as body, end flanges and welding ends as well as bolting material for pressure containing parts. Unless specified otherwise, the Charpy impact test shall be conducted at 0 Deg C. The Charpy impact test specimen shall be taken in the direction of principal grain flow and notched perpendicular to the original surface of plate or forging. The minimum average absorbed energy per set of three specimens shall be 27 J with an individual minimum per specimen of 22 J. No specimen shall exhibit less than 80 percent shear area.
3.5
All process wetted parts, metallic and non-metallic, shall be suitable for the fluids and service specified by the Purchaser. DESIGN AND CONSTRUCTION Following types of check valves, meeting the requirements of applicable standards (refer clause 2.1 of this specification) are acceptable: a) b) c) Swing Check Valve Dual Plate Check Valve Axial Flow (Nozzle) Check Valve
4.0 4.1
Valve design shall be suitable for the service conditions indicated in Valve Data Sheet. Corrosion allowance indicated in Valve Data Sheet shall be considered in valve design. 4.2 In case of swing check valves, the disc hinge shall be mounted on the valve body and shall not be attached to the valve body cover. Valve body cover joint shall be of bolted design. Screwed covers shall not be used.
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4.3
Valves shall be provided with non-renewable integral type seats as indicated in Valve Data Sheet. Nonrenewable seats shall be of a design which does not require renewal over the design life of the valve. Valves shall be provided with drain connection as per the Manufacturers standard. Drain tapping shall be provided in a position suitable to completely drain the valve with valve in horizontal position. Valve ends shall be either flanged or butt welded or one end flanged and one end butt welded as indicated in Valve Data Sheet. Flanged end shall have dimensions as per ASME B16.5 for sizes upto DN 400mm (16). Flanges of the flanged end cast body valves shall be integrally cast with the body of the valve. Butt weld end preparation shall be as per ANSI B 16.25. The thickness of the pipe to which the valve has to be welded shall be as indicated in Valve Data Sheet. Valves shall be without transition pups. In case difference exists between thickness of valve neck end and connecting pipe, the bevel end of valve shall be prepared as per ANSI B31.8 or ANSI B 31.3, as applicable. Valves of size DN 200mm (8) and above shall be equipped with lifting lugs. Tapped holes and eye bolts shall not be used for lifting lugs. An arrow indicating the direction of flow shall be embossed or cast on the body of all valves. All welds shall be made by welders and welding procedures qualified in accordance with the provisions of ASME Section IX. The welding and repair welding procedure qualification shall include impact test and shall meet the requirements of clause 3.4 of this specification. Repair by welding is permitted for cast body valves subject to written approval by Purchaser and shall be carried out as per ANSI B16.34. Repair shall be carried out before any heat treatment of casting is done. 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. Inspection certification shall be confirmed to EN10204-3.1b. Such inspection and tests shall be, but not limited to, the following: All valves shall be visually inspected. Dimensional check on all valves shall be carried out as per the Purchaser approved drawings. Chemical compositions and mechanical properties shall be checked as per relevant material standards and this specification, for each heat of steel used. a) Wherever applicable, the body castings of valves shall be radio graphically examined on 100% of the surface of critical areas as per ANSI B16.34. Procedure and acceptance criteria shall be as per ANSI B16.34. Where applicable, valve body made by forging and plate components shall be ultrasonically examined in accordance with procedure and acceptance standard of Annexure E of ANSI B16.34. The extent of radiography/ultrasonic examination shall be as follows : ANSI Class 150 ANSI Class 300 All sizes < DN 400mm (16) > DN 450mm (18) All sizes Nil 100% 100% 100%
4.4
4.5
4.6
4.7
4.8 4.9
4.10
5.0 5.1
5.1.1 5.1.2 5.1.3
5.1.4
b)
c)
ANSI Class 600
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5.1.5 5.2
All valves shall be tested in compliance with the requirements of applicable standard (refer clause 2.0). Purchaser reserves the right to perform stage-wise inspection and witness tests as indicated in clause 5.1 above at Manufacturers works prior to shipment. Manufacturer shall give reasonable access and facilities required for inspection to the Purchasers Inspector. Purchaser reserves the right to require additional testing at any time to confirm or further investigate a suspected fault. The cost incurred shall be to Manufacturers account. In no case shall any action of Purchaser or its Inspector relieve the Manufacturer of his responsibility for material, design, quality or operation of valves. Inspection and tests performed/witnessed by the Purchasers Inspector shall in no way relieve the Manufacturers obligation to perform the required inspection and tests.
6.0
TEST CERTIFICATES Manufacturer shall submit the following certificates: a) Mil test certificates relevant to the chemical analysis and mechanical properties of the materials used for the valve construction as per the relevant standards. Hydrostatic test certificates complete with records of timing and pressure of each test. Test reports of radiograph and ultrasonic inspection, as applicable. All other tests reports and certificates as required by applicable standard and this specification.
b) c) d)
The certificates shall be valid only when signed by Purchasers Inspector. Only those valves which have been certified by Purchasers Inspector shall be dispatched from Manufacturers works. 7.0 7.1 PAINTING, MARKING AND SHIPMENT Valve surface shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot blasting to SP-6 in accordance with Steel Structures Painting Council Visual Standard SSPC-VIS-1. All valves shall be marked as per applicable standard. The units of marking shall be metric except nominal diameter, which shall be in inches. Valve ends shall be suitably protected to avoid any damage during transit. All threaded and machined surfaces subject to corrosion shall be well protected by a coat of grease or other suitable material. All valves shall be provided with suitable protectors for flange faces, securely attached to the valves. Packaging and shipping instructions shall be as per applicable standard. On packages, the following shall be marked legibly with suitable marking ink : a) b) c) d) e) Order Number Manufacturers Name and trade mark. Valve Size and Rating Tag Number. Minimum & maximum operating temperature.
7.2
7.3
7.4 7.5
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f) g) 8.0 8.1
Body material designation. Maximum operating pressure.
SPARES AND ACCESSORIES Manufacturer shall recommend and quote separately the spares for valves required for commissioning and two years of normal operation. DOCUMENTATION At the time of bidding, Manufacturer shall submit the following documents: a) General arrangement drawings showing all features together with overall dimensions and actual valve bore size. Sectional drawing showing major parts with reference numbers and material specification and Quality assurance plan (QAP). Details of corrosion resistant paint proposed to be applied.
9.0 9.1
b)
c)
Reference list of similar supplies of check valves, including project, year, client, location, size, rating, the Manufacturer shall furnish services, etc. for the last three years. (The valves shall be proven for service indicated in Valve Data Sheet). 9.2 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 Purchasers approval. a) b) Detailed sectional drawings showing all parts with reference numbers and material specification. Assembly drawings indicating overall dimensions, features and painting scheme.
Once the approval has been given by Purchaser, any changes in design, material and method of manufacture shall be notified to Purchaser whose approval in writing of all changes shall be obtained before the valve is manufactured. 9.3 Within 30 days from the approval date, Manufacturer shall submit to Purchaser one reproducible and six copies of all approved drawings, documents and specifications as listed in clause 9.2 above. Prior to shipment, Manufacturer shall submit to Purchaser one reproducible and six copies of the following: a) b) Test certificates as listed in clause 6.0 of this specification. Manual for installation, erection, maintenance and operation instructions, including a list of recommended spares for the valves.
9.4
9.5 10.0 10.1
All documents shall be in English language. GUARANTEE Manufacturer shall guarantee that the materials and machining of valves and fittings comply with the requirements in this specification and in the Purchase Order. Manufacturer is bound to replace or repair all valve parts which should result defective due to inadequate engineering or to the quality of materials and machining. If valve defect or malfunctioning cannot be eliminated, Manufacturer shall replace the valve without delay. Document No. 11-0330G01-01-08-02-008 SHEET 35 of 36
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10.2
10.3
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10.4
Any defect occurring during the period of Guarantee shall be attended to by making all necessary modifications and repair of defective parts free of charge to the Purchaser as per the relevant clause of the bid document. All expenses shall be to Manufacturers account.
10.5
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CLIENT SIZE/QUANTITY
GAIL (India) LIMITED **
PROJECT:PIPELINE FROM HANUMAN JUNCTION TO VCL
GENERAL SPECIFICATION Process Fluid Design Temperature Design Standard Size, mm (inch) Body Type End Connection Type Flange Face Finish Locking Device Reqd 2" to 12" Full Bore NG ( 0 to 65 deg C) API 6D ANSI Rating Design Pressure Piping Class 300# 49 barg 3A1
** RF 125AARH
Standard Special Requirement
ASME B16.25/ASME B16.5 Vent, drain & Sealant connection Anti Blow out system
As per Technical Spec. VALVE DESIGN CONDITIONS
Corrosion Allowance Installation
Design Factor
0.5 2 meter (Approx for U/G installation)
Underground/Aboveground Stem Ext Length, mm CONNECTING PIPE DETAILS
Diameter, mm (inch) Diameter, mm (inch)
10"/8"/6"/4" 2"
MATERIAL MATERIAL VALVE OPERATION
Refer P&Id Refer P&Id
Actuation Type Type of Actuator
As per Technical Spec. Not Applicable VALVE MATERIAL SPECIFICATION
PART DISCRIPTION Body Ball Seat Rings Seat Seal Stem Stem Seal Stud Bolts Nuts A 216 Gr. WCB / A234GrWPB
SPECIFIED
(A 216 Gr. WCB / A234GrWPB) + 0.003" ENP AISI 4140 + 75 micrometer (0.003") ENP/ AISI 410 VITON AISI 4140 + 75 micrometer (0.003") ENP/ AISI 410 PTFE/ VITON ASTM A 193 Gr. B7 A194 Gr. 2H TESTING REQUIREMENT
Hydrostatic Test Pressure Air Test Pressure Anti-Static Testing Requirement Hardness Test Charpy Impact Test/ Temperature
Body: 74 barg
Seat: 54 barg 7barg As per API 6D Latest Edition 248 HV10 Yes (at 0 deg C) Document No. Rev. 0
DATA SHEET FOR BALL VALVES (2"-12," 300#)
11-0330G01-01-08-03-002 SHEET 1 of 2
69 of 245
CLIENT GAIL (India) LIMITED SIZE/QUANTITY **
PROJECT: PIPELINE FROM HANUMAN JUNCTION TO VCL
Fire Safe Test Valve Painting Specification Manufacturer's Painting Specification Number
As per API 6FA Suitable for Corrosive Industrial Environment *
Notes 1. This Data Sheet Shall be read in conjunction with the Material Requsition, Technical Specification, M.T.O.(if any) and PMS which are enclosed along with this requisition.
* To be filled by Vendor ** Refer MTO Legend: B.W - Butt welded, RF - Raised Face,U/G - Underground
DATA SHEET FOR BALL VALVES (2"-12", 300#)
Rev. 0
70 of 245
GENERAL SPECIFICATION Process Fluid Design Temperature Design Standard Size, mm (inch) Body Type End Connection Type Flange Face Finish Locking Device Reqd NG ( 0 to 65 deg C) API 6D 2" to 12" Full Bore ANSI Rating Design Pressure Piping Class 600# 92 Kg/cm2 g 6A1
** RF 125AARH
Standard Special Requirement
ASME B16.25/ASME B16.5 Vent, drain & Sealant connection Anti Blow out system
As per Technical Spec. VALVE DESIGN CONDITIONS
Corrosion Allowance Installation
Design Factor
0.5 2 meter (Approx for U/G installation)
Underground/Aboveground Stem Ext Length, mm CONNECTING PIPE DETAILS
Diameter, mm (inch) Diameter, mm (inch)
10"/8"/6"/4" 2"
MATERIAL MATERIAL VALVE OPERATION
Refer P&Id Refer P&Id
Actuation Type Type of Actuator
As per Technical Spec. Not Applicable VALVE MATERIAL SPECIFICATION
PART DISCRIPTION Body Ball Seat Rings Seat Seal Stem Stem Seal Stud Bolts Nuts
SPECIFIED A 216 Gr. WCB / A234GrWPB (A 216 Gr. WCB / A234GrWPB) + 0.003" ENP AISI 4140 + 75 micrometer (0.003") ENP/ AISI 410 VITON AISI 4140 + 75 micrometer (0.003") ENP/ AISI 410 PTFE/ VITON ASTM A 193 Gr. B7 A194 Gr. 2H
TESTING REQUIREMENT
Hydrostatic Test Pressure Air Test Pressure Anti-Static Testing Requirement Hardness Test Charpy Impact Test/ Temperature Body:147 Kg/cm2 g Seat:107.8 Kg/cm2 g 7barg As per API 6D Latest Edition 248 HV10 Yes (at 0 deg C) Document No. DATA SHEET FOR BALL VALVES (2"-12," 600#) 11-0330G01-01-08-03-002 SHEET 1 of 2 Rev. 0
71 of 245
* To be filled by Vendor ** Refer MTO Legend: B.W - Butt welded, RF - Raised Face,U/G-Underground
DATA SHEET FOR BALL VALVES (2"-12", 600#)
Rev. 0
72 of 245
GENERAL SPECIFICATION Process Fluid Design Temperature Design Standard Size, mm (inch) Body Type End Connection Type Flange Face Finish Locking Device Reqd NG ( 0 to 65 deg C) API 6D 2" to 12" Full Bore ** RF 125AARH Special Requirement As per Technical Spec. VALVE DESIGN CONDITIONS Corrosion Allowance Installation 0 ** Design Factor Stem Ext Length, mm CONNECTING PIPE DETAILS Diameter, mm (inch) Diameter, mm (inch) 10"/8"/6"/4" 2" MATERIAL MATERIAL VALVE OPERATION Actuation Type Type of Actuator As per Technical Spec. Not Applicable VALVE MATERIAL SPECIFICATION PART DISCRIPTION Body Ball Seat Rings Seat Seal Stem Stem Seal Stud Bolts Nuts SPECIFIED A 216 Gr. WCB / A234GrWPB (A 216 Gr. WCB / A234GrWPB) + 0.003" ENP AISI 4140 + 75 micrometer (0.003") ENP/ AISI 410 VITON AISI 4140 + 75 micrometer (0.003") ENP/ AISI 410 PTFE/ VITON ASTM A 193 Gr. B7 A194 Gr. 2H Refer P&Id Refer P&Id 0.5 Not Applicable Standard ASME B16.25/ASME B16.5 Vent, drain & Sealant connection Anti Blow out system ANSI Rating Design Pressure Piping Class 150# 19 barg 1A1
TESTING REQUIREMENT
Hydrostatic Test Pressure Air Test Pressure Anti-Static Testing Requirement Hardness Test Charpy Impact Test/ Temperature Body: 29 barg Seat: 21 barg 7 barg As per API 6D Latest Edition 248 HV10 Yes (at 0 deg C) Document No. DATA SHEET FOR BALL VALVES (2"-12",150#) 11-0330G01-01-08-03-002 SHEET 1 of 2 Rev. 0
73 of 245
GAIL GAS LIMITED **
* To be filled by Vendor ** Refer MTO Legend: B.W - Butt welded, RF - Raised Face
DATA SHEET FOR BALL VALVES (2"-12",150#)
Rev. 0
74 of 245
PROJECT: GAIL (India) LIMITED WGI INSPECTION SUBVENDOR/ VENDOR TPI WGI/GAIL QAP NO: 11-0330G01-02-08-10-002 REV NO: 0 ITEM DESCRIPTION/ QUANTITY: BALL VALVE JOB NO.: 110330G01 PAGE NO: 1 of 3 FORMAT OF RECORD
CLIENT: CONSULTANT: VENDOR: QUANTAM OF CHECK ACCEPTANCE NORMS REFERENCE DOCUMENT
SR. NO. COMPONENTS & OPERATIONS TYPES OF CHECK
RAW MATERIAL
CHEM. TEST
PER HEAT
MOC
MOC
3.2 Certificate
P/R
PHY. TEST
PER HEAT
MOC
MOC
3.2 Certificate
P/W
1. BODY & BONET ( REFER NOTE-1) 100% ( PER HEAT ASTM A 370 35J AVERAGE VALUE / 28J (ONE SPECIMEN) T.C. MSS-SP-75 INTERNAL Q.C
VISUAL
P/W
IMPACT TEST 0 DEG C )
P/W
RADIOGRAPHY
100%
ASTM A 16.34
ASTM A 16.34
INSPECTION REPORT/RT FILMS INSPECTION REPORT SUPPLIER T.C.
P/W
MPT
100%
ASTM A 16.34
ASTM A 16.34
P/W
CHEM. TEST
PER HEAT
MOC
MOC
P/W
PHY. TEST
PER HEAT
MOC
MOC
SUPPLIER T.C.
P/W
2. DISC & SEAT RING 10% WITNESS & 100% REVIEW PER HEAT ASTM A 370 P/W W R
VISUAL
IMPACT TEST ( 0 DEG C ) PER HEAT
35J AVERAGE VALUE / 28J (ONE SPECIMEN) MOC MOC
INSPECTION REPORT LAB T.C.
P/W
RW
CHEM. TEST
P/R
3. SPINDLE PER HEAT MOC MOC LAB T.C. P/W W R
PHY. TEST
75 of 245
PROJECT: QAP NO: 11-0330G01-02-08-10-002 REV NO: 0 ITEM DESCRIPTION/ QUANTITY: BALL VALVE JOB NO.:110330G01 PAGE NO: 2 of 3 INSPECTION SUBVENDOR /VENDOR TPI WGI/GAIL REFERENCE DOCUMENT ACCEPTANCE NORMS FORMAT OF RECORD GAIL (India) LTD. WGI
CLIENT: CONSULTANT: VENDOR: QUANTAM OF CHECK
SR. NO.
COMPONENTS & OPERATIONS TYPES OF CHECK
INPROCESS INP 100% P/W INSPECTION REPORT INSPECTION REPORT P/W W R
TRANSFER OF HEAT NO. 100% APPVD.DRG APPVD.DRG
1. BODY & BONET
DIMENSIONS
2. DISC & SEAT RING
DIMENSIONS
100%
-DO-
-DO-
-DO-
P/W
3. SPINDLE
DIMENSIONS
100%
-DO-
-DO-
-DO-
P/W
4. HARD FACING
HARDNESS & D.P.
100%
ASTM B 16.34
ASTM B 16.34 350 to 450 BHN
INSPECTION REPORT
P/W
RW
BROUGHTOUT ITEM
3 PER LOT ASTM A 193 Gr. B7 & ASTM A 193 Gr. B7 & A 194 Gr. 2H A 194 Gr. 2H P R R
CHEMICAL
PHYSICAL
PER LOT
ASTM A 193 Gr. B7 & ASTM A 193 Gr. B7 & A 194 Gr. 2H A 194 Gr. 2H INSPECTION REPORT
1. FASTNERS 10%
DIMENSIONS
3.2 Certificate
IMPACT TEST ( 0 DEG C ) PER LOT
ASTM A 370
35J AVERAGE VALUE / 28J (ONE SPECIMEN)
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PROJECT: GAIL (INDIA) LIMITED. WGI INSPECTION SUBVENDOR/ VENDOR TPI WGI/GAIL
CLIENT: CONSULTANT: VENDOR: QUANTAM OF CHECK REFERENCE DOCUMENT ACCEPTANCE NORMS FORMAT OF RECORD
QAP NO: 11-0330G01-01-08-10-002 REV NO: 0 ITEM DESCRIPTION/ QUANTITY: BALL VALVE JOB NO.: 110330G01 PAGE NO: 3 of 3
SR.
COMPONENTS & OPERATIONS
TYPES OF CHECK
NO.
4 100% 100% 100% APPVD.DRG & API 598 -DOP/W APPVD.DRG & API 598 -DOAPPVD.DRG & API 598 P/W APPVD.DRG & API 598 APPVD.DRG & API 598 P/W APPVD.DRG & API 598 INSPECTION REPORT P W W W
FINAL INSPECTION R RW RW
VISUAL
DIMENSIONS
HYD. BODY TEST
ASPER API 598 100%
HIGH PRESSURE CLOSER ( SEAT) TEST
RW
LOW PRESSURE CLOSER (SEAT) TEST 100% APPVD.DRG & API 598 -DOAPI 598 SPEC SPEC 60-80 ROUGH SPEC 60-80 EACH COAT & TOTAL WITHIN 300 AS PER SPEC./APPD.DRG. INSPECTION REPORT PAINT.INSP. REPORT API 598 -DOAPPVD.DRG & API 598 100% 10% WITNESS & 100% REVIEW 100%
P/W
HIGH PRESSURE PNEUMATIC SHELL TEST
P/W P P
W R W
RW R R
VISUAL
5 100% SPEC
PAINTING
SURFACE PREPARATION SA 2/
PRIMER & FINISH COAT (EACH TWO COAT) 100% AS PER SPEC./APPD.DRG.
REVIEW
6 100%
FINAL DOCUMENTS
MARKING/TAG DETAILS
Final dossier - IRN, 3.2 Certificate, Insp & AS PER SPEC./MSS AS PER SPEC./MSS test report, Drawing etc SP25 SP 25
LEGEND: W - WITNESS, R - REVIEW, TPI - THIRD PARTY INSPECTION, RW - RANDOM WITNESS,MOC-MATERIAL OF CONSTRUCTION NOTES : 1. ALL INSTRUMENTS & EQUIPMENT SHALL HAVE VALID CALIBRATION CERTIFICATE TO BE REVIEWED BY TPI. 2. MATERIAL TEST CERTIFICATE OF CASTING AND FASTENERS SHALL BE IN 3.2 AS PER EN-10204. 3. TPIA TO ISSUE 3.2 CERTIFICATE AS PER EN 10204 SPEC.
77 of 245
GENERAL SPECIFICATION Process Fluid Design Temperature Design Standard Size, mm (inch) Valve Pattern End Connection Flange Face Finish Locking Device Reqd NG/ R-LNG ( 0 to 65 deg C) API6D / BS 5353 2" & above Regular ** RF 125AARH Special Requirement NA VALVE DESIGN CONDITIONS Corrosion Allowance Installation Opening/Closing time 0 mm Design Factor 0.5 NA/ ~2 meter for Underground Valves Standard ASME B16.25/ASME B16.5 ANSI Rating Design Pressure Piping Class 300# 49 barg 3A1
Aboveground/Underground Stem Ext Length, mm NA CONNECTING PIPE DETAILS
Diameter, mm (inch) Material Out of roundness
*** ASTM A 106 Gr.B (Schedule 80) Not Applicable VALVE OPERATION
Actuation Reqd Type of Actuator
As per tech. spec. Manual VALVE MATERIAL SPECIFICATION
PART DISCRIPTION Body Plug (Lubricated) Cover Stem Stem Seal Lubricant Screw
SPECIFIED A 216 Gr. WCB / A234GrWPB ASTM A 216 Gr WCB + 0.003ENP ASTM A 216 Gr WCB AISI 4140 + 0.03" ENP/ AISI 410 PTFE/ Graphite Manufacturer's Standard
TESTING REQUIREMENT
Hydrostatic Test Pressure Air Test Pressure Anti-Static Testing Requirement Hardness Test Charpy Impact Test/ Temperature Body: 74 barg Seat: 54 barg 7 bar As per API 6D Latest Edition 248 HV10 Yes (at 0 deg C) Document No. 11-0330G01-01-08-03-008 SHEET 1 of 2 Rev. 0
DATA SHEET FOR PLUG VALVES 300#
78 of 245
Notes 1. This Data Sheet Shall be read in conjunction with the Technical Notes, M.T.O.(if any), PMS which are enclosed along with this requisition. 2. Stem packing shall be renewable with valve open on stream. 3. All valves shall be provided with valve position indicator. 4. Valve shall be "pressure balanced design ". i.e It shall have an inherent feature using the line pressure to ensure that the line pressure cannot cause taper locking of the plug/plug movement into the taper. Abbreviations: SB - BW - Butt welded, FLG - Flange * To be filled by Vendor ** Refer MR *** Refer P& Id
DATA SHEET FOR PLUG VALVES
Rev. 0
79 of 245
CLIENT GAIL (India) LIMITED SIZE/QUANTITY **
GENERAL SPECIFICATION Process Fluid Design Temperature Design Standard Size, mm (inch) Valve Pattern End Connection Flange Face Finish Locking Device Reqd NG/ R-LNG ( 0 to 65 deg C) API6D / BS 5353 2" & above Regular ** RF 125AARH NA VALVE DESIGN CONDITIONS Corrosion Allowance Installation Opening/Closing time 0.0 mm Design Factor 0.5 NA/ ~2 meter for Underground Valves Standard ASME B16.25/ASME B16.5 ANSI Rating Design Pressure Piping Class 150# 19 barg 1A1
Special Requirement
Aboveground/Underground Stem Ext Length, mm NA CONNECTING PIPE DETAILS
Diameter, mm (inch) Material Out of roundness
Refer P&Id Refer P&Id Not Applicable VALVE OPERATION
Actuation Reqd Type of Actuator
As per tech. spec. Manual VALVE MATERIAL SPECIFICATION
PART DISCRIPTION Body Plug (Lubricated) Cover Stem Stem Seal Lubricant Screw
SPECIFIED ASTM A 216 Gr WCB / A234Gr.WPB ASTM A 216 Gr WCB + 0.003ENP ASTM A 216 Gr WCB AISI 4140 + 0.03" ENP/ AISI 410 PTFE/ Graphite Manufacturer's Standard
TESTING REQUIREMENT
Hydrostatic Test Pressure Air Test Pressure Anti-Static Testing Requirement Hardness Test Charpy Impact Test/ Temperature Body: 29 barg Seat: 21 barg 7 bar As per API 6D Latest Edition 248 HV10 Yes (at 0 deg C) Document No. 11-0330G01-01-08-03-008 SHEET 1 of 2
Rev. 0
80 of 245
Notes 1. This Data Sheet Shall be read in conjunction with the Technical Notes, M.T.O.(if any), PMS which are enclosed along with this requisition. 2. Stem packing shall be renewable with valve open on stream. 3. All valves shall be provided with valve position indicator. 4. Valve shall be "pressure balanced design ". i.e It shall have an inherent feature using the line pressure to ensure that the line pressure cannot cause taper locking of the plug/plug movement into the taper. Abbreviations: SB - BW - Butt welded, FLG - Flange * To be filled by Vendor ** Refer MR *** Refer P & Id
Rev. 0
81 of 245
GENERAL SPECIFICATION Process Fluid Design Temperature Design Standard Size, mm (inch) Valve Pattern Connection Type Pup piece/ Flange Face Finish Locking Device Reqd NG/ R-LNG ( 0 to 65 deg C) API 6D 2" & above Regular B.W./ FLG N.A./ RF 125AARH Special Requirement * VALVE DESIGN CONDITIONS Corrosion Allowance Installation Opening/Closing time 0 mm Design Factor 0.5 N.A./2.0 m approx. for underground Valves Standard ASME B16.25/ ASME B16.5, B16.47 Vent, drain & Sealant connection Anti Blow out system ANSI Rating Design Pressure Piping Class 600# 92 Kg/cm2 g 6A1
Aboveground/Underground Stem Ext Length, mm * CONNECTING PIPE DETAILS
Diameter, mm (inch) Wall Thck, mm/Sch Out of roundness
* * * VALVE OPERATION
Actuation Requirement Type of Actuator
* * VALVE MATERIAL SPECIFICATION
PART DISCRIPTION Body Plug Cover Stem Stem Seal Gasket Stud Bolts Nuts
SPECIFIED A 216 Gr.WCB / A234Gr.WPB A 216 Gr.WCB + 0.003" ENP A 216 Gr.WCB AISI 4140 + 0.03" ENP/ AISI 410 PTFE/ Graphite Graphoil ASTM A 193 Gr.B7 A194 Gr. 2H
MATERIAL OFFERED * * * * * * * *
TESTING REQUIREMENT
Hydrostatic Test Pressure Air Test Pressure Anti-Static Testing Requirement Hardness Test Charpy Impact Test/ Temperature Body: 147 Kg/cm2 g Seat: 107.8 Kg/cm2 g 7 bar As per API 6D Latest Edition 248 HV10 Yes (at 0 deg C) Document No. 11-0330G01-01-08-03-008 SHEET 1 of 2 Rev. 0
82 of 245
Notes 1. This Data Sheet Shall be read in conjunction with the Technical Notes, M.T.O.(if any), PMS which are enclosed along with this requisition. 2. Valve shall be provided with a pup piece integrally welded (in controlled factory conditions only) to the valve whose strength shall be equivalent to attached pipe specification. 3. All Underground Valves shall be supplied with extended stem and Welded body type. 4. Stem packing shall be renewable with valve open on stream. 5. All valves shall be provided with valve position indicator. 6. Valve shall be "pressure balanced design ". i.e It shall have an inherent feature using the line pressure to ensure that the line pressure cannot cause taper locking of the plug/plug movement into the taper. Abbreviations: SB - Small Bore, LB - Large Bore, BW - Butt welded, FLG - Flange, GPV - Gear Operated Plug Valve * To be filled by Vendor
Document No. DATA SHEET FOR PLUG VALVES 11- 0330G01-01-08-03-008 SHEET 2 of 2
Rev. 0
83 of 245
GENERAL SPECIFICATION Process Fluid Design Temperature Design Standard Size, mm (inch) Valve Pattern End Connection Pup piece/ Flange Face Finish Locking Device Reqd NG/ R-LNG ( 0 to 65 deg C) BS 5353 15(1/2") to 40(1.1/2") Regular S.W, 800# Not Required Special Requirement * VALVE DESIGN CONDITIONS Corrosion Allowance Installation Opening/Closing time 0 Aboveground N.A. CONNECTING PIPE DETAILS Diameter, mm (inch) Wall Thck, mm/Sch Out of roundness * * * VALVE OPERATION Actuation Reqd Type of Actuator Yes Manual VALVE MATERIAL SPECIFICATION PART DISCRIPTION Body Plug (Lubricated) Cover Stem Stem Seal Lubricant Screw SPECIFIED ASTM A 105 ASTM A 105 + 0.003ENP ASTM A 105 AISI 4140 + 0.03" ENP/ AISI 410 PTFE/ Graphite Manufacturer's Standard MATERIAL OFFERED * * * * * * Design Factor Stem Ext Length, mm 0.5 N.A. * Standard ASME B16.11 ANSI Rating Design Pressure Piping Class 600# 92 Kg/cm2 g 6A1
TESTING REQUIREMENT
Hydrostatic Test Pressure Air Test Pressure Anti-Static Testing Requirement Hardness Test Charpy Impact Test/ Temperature DATA SHEET FOR PLUG VALVES 800# Body: 147 Kg/cm2 g Seat: 107.8 Kg/cm2 g 7 bar As per API 6D Latest Edition 248 HV10 Yes (at 0 deg C) Document No. 11-0330G01-01-08-03-008 SHEET 1 of 2 Rev. 0
84 of 245
Notes 1. This Data Sheet Shall be read in conjunction with the Technical Notes, M.T.O.(if any), PMS which are enclosed along with this requisition. 2. Valve shall be provided with a pup piece integrally welded (in controlled factory conditions only) to the valve whose strength shall be equivalent to attached pipe specification. 3. All Underground Valves shall be supplied with extended stem and Welded body type. 4. Stem packing shall be renewable with valve open on stream. 5. All valves shall be provided with valve position indicator. 6. Valve shall be "pressure balanced design ". i.e It shall have an inherent feature using the line pressure to ensure that the line pressure cannot cause taper locking of the plug/plug movement into the taper. Abbreviations: SB - Small Bore, LB - Large Bore, BW - Butt welded, FLG - Flange * To be filled by Vendor
Size (inch)
Description
TAG NUMBERS
QTY
Rev. 0
85 of 245
CLIENT: GAIL (India) LIMITED CONSULTANT: WGI VENDOR:

PAGE NO: 1 of 3
QAP NO: 11-0330G01-01-08-10-004 REV NO: 0 ITEM DESCRIPTION/ QUANTITY: PLUG VALVE JOB NO.: 110330G01
INSPECTION SUBVENDOR/ VENDOR TPI WGI/GAIL
SR. NO. COMPONENTS & OPERATIONS
TYPES OF CHECK
QUANTAM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORMS
FORMAT OF RECORD
1 PER HEAT ASTM A 216 Gr WCB 3.2 Certificate P/R
RAW MATERIAL R R
CHEM. TEST
PHY. TEST ASTM A 216 Gr WCB MSS-SP-75 INTERNAL Q.C 3.2 Certificate 100%
PER HEAT
ASTM A 216 Gr WCB EN 10204/3.1B ASTM A 216 Gr WCB EN 10204/3.1B P/W P/W
W R
W R
VISUAL
1. BODY & BONET REFER NOTE-1) PER HEAT ASTM A 370 35J AVERAGE VALUE / 28J (ONE SPECIMEN) T.C. ASTM A 16.34 INSPECTION REPORT/RT FILMS INSPECTION REPORT SUPPLIER T.C. SUPPLIER T.C.
IMPACT TEST ( 0 DEG C )
P/W
RADIOGRAPHY
100%
ASTM A 16.34
P/W
MPT PER HEAT PER HEAT 10% WITNESS & 100% REVIEW ASTM A 216 Gr WCB ASTM A 216 Gr WCB
100%
ASTM A 16.34
ASTM A 16.34 ASTM A 216 Gr WCB ASTM A 216 Gr WCB
P/W P/W P/W P/W
W R W W
R R W R
CHEM. TEST
PHY. TEST
2. PLUG & SEAT RING
VISUAL
IMPACT TEST ( 0 DEG C ) PER HEAT PER HEAT PER HEAT
ASTM A 370
INSPECTION REPORT LAB T.C.
P/W
RW
CHEM. TEST
AISI 4140/AISI 410 AISI 4140/AISI 410
P/R LAB T.C. P/W
R W
R R
3. SPINDLE
PHY. TEST
35J AVERAGE VALUE / 28J (ONE SPECIMEN) AISI 4140/AISI 410 AISI 4140/AISI 410
86 of 245
PROJECT: PIPELINE FROM HANUMAN JUNCTION TO VCL CLIENT: GAIL (India) LIMITED CONSULTANT:WGI VENDOR: REV NO: 0 ITEM DESCRIPTION/ QUANTITY: PLUG VALVE JOB NO.: 110330G01
PAGE NO: 2 of 3
QAP NO: 11-0330G01-01-08-10-004
INSPECTION SUBVENDOR /VENDOR TPI WGI/GAIL
SR. NO.
COMPONENTS & OPERATIONS QUANTAM OF CHECK REFERENCE DOCUMENT ACCEPTANCE NORMS FORMAT OF RECORD
TYPES OF CHECK
INPROCESS INP 100% P/W INSPECTION REPORT INSPECTION REPORT P/W RW R
1. BODY & BONET
DIMENSIONS
RW
2. PLUG & SEAT RING 100% -DO-DO-DO-
DIMENSIONS
100%
-DO-
-DO-
-DO-
P/W P/W
R R
R R
3. SPINDLE
DIMENSIONS
4. HARD FACING
HARDNESS & D.P.
100%
ASTM B 16.34
ASTM B 16.34 350 to 450 BHN
INSPECTION REPORT
P/W
RW
BROUGHTOUT ITEM PER LOT P R R
CHEMICAL PER LOT 10%
P INSPECTION REPORT 3.2 Certificate 35J AVERAGE VALUE / 28J (ONE SPECIMEN) P
R R
R R
PHYSICAL
A193 B7 & A194 Gr.2H A193 B7 & A194 Gr.2H
A193 B7 & A194 Gr.2H A193 B7 & A194 Gr.2H
1. FASTNERS
DIMENSIONS PER LOT ASTM A 370
IMPACT TEST ( 0 DEG C )
87 of 245
PROJECT:PIPELINE FROM HANUMAN JUNCTION TO VCL CLIENT: GAIL GAS LIMITED CONSULTANT: WGI VENDOR:
PAGE NO: 3 of 3
QAP NO: 11-0330G01-01-08-10-004 REV NO: 0 ITEM DESCRIPTION/ QUANTITY: PLUG VALVE JOB NO.: 110330G01
INSPECTION SUBVENDOR/ VENDOR TPI WGI/GAIL
SR. QUANTAM OF CHECK REFERENCE DOCUMENT ACCEPTANCE NORMS FORMAT OF RECORD
TYPES OF CHECK
NO.
4 100% W W 100% APPVD.DRG & API 598 P/W APPVD.DRG & API 598 -DOP/W APPVD.DRG & API 598 -DOP/W APPVD.DRG & API 598 APPVD.DRG & API 598 W APPVD.DRG & API 598 INSPECTION REPORT P
FINAL INSPECTION R RW
VISUAL
DIMENSIONS
HYD. BODY TEST
100%
RW
ASPER API 598 ( REF.ANNEXURE-1 ) 100% APPVD.DRG & API 598 -DOAPPVD.DRG & API 598 -DO-DO-DOAPI 598 API 598 API 598 API 598 APPVD.DRG & API 598 APPVD.DRG & API 598 P/W
HIGH PRESSURE CLOSER ( SEAT) TEST 100%
RW
LOW PRESSURE CLOSER (SEAT) TEST 100% 100% 100%
BACKSEAT TEST
P/W P/W P/W
W W W
R RW RW
PERFORMANCE TEST
HIGH PRESSURE PNEUMATIC SHELL TEST 10% WITNESS & 100% REVIEW 100% SPEC SPEC 60-80 ROUGH
VISUAL
PAINTING
INSPECTION REPORT
PRIMER & FINISH COAT (EACH TWO COAT) 100% SPEC
SPEC 60-80 EACH COAT & TOTAL WITHIN 300
PAINT.INSP. REPORT
REVIEW
100%
P P
R R
R R
AS PER AS PER Final dossier - IRN, SPEC./APPVD.DRG. SPEC./APPVD.DRG. 3.2 Certificate, Insp & 6 FINAL DOCUMENTS test report, Drawing AS PER SPEC./MSS AS PER SPEC./MSS MARKING/TAG DETAILS 100% etc SP25 SP 25 LEGEND: W - WITNESS, R - REVIEW, TPI - THIRD PARTY INSPECTION, RW - RANDOM WITNESS NOTES : 1. ALL INSTRUMENTS & EQUIPMENT SHALL HAVE VALID CALIBRATION CERTIFICATE TO BE REVIEWED BY TPI. 2. MATERIAL TEST CERTIFICATE OF CASTING AND FASTENERS SHALL BE IN 3.2 AS PER EN-10204. 3. TPIA TO ISSUE 3.2 CERTIFICATE AS PER EN 10204 SPEC.
88 of 245
GENERAL SPECIFICATION Process Fluid Design Temperature Design Standard Size, mm (inch) Type End Connection Type Flange Face Finish FLG RF 125AARH Standard Special Requirement VALVE DESIGN CONDITIONS Corrosion Allowance Installation Opening/Closing time 0 mm Aboveground * VALVE OPERATION Actuation Requirement Type of Actuator Not Applicable Not Applicable VALVE MATERIAL SPECIFICATION PART DISCRIPTION Body Wedge Disc Hinge Pin Gasket Stud Bolts Nuts SPECIFIED ASTM A216 Gr.WCB /A234GrWPB ASTM A216 Gr.WCB ASTM A216 Gr.WCB ASTM A 182 F6 Grafoil A193 B7 A194 Gr.2H MATERIAL OFFERED * * * * * * * Design Factor Stem Ext Length, mm 0.5 N.A. NG/ R-LNG ( 0 to 65 deg C) API 6D ANSI Rating Design Pressure Piping Class 2" & above Swing check ASME B16.5, B16.47 150# 19 barg 1A1
TESTING REQUIREMENT
Hydrostatic Test Pressure Air Test Pressure High Pressure Closure Test Low Pressure Closure Test Leak Test Body: 29 barg Seat: 21 barg 7 barg API 598 API 598 API 598
Document No. DATA SHEET FOR CHECK VALVES 11-0330G01-01-08-03-005 SHEET 1 of 2
Rev. 0
89 of 245
Fire Safe Test Manufacturer's Painting Specification Number
As per API 6FA *
PAINTING Surface Preparation Primer Finish Notes
A/G SA 2.5 30-40 micrometer 30-40 micrometer
U/G SA 2.5 30-40 micrometer 2 - layers polyurethane - 1000 microns
1. This Data Sheet Shall be read in conjunction with the Technical Notes, M.T.O.(if any), PMS which are enclosed along with this requisition. 2. Unless otherwise stated, all tests will be witnessed by the purchaser/ control authority
* To be filled by Vendor ** Refer MTO Legend: B.W - Butt welded, FLG - Flange, A/G- Above Ground, U/G - Underground
DATA SHEET FOR CHECK VALVES
Document No. 11- 0330G01-01-08-03-005 SHEET 2 of 2
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GENERAL SPECIFICATION Process Fluid Design Temperature Design Standard Size, mm (inch) Type End Connection Type Flange Face Finish FLG RF 125AARH Standard Special Requirement VALVE DESIGN CONDITIONS Corrosion Allowance Installation Opening/Closing time 0 Aboveground * VALVE OPERATION Actuation Requirement Type of Actuator Not Applicable Not Applicable VALVE MATERIAL SPECIFICATION PART DISCRIPTION Body Wedge Disc Hinge Pin Gasket Stud Bolts Nuts SPECIFIED ASTM A216 Gr.WCB / A234GrWPB ASTM A216 Gr.WCB ASTM A216 Gr.WCB ASTM A 182 F6 Grafoil A193 B7 A194 Gr.2H MATERIAL OFFERED * * * * * * * Design Factor Stem Ext Length, mm 0.5 N.A. NG/ R-LNG ( 0 to 65 deg C) API 6D ANSI Rating Design Pressure Piping Class 2" & above Swing check ASME B16.5, B16.47 300# 49 barg 3A1
TESTING REQUIREMENT
Hydrostatic Test Pressure Air Test Pressure High Pressure Closure Test Low Pressure Closure Test Leak Test Body: 74 barg Seat: 54 barg 7 barg API 598 API 598 API 598
Document No. DATA SHEET FOR CHECK VALVES 11-0330G01-01-08-03-005 SHEET 1 of 2
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As per API 6FA *
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GENERAL SPECIFICATION Process Fluid Design Temperature Design Standard Size, mm (inch) Type End Connection Type Flange Face Finish BW / FLG NA / RF 125AARH Standard Special Requirement NG/ R-LNG ( 0 to 65 deg C) API 6D ANSI Rating Design Pressure Piping Class 2" & above Swing check ASME B16.5, B16.47 600# 92 Kg/cm2 g 6A1
VALVE DESIGN CONDITIONS Corrosion Allowance Installation Opening/Closing time 0 Aboveground * VALVE OPERATION Actuation Requirement Type of Actuator Not Applicable Not Applicable VALVE MATERIAL SPECIFICATION PART DISCRIPTION Body Wedge Disc Hinge Pin Gasket Stud Bolts Nuts SPECIFIED ASTM A216 Gr.WCB /A234GrWPB ASTM A216 Gr.WCB ASTM A216 Gr.WCB ASTM A 182 F6 Grafoil A193 B7 A194 Gr.2H MATERIAL OFFERED * * * * * * * Design Factor Stem Ext Length, mm 0.5 N.A.
TESTING REQUIREMENT
Hydrostatic Test Pressure Air Test Pressure High Pressure Closure Test Low Pressure Closure Test Leak Test Body:147 Kg/cm2 g Seat: 107.8 Kg/cm2 g 7 barg API 598 API 598 API 598
Document No. DATA SHEET FOR CHECK VALVES 11- 0330G01-01-08-03-005 SHEET 1 of 2
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As per API 6FA *
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QAP NO: 11-0330G01-01-08-10-005 REV NO: 0 ITEM DESCRIPTION/ QUANTITY: CHECK VALVE JOB NO.: 110330G01
PAGE NO: 1 of 3
CLIENT: GAIL (India) LIMITED CONSULTANT: WGI VENDOR:

QUANTAM OF CHECK REFERENCE DOCUMENT SUBVENDOR/ VENDOR TPI ACCEPTANCE NORMS FORMAT OF RECORD INSPECTION WGI
SR. NO.
TYPES OF CHECK
1 PER HEAT ASTM A 216 Gr. WCB 3.2 Certificate P/R R
RAW MATERIAL R
CHEM. TEST
PHY. TEST
PER HEAT
ASTM A 216 Gr. WCB EN 10204/3.1B ASTM A 216 Gr. ASTM A 216 Gr. WCB WCB EN 10204/3.1B 3.2 Certificate P/W W MSS-SP-75 INTERNAL Q.C P/W R
1. BODY & BONET ( REFER NOTE-1) 100% 100% ASTM A 16.34 ASTM A 16.34 INSPECTION REPORT/RT FILMS INSPECTION REPORT P/W
VISUAL
RADIOGRAPHY
MPT PER HEAT PER HEAT 10% WITNESS & 100% REVIEW ASTM A 216 Gr. WCB ASTM A 216 Gr. WCB
100%
ASTM A 16.34
ASTM A 16.34
P/W P/W P/W P/W
W R W W
R R W R
CHEM. TEST
ASTM A 216 Gr. SUPPLIER T.C. WCB ASTM A 216 Gr. SUPPLIER T.C. WCB
2. DISC & SEAT RING
PHY. TEST
VISUAL
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PROJECT:PIPELINE FROM HANUMAN JUNCTION TO VCL QAP NO: 11-0330G01-01-08-10-005 REV NO: 0 CLIENT: GAIL (India) LIMITED ITEM DESCRIPTION/ QUANTITY: CHECK VALVE CONSULTANT: WGI JOB NO.: 110330G01 PAGE NO: 2 of 3 VENDOR:
INSPECTION QUANTAM OF CHECK REFERENCE DOCUMENT SUBVENDOR /VENDOR TPI ACCEPTANCE NORMS FORMAT OF RECORD WGI
SR. NO.
TYPES OF CHECK
INPROCESS INP 100% INSPECTION REPORT P/W INSPECTION REPORT P/W W R
1. BODY & BONET
DIMENSIONS
2. DISC & SEAT RING
DIMENSIONS
100%
-DO-
-DO-
-DO-
P/W
3. SPINDLE
DIMENSIONS
100%
-DO-
-DO-
-DO-
P/W
4. HARD FACING
HARDNESS & D.P.
100%
ASTM B 16.34
ASTM B 16.34 350 to 450 BHN
INSPECTION REPORT
P/W
RW
BROUGHTOUT ITEM PER LOT PER LOT 10% A 193 Gr.B7 & A A 193 Gr.B7 & A 194 GR 2H 194 GR 2H A 193 Gr.B7 & A A 193 Gr.B7 & A 194 GR 2H 194 GR 2H P INSPECTION REPORT 3.2 Certificate P R R P R R R R
CHEMICAL
1. FASTNERS
PHYSICAL
DIMENSIONS
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QAP NO:11-0330G01-01-08-10-005 REV NO: 0 ITEM DESCRIPTION/ QUANTITY: CHECK VALVE JOB NO.: 110330G01
PAGE NO: 3 of 3
CLIENT: GAIL (India) LIMITED
CONSULTANT: WGI VENDOR:

INSPECTION SUBVENDOR/ VENDOR TPI WGI
SR. QUANTAM OF CHECK REFERENCE DOCUMENT ACCEPTANCE NORMS FORMAT OF RECORD
TYPES OF CHECK
NO.
4 100% 100% APPVD.DRG & API 598 P/W W APPVD.DRG & API 598 -DOP/W APPVD.DRG & API 598 -DOP/W APPVD.DRG & API 598 APPVD.DRG & API 598 W APPVD.DRG & API 598 INSPECTION REPORT P W R
FINAL INSPECTION
VISUAL
DIMENSIONS
RW
HYD. BODY TEST
100%
RW
ASPER API 598 ( REF.ANNEXURE-1 ) 100% APPVD.DRG & API 598 -DOAPPVD.DRG & API 598 -DO-DO-DOAPI 598 API 598 API 598 API 598 APPVD.DRG & API 598 APPVD.DRG & API 598 P/W
HIGH PRESSURE CLOSER ( SEAT) TEST 100%
RW
LOW PRESSURE CLOSER (SEAT) TEST 100% 100% 100%
BACKSEAT TEST
P/W P/W P/W
W W W
R RW RW
PERFORMANCE TEST
HIGH PRESSURE PNEUMATIC SHELL TEST 10% WITNESS & 100% REVIEW 100% SPEC SPEC 60-80 ROUGH
VISUAL
PAINTING
INSPECTION REPORT
PRIMER & FINISH COAT (EACH TWO COAT) 100% SPEC
SPEC 60-80 EACH COAT & TOTAL WITHIN 300
PAINT.INSP. REPORT
REVIEW
100%
6 100%
FINAL DOCUMENTS
MARKING/TAG DETAILS
AS PER AS PER Final dossier - IRN, SPEC./APPVD.DRG. SPEC./APPVD.DRG. 3.2 Certificate, Insp & test report, Drawing AS PER SPEC./MSS AS PER SPEC./MSS etc SP25 SP 25
LEGEND: W - WITNESS, R - REVIEW, TPI - THIRD PARTY INSPECTION, RW - RANDOM WITNESS NOTES : 1. ALL INSTRUMENTS & EQUIPMENT SHALL HAVE VALID CALIBRATION CERTIFICATE TO BE REVIEWED BY TPI. 2. TPIA TO ISSUE 3.2 CERTIFICATE AS PER EN 10204 SPEC.
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CLIENT JOB NO.
STANDARD SPECIFICATION FOR ASSORTED PIPES

TOTAL SHEETS
8 011
DOCUMENT NO
11
0330G01
01
08
02
0 A REV
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TABLE OF CONTENT
1.0 2.0 3.0 4.0
GENERAL .............................................................................................................................. 3 IBR PIPES.............................................................................................................................. 4 HYDROSTATIC TEST............................................................................................................ 5 MARKING AND DISPATCH................................................................................................... 5
SPECIFICATION FOR ASSORTED PIPES
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1.0 1.1
GENERAL All pipes and their dimensions, tolerances, chemical composition, physical properties, heat treatment, hydro test and other testing and marking requirements shall conform to the latest codes and standards specified in the Material Requisition (MR).Deviation(s), if any, shall be clearly highlighted in the offer. Testing Test reports shall be supplied for all mandatory tests as per the applicable Material specifications. Test reports shall also be furnished for any supplementary tests as specified in the MR & Clauses 1.10 & 1.11. Material test certificates (physical property, chemical Composition & treatment report) shall also be furnished for the pipes supplied. Manufacturing Processes Steel made by Acid Bessemer Process shall not be acceptable. All longitudinally welded pipes other than IS:3589 should employ automatic welding. Pipe shall be supplied in single or double random length of 4 to 7 and 7 to14 meters, respectively Seamless and E.R.W. pipes shall not have any circumferential seam joint in a random length. However, in case of E.FS.W. pipe, in one random length one welded circumferential seam same quality as longitudinal weld is permitted. This weld shall be at least 2.5 m from either end.
1.2 1.2.1
1.2.2
1.3 1.3.1 1.3.2 1.4
1.5 a) The longitudinal seams of the two portions shall be staggered by 90. Single random length in such cases shall be 5 to 7m. b) Unless otherwise mentioned in the respective material code, E.FS.W. pipes < 36 shall not have more than one longitudinal seam joint and E.FS.W. Pipes >36 shall not have more than two longitudinal seam joints. 1.6 Pipe with screwed ends shall have NPT external taper pipe threads conforming to ASME/ ANSI B1.20.1upto 1.5 NB & IS:554 for 2 to 6 NB. Pipe with beveled ends shall be in accordance with ASME B16.25. Weld contours shall be as follows Material Carbon Steel (Except Low Temp. Carbon Steel) > 22mm Alloy Steel Stainless Steel & Low Temp. Carbon Steel >10 mm & Upto 25 mm >25mm Wall Thickness Weld Contour Upto 22mm Figure 2 Type A Figure 3 Type A Upto 10 mm Figure 5 Type A Figure 6 Type A Figure 4
1.7
1.8 1.9 1.10
Galvanized pipes shall be coated with zinc by hot dip process conforming to IS: 4736/ ASTM A 153. All austenitic stainless steel pipes shall be supplied in solution annealed condition. I.G.C. Test for Stainless Steels
1.10.1 For all austenitic stainless steel pipes, intergranular corrosion test shall have to be conducted as per following: ASTM A262 practice B with acceptance criteria of 60 mils/ year (max.)
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OR ASTM 262 practice E with acceptance criteria of No cracks as observed from 20X magnification & Microscopic structure to be observed from 250X magnification. 1.10.2 When specifically asked for in MR for high temperature application of some grades of austenitic stainless steel (eg .SS 309, 310, 316, 316H etc.), ASTM A262 practice C with acceptance criteria of 15 mils/ year (max.) shall have to be conducted. 1.10.3 For the IGC test as described in 1.10.1 & 1.10.2, two sets of samples shall be drawn from each solution annealing lot; one set corresponding to highest carbon content and the other corresponding to the highest pipe thickness. When testing in is conducted as per Practice E, photograph of microscopic structure shall be submitted for record. 1.11 All welded pipes indicated as CRYO & LT in MR shall be impact tested per requirement and acceptance criteria of ASME B31.3. The impact test temperature shall be 196 C & -45 C for stainless steel and carbon steel, respectively, unless specifically mentioned otherwise in MR. Pipes under NACE category shall meet the requirements given in MR-01-75. Specified heat treatment for carbon steel & alloy steel and solution annealing for stainless steel pipes shall be carried out after weld repairs. Number of weld repairs at the same spot shall be restricted to maximum two by approved repair procedure. For black or galvanised pipes to IS: 1239, the minimum percentage of elongation shall be 20%. IBR PIPES IBR Documentation Pipes under purview of IBR shall be accompanied with IBR certificate original in Form III A, duly approved and counter signed by IBR authority local authority empowered by the Central Boiler Board of India. Photocopy of the original certificate duly attested by the local boiler inspector where the supplier is located is the minimum requirement for acceptance. For materials 1 1/4 Cr- 1/2 Mo (ASTM A335 Gr. P11 A691 Gr. 1 1/4 Cr) & 2 1/4 Cr-iMo (ASTM A335r.P22/ A691 Gr. 2 1/4 Cr.), from Ill-A approved by IBR shall include the tabulation of E , S & Sr values for the entire temperature range given below. Et, S & Sr values shall be such that throughout the temperature range. E t / 1.5 Sa Sr/1.5 Sa Sc Sa where, Sa Et Sc : Allowable stress at the working metal temperature. : Yield point (0.2% proof stress at the working metal temperature. : The average stress to produce elongation of 1% (creep) in 1, 00,000 hrs at the working metal temperature. : The average stress to produce rupture in 1,00,000 hrs. at the working metal temperature and in no case more than 1.33 times the lowest stress to produce rupture at this temperature.
1.12 1.13
1.14 2.0 2.1 2.1.1
2.1.2
Sr
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SA (psi) Material A335 Gr. P11 A 691 Gr. 1 Cr A335 Gr. P2/ A691 Gr. 2 1/4 Cr 500 17200 18900 17900 600 16700 18300 17900
Temperature (F) 650 16200 18000 17900 700 15600 17600 17900 750 800 850 900 950 9300 9900 1000 6300 6300 7800 1050 4200 4200 1100 2800 2800
15200 15000 14500 12800 17300 16800 16300 15000
17900 17800 14500 12800 10800
5100
3200
Note : Sa values given above are as per ASME B31.3-1999. Values shall be as per the latest edition prevailing. 2.2 For carbon steel pipes under IBR, the chemical composition shall conform to the following: Carbon (max.): 0.25% Others (S, P, Mn): As prescribed in IBR regulation. The chemical composition as indicated in this clause is not applicable for pipes other than IBR services. 3.0 HYDROSTATIC TEST Refer Annexure I. 4.0 4.1 MARKING AND DESPATCH All pipes shall be marked in accordance with the applicable codes, standards and specifications. In addition, the purchase order number, the item code & special conditions like IBR, CRYO, NACE, etc., shall also be marked. Pipes under IBR, CRYO, & NACE shall be painted in red stripes, light purple brown stripes & canary yellow stripes, respectively, longitudinally throughout the length for easy identification. Paint or ink for marking shall not contain any harmful metal or metallic salts such as zinc, lead or copper which cause corrosive attack on heating. Pipes shall be dry, clean and free from from moisture, dirt and loose foreign materials of any kind. Pipes shall be protected from rust, corrosion and mechanical damage during transportation, shipment and storage. Rust preventive used on machined surfaces to be welded shall be easily removable with petroleum solvent and the same shall not be harmful to welding. Both ends of the pipe shall be protected with the following material: Plain end : Bevel end : Threaded end : 4.8 4.9 Plastic cap Wood, Metal or Plastic cover Metal or Plastic threaded cap
4.2
4.3
4.4 4.5
4.6
4.7
End protectors to be used on bevelled ends shall be securely and tightly attached with belt or wire. Steel end protectors to be used on galvanised pipes shall be galvanized.
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ANNEXURE I 3.0 3.1 3.2 3.2.1 HYDROSTATIC TEST All pipes shall be hydrostatically tested. The mill test pressure shall be as follows: Seamless, E.R.W. & Spiral Welded a) Carbon Steel Material Standard ASTM A 106 Gr. B API 5L Gr. B, Seamless API 5L, E.R.W. API 5L, Spiral ASTM A333 Gr.3 & 6, Seamless ASTM A 333 Gr. 3 & 6, E.R.W. b) Seamless Alloy Steel Material Standard ASTM A335 GR.P1, P12, P11, P22, P5 P9 ASTM A268 TP 405, TP41O Test Pressure Standard ASTM A 530 ASTM A 530 Test Pressure Standard ASTM A 530 API 5L API 5L API 5L ASTM A 530 ASTM A 530
c)
Seamless Stainless Steel Material Standard ASTM A312 GR.TP304,304L,304H, ASTM A 530 316,316L, 316H, 321,347 Test Pressure Standard
d)
Seamless Nickel Alloy Material Standard ASTM B161 UNS No.2200 ASTM B165 UNS No.4400 ASTM B167 UNS No.6600 ASTM B407 UNS No. 8800 Test Pressure Standard ASTM B161 ASTM B165 ASTM B167 ASTM B407
e)
Welded Nickel Alloy Material Standard ASTM B725 UNS No.2200,4400 ASTM B517 UNS No.6600 ASTM B514 UNS No.8800 Test Pressure Standard ASTM B725 ASTM B517 ASTM B514
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3.2.2
Electric Fusion Welded
a)
Carbon Steel & Alloy Steel E.FS.W. (16 & above )
Material Standard API 5L Gr.B ASTM A 671 Gr. CC65, 70 (Cl.32) ASTM A 672 Gr.C60,65,70 (Cl.12,22) ASTM A 671 Gr.CF60,65,66,70 (Cl.32) ASTM A 691 Gr. Cr, 1Cr, 1 1/4Cr ,2 1/4Cr,5Cr,9Cr (Cl.42)
Test Pressure Standard P=2ST / D S=90% OF SMYS (except for API 5L Gr.B) S=85% of SMYS for API 5L Gr.B T=Nominal Wall Thickeness D=O.D. of pipe
b)
Stainless Steel E.FS.W. (2 to 6) The hydrostatic test pressure in kg /cm for the following materials shall be as given below: Material Gr.1: ASTM A312 TP304/ 304H/ 316/ 316H/ 321/347 welded Material Gr.2: ASTM A312 TP 304L/ 316L welded
Pipe Schedule: S l0 Size Material Gr.1 100 80 80 65 Material Gr.2 80 60 50 35
Pipe Schedule: S 40 Material Gr.1. 155 155 155 90 Material Gr.2 130 130 130 75
Pipe Schedule: S 80 Material Gr.1 230 230 230 155 Material Gr.2 190 190 190 130
2 3 4 6
c)
Stainless Steel E.FS.W. ( 8 and above) Material Standard ASTM A358 TP 304L,304,304H,316L,316,316H,321,347 (Classes 1, 3 & 4) Test Pressure standard P=2ST/D S=85% of SMSYS T=Nominal wall thickness D=O.D. of pipe P=2ST/D S=72% of SMYS T=Nominal Wall thickness D=O.D. of pipe Document No. 11-0330G01-01-08-02-011 SHEET 7 of 8
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ASTM A358 TP 304L, 304, 304H, 316L, 316 316H, 321, 347 (Classes 2 & 5)
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3.2.3
Carbon Steel Pipes to IS Standards
Material Standard IS : 1239 IS : 3589
Test Pressure Standard IS : 1239 IS : 3589
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CLIENT JOB NO.
11 016
TECHNICAL NOTES FOR VALVES

TOTAL SHEETS
DOCUMENT NO
11
0330G01
01
08
02
0 A REV
28.06.11 24.06.11 DATE

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TABLE OF CONTENT 1. GENERAL 2. DOCUMENTATION 3. DESIGN AND CONSTRUCTION 4. OPERATION 5. INSPECTION & TESTING 6. RADIOGRAPHY OF CAST VALVES 7. IBR CERTIFICATION 8. MARKING 9. DESPATCH 3 3 3 7 8 9 9 10 10
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TECHNICAL NOTES FOR VALVES 1.0 1.1 GENERAL Vendor shall supply valves in accordance with the valve specification sheets along with auxiliaries, if any, such as gear operator, bypasses, drains etc. wherever specified in the specification sheets, subject notes and other enclosures to the material requisition (MR). Vendor shall quote in strict accordance with the valve data / specification sheets, subject technical notes and all other enclosures to the MR. Deviations to the specification / data sheets, subject technical notes and other enclosures of the MR, if any, shall be asked as explained in clause 2.0. All codes and standards for manufacture, testing, inspection etc. shall be of latest editions. DOCUMENTATION Vendor shall submit the following with the offer: Manufacturers complete descriptive and illustrative catalogue I literature. Detailed dimensioned cross section drawing with parts/material lists, weight etc. for the ball valves, plug valves, butterfly valves, diaphragm valves and valves to manufacturers standard. Drawings for valves with accessories like gear operator, hydraulic / pneumatic operator, motor, extension bonnet, extended stems with stands, bypass etc. giving major salient dimensions. One copy of the valve specification sheets signed as Accepted by the manufacturer with all deviations marked clearly. If the valve is regretted or has no deviation, the manufacturer shall write clearly on valve specification sheets as Regret or No Deviation. For subject notes, if there is any deviation, the same shall be listed clausewise. Even clauses which are acceptable shall be categorically confirmed as Accepted. On failure to submit documents as specified in clauses 2.1.1 to 2.1 .6 above, the offer is likely to he rejected. The following documents shall be submitted after placement of the order Vendor shall submit for approval drawings mentioned in clauses 2.1.2 & 2.1.3 before start of manufacture. No other drawing shall be submitted for approval. Test report shall he supplied for all mandatory tests as per the applicable code. Test reports shall also be furnished for any supplementary tests as specified in clauses 3.13, 3.14 & 3.15. Material test certificates (physical properties, chemical composition & heat - treatment report) of the pressure containing parts shall he furnished for the valves supplied. Material test certificates for the other parts shall also he furnished for verification during inspection. DESIGN AND CONSTRUCTION Valve shall be designed, manufactured, tested, inspected and marked as per the manufacturing standards; design codes and standards (latest editions) indicated in the respective valve specification sheets.Any conflict between the requisition, enclosures, specification sheets and referred standard codes shall be brought to the notice of the purchaser for clarifications. But generally, specification sheets and enclosures of the requisition including subject notes shall govern. After issue of the Purchase Requisition (PR). no deviation to specification/standards shall be permitted through vendor drawing approval. Approval of drawings shall be valid only for design / constructional features. TECHNICAL NOTES FOR VALVES Document No. 11-0330G01-01-08-02-016 SHEET 3 of 11
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1.2
1 .3 2.0 2.1 2.1.1 2.1.2
2.1.3
2.1 .4
2.1.5
2.1.6
2.1.7
2.2 2.2.1
2.2.2
2.2.3
3.0 3.1
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3.2
All flanged valves shall have flanges integral (except forged valves) with the valve body. Flange face finish shall be normally specified in the valve specification sheet as serrated finish, 125 AARH etc. The interpretation for range of face finish shall be as follows: Stock finish Serrated finish / smooth Finish / 125 AARH : serrations with 125 to 250 u m in AARH 32 to 63 u in AARH : 1000 u in AARH max
Extra Smooth Finish / 63 AARH : 3.3
All weld end valves with bevel end as per ASME B16.25. the contour of bevel shall be as follows: Material Carbon Steel (Except low Temp. Carbon Steel) Wall Thickness Upto 22 mm > 22 mm Upto 10 mm Alloy Steel. Stainless Steel & Low temp. Carbon Steel > 10mm & Upto 25 mm > 25 mm Weld Contour Figure 2 Type A Figure 3 Type A Figure 4
Figure 5 Type A Figure 6 Type A
3.4
For flanged valves with ring joint flanges, the hardness shall be as follows Flange Material Carbon Steed 1% Cr to 5 Cr Type 304, 316, 321, 347 Type 304L, 316L. Mm. Hardness of Groove (BHN) 140 150 160 140
3.5 3.5.1
Following requirements for check valves shall be met over and above the valve spec sheet requirements: Unless specified otherwise in the data sheet all check valves 3 & above (except in 900#, 1500# & 2500# rating) shall have a drain boss at location G (Refer Fig. No. 1 of ASME B16.34). A tapped drain hole with plug shall be provided as per ASME B16.34. Threads shall be as per ASME B1.20.l (Taper) NPT. Wherever check valve disc assembly is supported from the cover of the check valves the following shall be ascertained. i) Positive location / positioning of cover must he provided to ensure correct alignment of the valve disc. ii) Hinge pin design must permit accurate alignment of the disc and valve seat.
3.5.2
3.5.3
For heavy check valves, provisions shall be available for lifting by way of lugs, eye bolts and other such standard devices. TECHNICAL NOTES FOR VALVES Document No. 11-0330G01-01-08-02-016 SHEET 4 of 11
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3.6
If an overlay weld-deposit is used for the body seat ring seating surface, the corrosion resistance of the seat ring base material shall be at least equal to the corrosion resistance of the material of the shell. Following valve bypass requirements shall be met By-pass requirement for (Gate valves is indicated in the respective data sheets. As a rule, the following shall be followed ANSI 150 Class ANSI 300 Class ANSI 600 Class ANSI 900 Class ANSI 1500 Class ANSI 2500 Class On sizes 26 and above On sizes 16 and above On sizes 6 and above On sizes 4 and above On sizes 4 and above On sizes 3 and above
3.7 3.7. 1
3.7.2
The by-pass piping arrangement shall be such that clearance between main valve body and by-pass assembly shall be the minimum possible for layout reasons. By-pass valve shall be a globe valve. The sizes shall be as under On main valve 4 On main valve > 4 but 10 On main valve > 10 : : : 1/2 or more 3/4 or more 1 or more
3.7.3
3.7.4
Vendor shall supply the by-pass valve duly tested and fitted to the main valve. Valves with by-pass shall have the direction of flow marked on the main valve. Bypass attachment to the main valve body shall not be screwed. All fillet welds for bypass installation shall be 100% examined by DP/MP test. Valve body / bonnet shall be forged / cast as specified. Forgings are acceptable in place of casting but not vice-versa. Material of construction of yoke shall be minimum equivalent to body / bonnet material. Stem shall be forged or machined from forged / rolled bar. No casting is permitted. However, integral stem of cast stainless steel ball valve is acceptable. Stelliting / hardfacing by deposition shall be minimum 1.6 mm. Renewable seat rings shall be seal welded. Valves under NACE category shall meet the requirements specified in MR-0l-75 unless otherwise specified. For all austenitic stainless steel valves Inter Granular Corrosion (IGC) test shall be conducted as per the following
3.8
3.9 3.10
3.11
3.12
3.13
3.14.1 ASTM A262 Practice B with acceptance criteria of 60 mils/year (max for all materials - forged, rolled, wrought and casting. Or ASTM A262 Practice E with acceptance criteria of No cracks as observed from 20X magnification for all materials other than castings. Microscopic structure to be observed from 250X magnification in addition. 3.14.2 When specifically asked for in MR for high temperature application of some grades of austenitic stainless steel (e.g. SS309, 310, 316, 316H etc.) ASTM A262 Practice 7 C with acceptance criteria of 15 mils/year (max.) shall he conducted.
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3.14.3 For the IGC test as described in Clauses 3.14.1 & 3.14.2, two sets of samples shall be drawn from each solution annealing lot. One set shall correspond to the highest Carbon content and the other to the highest pressure rating. When testing is conducted as per practice E, photograph of the microscopic structure shall be submitted for record. 3.15 All types of 321 or 347 stainless steel valves shall be in a stabilized heat treated condition. Stabilizing heat treatment shall be carried out subsequent to the normal solution annealing. Soaking temperature and holding time for stabilizing heat treatment shall be 900C and 4 hours respectively. Spiral wound bonnet gaskets are to he provided with inner/outer ring except when encapsulated gaskets type body-bonnet joints are employed. Outer ring may be avoided in case of non-circular spiral wound gasket used in 150# valve provided the outermost layer of spiral touches the bolts ascertaining the centering. Ball / Plug / Butterfly Valves
3.16
3.17
3.17.1 As a prequalification, fire safe test as per API 607 / API 6FA / BS 6755 Part 117 shall he carried out on soft seated ball, plug & butterfly valves and also on lubricated plug valves. The test shall be witnessed and certified by a third party inspection agency like Lloyds, B.V, DNV.The vendor has to submit test certificate for the particular design of the valve offered. 3 17.2 Each valve shall he supplied with a lever / wrench except the gear operated / motor operated valves. 3.17.3 Soft-seated ball, plug & butterfly valves shall he supplied with antistatic devices. 3. 17.4 Soft-seated BW / SW end ball valves shall have a 100 mm long seamless pipe nipple welded to each end of the valve. Nipples are to be welded prior to assembling Teflon seats / seals. Specifications of the nipples shall be as indicated in the MR. 3.17.5 The face-to-face dimensions of all ball valves shall be same as those of gate valves of the corresponding ANSI class (except 10 onwards in Class 150 where the face to-face dimensions shall be as per API 6D long pattern). 3.17.6 The ball of ball valve shall not protrude outside the end flanges of valve. 3.17.7 Ball valves shall be of floating ball/trunnion mounted type as per following: 8 & below 150# 10 & above 4 & below 300# 6 & above 1.5 & below 600# & above 2 & above Trunnion mounted Floating ball Trunnion mounted Trunnion mounted Floating ball Floating ball
3.17.8 Unless otherwise specified in the data sheets, bore of all reduced bore ball valves shall he limited to one size lower than the nominal bore.
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3.18
The MOVs are to be installed in an open area and the actuators shall be suitable for all weather conditions. The testing of complete assemblies of MOVs along with the actuators shall be done by the supplier at his works. Torque details for MOVs shall be furnished by the bidder/supplier. OPERATION Generally the valves are hand wheel or lever operated. Gear operation shall be provided as under Size Requiring GearOperator 14 and larger 14 and larger 12 and larger 6 and larger 3 and larger 3 and larger
4.0 4.1
Valve Type
Class
150 Class 300 Class 600 Class Gate Valve & Diaphragm Valve 900 Class 1500 Class 2500 Class 300 & 600 Class 900 Class 1500 Class 2500 Class 150 Class 300 Class Ball Valve/Plug Valve (Other than pressure balance plug valves) 600 Class 900 Class 1500 Class Butterfly Valve 150, 300 Class
6 and larger
Globe Valve
6 and larger 3 and larger 3 and larger 6 and larger 6 and larger 4 and larger 3 and larger 3 and larger 6 and larger
For sizes lower than these ranges, hand wheel / lever / wrench shall he provided. For pressure balance plug valves manufacturers recommendation shall be acceptable provided the requirements specified in clause 4.6 are met.
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4.2
Gear operator shall be as under with position indicators for open /close positions and with limit stops. (Limit stops are not applicable for gate and globe valves). For Gate / Globe I Diaphragm Valves For Ball/ Plug I Butterfly Valves Totally enclosed bevel gear in grease case with grease nipples / plugs. Totally enclosed helical worm or combination of helical worm and spur gear in grease case with grease nipples I plugs.
4.3
Where gear operator is not called for as per Clause 4, 1 but vendor recommends a gear operator, he shall highlight such case(s). Gear operator shall be so designed as to operate effectively with the differential pressure across the closed valve equal to the cold non-shock pressure rating. Ball, plug and butterfly valves, even with wrench or lever operators shall have Open position indicators with limit stops. Hand wheel diameter shall not exceed 750mm and lever length shall not exceed 500mm on either side. Effort to operate shall not exceed 35 Kg at handwheel periphery. However, failing to meet the above requirements, vendor shall offer gear operated valve and quote as per clause 4.3. INSPECTION AND TESTING Every valve shall he subjected to all the mandatory tests and checks called in the respective codes / data sheet by Wood Group Kenny inspection or any third party as approved by the purchaser. Every valve, its components and auxiliaries must be subjected to all the mandatory tests and checks called for in the respective codes, data sheets etc. by the manufacturer. Though the extent of inspection shall be as under, exact extent with hold points shall he decided by Wood Group Kenny regional inspection and recorded in the form of inspection plan. In case of third party inspection,the inspection plan shall be approved by the purchaser. Forged Valves: 1. 2. 3. 4. 5. Visual and dimensional inspection. Review of material test certificates. Any mandatory or supplementary test. Hydrostatic test on 10% valves selected on random basis. Strip check is required for 1 % of total ordered quantity of valves (min. 1 No.) against each sheet no.
4.4
4.5
4.6
5.0 5.1
5.2
5.3
Cast Steel Vales 1. 2. 3. 4. 5. 6. Visual and dimensional inspection. Review of material test certificates. Review of radiographs/radiographic reports or any other NDT tests wherever applicable as per data sheet. Any mandatory or supplementary test. Hydrostatic test 100% for body, 10% other test. Strip check is required for 1% of total ordered quantity of valves (min. 1 No.) against each sheet no. Samples for strip check shall be selected at random and shall generally be in the highest size in the lot.
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5.4
In case of motor operated or actuator operated valves, functional / operational checks as per the requirements of the specifications shall be made on each valve. Positive Material Identification (PMI) shall be performed as per the scope and procedures as defined in the Specification for Positive Material Identification (PMI) at Vendors Works RADIOGRAPHY OF CAST VALVES Valve castings shall undergo radiographic examination as specified below. However, for sizes 24 & below in 150# and 16 & below in 300#, radiography percentage specifically mentioned in individual valve material spec sheet shall govern. Rating 150# All Size Range 24 and below Radiography NIL
5.5
6.0 6.1
Material
26 and above* 100% 16 and below NIL 300# 18 and above 100% 600# & above All sizes 100% *No radiography is required for valves of size > 26 in cooling water service. Radiography specified as random 10% or 20% etc. in the respective valve data sheet implies 10% or 20% etc. of number of valves ordered against each item number with a minimum of one valve against each item. 6.2 Radiography procedure, areas of casting to be radiographed shall be as per ASME B16.34 and acceptance criteria shall be as per ASME B16.34 Annexure-B. However for areas of casting to be radiographed for types of valves not covered in ASME B 16.34, vendor shall enclose details of areas to be radiographed in line with ASME B16.34. For random radiography wherever specified in individual data sheets, the sampling shall he per size of the quantity ordered for each foundry. Radiography wherever specified in the data sheets or as per clause 6.1 shall be done by X-ray/gammaray to get the required sensitivity. IBR CERTIFICATION For valves described IBR, valves shall be in accordance with the latest IBR (Indian Boiler Regulation) including the requirements specified in the specification. For SW / BW end carbon steel valves under IBR, the chemical composition shall conform to the following Carbon (Max) 0.25% others (S. P, Mn): As per IBR regulations The above composition is not valid for non-IBR valves. Valves coming under the purview of IBR (Indian Boiler Regulations) shall each be individually accompanied by IBR certificate original in Form Ill-C duly approved by IBR authority / local authority empowered by the Central Boiler Board of India. Photocopy of original certificate duly attested by the local boiler inspector where the supplier is located is the minimum requirement for acceptance. All IBR valves shall be painted red in body-bonnet / body-cover joint.
6.3
6.4
7.0 7.1
7.2
7.3
7.4
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8.0 8.1
MARKING Valve markings, symbols, abbreviations etc. shall be in accordance with MSS-SP-25 or the standard referred in specification sheet as applicable. Vendors name, valve rating, material designation, nominal size, direction of flow (if any) etc. shall be integral on the body. Each valve shall have a corrosion resistant tag giving size, valve tag / code no., securely attached to the valve body. Paint or ink for marking shall not contain any harmful metal or metal salts such as zinc, lead or copper which cause corrosive attack on heating. Carbon Steel I Alloy Steel valves shall he painted with one coat of inorganic zinc silicate (minimum DFT 65 to 75 microns). DESPATCH Valve shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind. Valves shall be protected from rust, corrosion and any mechanical damage during transportation, shipment and storage. Rust preventive on machined surfaces to be welded shall be easily removable with a petroleum solvent or shall not be harmful to welding. Each end of valve shall be protected with the following materials Flange Face : Wood or Plastic Cover Beveled End : Wood or Plastic Cover SW & SCRD : End Plastic Cap End protectors of wood/plastic to be used on flange faces shall be attached by at least three bolts and shall not be smaller than the outside diameter of the flange. However plastic caps for SW & SCRD, end valves shall be press fit type. End protectors to be used on beveled end shall be securely and tightly attached. For special service valves additional requirement of dispatch shall be prescribed in data sheet.
8.2
8.3
8.4
9.0 9.1 9.2
9.3
9.4
9.5
9.6 9.7
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NOTES 1. The orientation & location of hand wheel of bevel gear operator & the bypass arrangement shall be strictly as per this sketch. 2. The bypass pipe ends shall be socket/butt welded to the body wall of the main valve. 3. The bypass arrangement shall he properly clamped to & supported by the body of the main valve. 4. Basic design of bypass shall he to MSS-SP-45 & ASME B16.34 5. Material of bypass pipe & 90 elbows shall be same or equivalent to the body material. 6. This sketch is applicable for both BGO & NON-BGO Valves. 7. Vendor shall furnish dimensions L1 to L8.
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TECHNICAL NOTES FOR BUTT WELDED, SOCKET WELDED AND SCREWED FITTINGS
CLIENT JOB NO. TOTAL SHEETS
5 017
DOCUMENT NO
11
0330G01
01
08
02
0 A REV
28.06.11 24.06.11 DATE
MH MH PREP
ASD ASD CHK
AD AD APPR
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TECHNICAL NOTES FOR BUTT WELDED, SOCKET WELDED AND SCREWED FITTINGS 1.0 1.1 GENERAL Chemical composition, physical properties, tests, dimensions and tolerances, heat treatment and marking shall conform to the applicable latest codes/standards/specifications as specified in the material requisition (MR). Any deviation shall be highlighted on a separate sheet by the vendor in the quotation itself. Test reports shall be supplied for all mandatory tests as per the material specifications Test reports shall also be furnished for any supplementary tests as specified in the MR, Clauses 1.7.8, 1.9, 1.10 & 1.11. Material test certificates (physical properties, chemical composition & heat treatment report) shall also be furnished for fittings supplied. All fittings shall be seamless in construction unless otherwise specified. If fittings are specified as welded, the same shall conform to Clause 1.7. Seamless fittings can be supplied in place of welded fitting but with maximum negative tolerance of 0.3mm (max.) on wall thickness. Welded fittings shall not be acceptable in place of seamless fittings. Outside diameters and wall thickness (unless otherwise mentioned) of butt welded fittings shall be in accordance with ASME B36.10 and ASME B36.19 as applicable. For reducing butt weld fittings having different wall thicknesses at each end, the greater wall thickness of the fitting shall be employed and inside bore at each end shall be matched with the specified inside diameter. Bevelled ends for all fittings shall conform to ASME B16.25. Contour of bevel shall be as follows: Material Carbon Steel (Except Low Temp. Carbon Steel) Alloy Steel, Stainless Steel & Low Temp. Carbon Steel Wall Thickness Upto 22 mm > 22 mm Upto 10 mm > 10 mm & Upto 25 mm > 25 mm Weld Contour Figure 2 Type A Figure 3 Type A Figure 4 Figure 5 Type A Figure 6 Type A
1.2
1.3
1.4
1.5
1.6
1.7
Welded Fittings:
1.7.1 All welded fittings shall be double welded. Inside weld projection shall not exceed 1.6 mm. Welds shall be ground smooth at least 25 mm from the ends. 1.7.2 For fittings made out of welded pipe, the welded pipe shall be double welded type & shall be manufactured with the addition of filler metal. 1.7.3 Welded tees shall not be of fabricated (stub-in) type. 1.7.4 All welded fittings shall be normalised & 100% radiographed by X-ray on all welds made by fitting manufacturers & also on the parent materials. 1.7.5 Welded pipes employed for manufacture of fittings shall be made by automatic welding only. 1.7.6 All welded carbon steel, alloy steel & stainless steel fittings shall have maximum negative tolerance of 0.3 mm. 1.7.7 Specified heat treatment for carbon steel & alloy steel fittings shall be carried out again after weld repairs.
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1.7.8 Irrespective of the material code requirement, all welded fittings indicated in the MR as Cryo& LT shall meet impact test requirements of ASME B31 .3. The impact test temperature shall be -196C & -45C for stainless steel & carbon steel respectively unless specifically mentioned otherwise in the MR. 1.8 Stainless Steel Fittings:
1.8.1 All stainless steel fittings shall be supplied in solution heat treated condition. 1.8.2 Solution annealing for stainless steel fittings shall be carried out again after weld repairs. 1.8.3 For all stainless steel fittings Inter Granular Corrosion (IGC) test shall have to be conducted as per the following: - ASTM A 262 Practice B with acceptance criteria of 60 mils/year (max.). Or - ASTM A 262 Practice E with acceptance criteria of no cracks as observed from 20X magnification & microscopic structure to be observed from 250X magnification 1.8.4 When specifically asked for in MR for high temperature application of some grades of austenitic stainless steel (eg. SS309, 310,316,316H etc.) ASTM A 262 Practice C with acceptance criteria of 15 mils/year shall have to be conducted. 1.8.5 For the IGC test as described in Clauses 1.8.3 & 1.8.4, two sets of samples shall be drawn from each solution treatment lot, one set corresponding to the highest carbon content and other set to the highest fitting thickness. When testing is conducted as per ASTM A 262 Practice E, photograph of microscopic structure shall he submitted for record. 1.9 1.10 1.11 Fittings under NACE category shall meet the requirements of MR-01-75. Thickness/schedule lower or higher than specified shall not be accepted. The gasket contact surfaces of stub ends shall be flat with face finish as specified below: x Serrated Finish Serrations with 250 to 500 in AARH x Smooth Finish: Serrations with 125 to 250 in AARH 1.12 1.13 1.14 Seamless stub ends shall not have any welds on the body. Galvanised fittings shall be coated with zinc by hot dip process conforming to IS 4736/ ASTM A 153. Threaded ends shall have NPT taper threads in accordance with ASME/ANSI B 1.20.1 upto 1.5 NB & IS 554 from 2 to 6 NB. Unless and otherwise specified in the MR, all socket welded and screwed fittings shall be in accordance with ASME B16. 11 to the extent covered in the specification except for unions which shall be in accordance with MSS-SP-83. Special fittings like weld-o-let, sock-o-let, sweep-o-let etc. which are not covered in ASME, MSS-SP & Wood Group Kenny Standards shall be as per manufacturers std. Contours of these fittings shall meet the requirements of ASME B3 1.3. Manufacturer shall submit drawings / catalogues of these items along with the offer. Length of all long half couplings shall be 100 mm unless otherwise specified. 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 given below:
1.15
1.16
1.17 1.18
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Welded Pipe Employed For Manufacture Of Welded Fittings. ASTM A671 Gr. C65,70 (Cl.32) ASTM A672 Gr. C60,65,70 (C1.12, 22) ASTM A671 Gr. CF60,65,70,66 (CL32) ASTM A691 Gr. 1/2Cr, 1Cr, l Cr, 2 Cr, 5Cr, 9Cr (Cl.42) API5L ASTM A358 TP 304, 304L, 304H,318, 318L, 318H,321,347 (Cl.1, 3, 4) ASTM B725 ASTM B517 ASTM B514 1.19 1.20
Test Criteria P = 2ST/D S = 90% of SMYS. T = Nom. Wall Thickness D = O.D. of Pipe. P = 2ST/D S = 85% of SMYS. T = Nom. Wall Thickness D = O.D. of Pipe. ASTM B725 ASTM B517 ASTM B514
The bevel ends of all butt weld fittings shall undergo 100% MP/DP test. Swage nipples (concentric/eccentric) if specified as pipe materials are acceptable in forging materials (upto 1) and wrought fitting materials (above 11/2) also in the corresponding material grades. Abbreviations for ends of swages and nipples shall be as follows: PBE : Plain Both Ends TBE : Threaded Both Ends IBR REQUIREMENTS IBR Documentation Required:
1.21
2.0 2.1
2.1.1 Fittings under the purview of IBR (Indian Boiler Regulations) shall be accompanied with original IBR certificate in Form Ill-C duly approved and countersigned by IBR authority / local authority empowered by Central Boiler Board of India. Photocopy of the original certificate duly attested by the local boiler inspector where the supplier is located is the minimum requirement for acceptance. 2.1.2 For materials 1Cr - Mo (ASTM A 234Gr.WP11 & ASTM A234 Gr.WP11W) & 2Cr - 1Mo (ASTM A 234 Gr.WP22 & ASTM A234 Gr. WP22W),where fittings are manufactured from pipe, Form Ill-C approved by IBR shall include the tabulation of Et, Sc, & Sr values for the entire temperature range given below. Et, Sc, & Sr values shall be such that throughout the temperature range Et /1.5 SA Sr /1.5 SA SA Sc SA Et Sc Sr : Allowable stress at the working metal temperature. : Yield point (0.2% proof stress at the working metal temperature) : The average stress to produce elongation of 1 % (creep) in 100000 hrs at the working metal temperature. : The average stress to produce rupture in 100000 hrs at the working metal temperature and in no case more than 1.33 times the lowest stress to produce rupture at this temperture.
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SA (psi) Temp(F) Material A 234 Gr.WP11 / A234 Gr.WPI1W A 234 Gr.WP22 / A234 Gr.WP22W 500 600 650 700 750 800 850 900 950 1000 1050 1100
21700
20900
20500
20100
19700
19200
18700
13700
9300
6300
4200
2800
17900
17900
17900
17900
17900
17800
14500
12800
10800
7800
5100
3200
Note : SA values given above are from ASME B31.3-1996. Values shall be as per the latest edition prevailing. 2.2 For carbon steel fittings described IBR chemical composition shall conform to the following: Carbon (max) : 0.25% Others (S, P, Mn) : As prescribed in IBR regulations The above composition is not valid for non-IBR fittings. 3.0 3.1 MARKING AND DISPATCH Each fitting shall be legibly and conspicuously stamped in accordance with the requirements of applicable standards along with special condition like IBR, Cryo, NACE etc. Steel die marking with round bottom punch may be permitted on body of butt weld CS & lower alloy steel fittings, but for SS & higher alloy steel fittings, the same should be marked by electro-etching only. Paint or ink for marking shall not contain any harmful metals or metal salts such as Zinc, Lead or Copper which causes corrosive attack on heating. Fittings shall be dry, clean and free of moisture, dirt and loose foreign materials of any kind. Fittings shall be protected from rust, corrosion and mechanical damage during transportation, shipment and storage. 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. Fittings under IBR, Cryo, NACE shall be painted in red, light purple and canary yellow stripes respectively for easy identification. Width of the stripe shall be 25 mm. Each end of fitting shall be protected with a wood, metal or plastic cover. Each size of fitting shall be supplied in separate packaging marked with the purchase order number, item code number, material specification, size and schedule I thickness / rating.
3.2
3.3
3.4 3.5
3.6
3.7
3.8 3.9
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CLIENT JOB NO.
4 010
TECHNICAL NOTES FOR BOLTS & NUTS

TOTAL SHEETS
DOCUMENT NO
11
0330G01
01
09
02
0 A REV
28.06.11 24.06.11 DATE

122 of 245
MH MH PREP
ASD ASD CHK
AD AD APPR
TABLE OF CONTENT
1.0 2.0
GENERAL ....................................................................................................................................... 3 ACCEPTABLE DEVIATIONS ......................................................................................................... 4
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TECHNICAL NOTES FOR BOLTS AND NUTS 1.0 1.1 GENERAL The process of manufacture, heat treatment, chemical & mechanical requirements and marking for all stud bolts, bolts, jack screws & nuts shall be in accordance with the codes/standards and specifications given in the requisition. The applicable identification symbol in accordance with the material specification shall be stamped on each bolt and nut. Vendor shall strictly comply with MR/PR stipulations and no deviations shall be permitted. Testing 1.2.1 1.2.2 Test reports shall be supplied for all mandatory tests as per the relevant material specifications. Material test certificate shall also be furnished. (Heat Analysis, Product Analysis and Mechanical Requirement) PMI shall be performed as per the scope and procedures defined in the Specification for PMI at Vendors Works. Stress Rupture Test as detailed in ASTM A453 shall be carried out for all ASTM A453 bolting material irrespective of the temperature.
1.2
1.2.3
1.2.4
1.3 1.4
All bolting shall be as per ANSI B 18.2.1 for studs, M/c bolts and jackscrews and ANSI B18.2.2 for nuts. Threads shall be unified (UNC for 1 dia and 8UN for > 1 dia) as per ANSI B.1.1 with class 2A fit for studs, M/c bolts and jackscrews and class 2B fit for nuts. Stud bolts shall be threaded full length with two heavy hexagonal nuts. Length tolerance shall be in accordance with the requirement of ANSI B 16.5. The nuts shall be double chamfered, semi-finished, heavy hexagonal type and shall be made by the hot forged process and stamped as per respective material specification. Heads of jackscrews and m/c bolts shall be heavy hexagonal type. Jackscrew end shall be rounded. Each size of studs & rn/c bolts with nuts and jackscrews shall be supplied in separate containers marked with size and material specifications. CRYO shall be marked additionally in case CRYO is specified in the requisition. All items shall be inspected and approved (stagewise) by Wood Group Kenny. The heat treatment for stud bolts & nuts shall be as per code unless mentioned otherwise. All austenitic stainless steel bolts, nuts, screws shall be supplied in solution annealed condition unless specified otherwise in the material specification. Stud bolts, nuts & jackscrews shall be impact tested wherever specified in the material specification and also where the material specification is indicated as CRYO. For S.S. nuts and bolts minimum impact energy absorption shall be 27 Joules and test temperature shall be - 196C unless mentioned otherwise. For other materials impact energy and test shall be as per respective code. Bolts/nuts of material of construction B7M/ 2HM shall be 100% Hardness tested as per supplementary requirement S3 of ASTM A 193. When specified as galvanized, the studs, M/C bolts and nuts shall be hot dip zinc coated in accordance with requirements of class C of ASTM A 153. As an alternative, electrogalvanizing as per IS 1573, Service Grade Number 2 is also acceptable. Document No. 11-0330G01-01-09-02-010 SHEET 3 of 4
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1.5
1.6
1.7 1.8
1.9 1.10 1.11
1.12
1.13
1.14
Rev 0
1.15
All Stud Bolts of Bolt diameter size 1 and above shall be provided with three nuts irrespective of whatever has been specified elsewhere in the MR. ACCEPTABLE DEVIATIONS Nuts to ASTM A194Gr.7 are acceptable in place of ASTM A194Gr.4.
2.0 2.1
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TECHNICAL NOTES FOR FLANGES, SPECTACLE BLIND AND DRIP RINGS
4 009
DOCUMENT NO
11
0330G01
01
09
03
0 A REV
28.06.11 24.06.11 DATE
MH MH PREP
ASD ASD CHK
AD AD APPR
126 of 245
TECHNICAL NOTES FOR FLANGES, SPECTACLE BLINDS AND DRIP RINGS 1.0 1.1 GENERAL All items, their dimensions, tolerances, chemical composition, physical properties, heat treatment and testing etc. shall conform to the latest codes and standards specified in the requisition. Deviations, if any, shall be clearly highlighted on a separate sheet by the vendor in the quotation itself. Testing
1 .2
1.2.1 Test reports shall he supply for all mandatory tests as per the relevant material specifications. Test reports shall also be furnished for any supplementary tests as specified in the requisition & Clauses 1.11, 1.12 & 1.15. 1.2.2 Material test certificates (physical property, chemical composition & heat treatment report) shall also be furnished for the flanges supplied. 1.3 Ends of weld neck flanges shall be bevelled to suit the schedule / thickness of matching pipe, as specified in the requisition Bevel end details for welding neck flanges shall be as per ASME B16,25. Contour of bevel end shall be as follows Material Carbon Steel (Except Low Temp. Carbon Steel) Alloy steel, stainless steel and low temp carbon steel Wall Thickness Upto 22 mm > 22 mm Upto 10 mm > 10 mm upto 25 mmm > 25 mm 1.5 Weld Contour Figure 2 Type A Figure 3 Type A Figure 4 Figure 5 Type A Figure 6 Type A
1.4
Bore of socket weld flanges & reducing blind flanges shall suit the outside diameter and schedule / thickness of matching pipe. Bore of slip on flanges shall suit the outside diameter of matching pipe. Flange face finish shall he normally specified in the requisition as serrated finish, 125 AARH etc. The interpretation for range of face finish shall be as follows: Stock Finish Serrated Finish/125 AARH 63 AARH : 1000 in AARH max. : Serrations with 125 to 250 in AARH : 32 TO 63 in AARH
1.6 1.7
1.8 1.9
Galvanised flanges shall be coated with zinc by hot dip process conforming to IS 4736 / ASTM A 153. Ends of screwed flanges unless otherwise specified shall have taper threads as per ASME/ANSI B1.20.1 (upto 1.5 NB) & IS 554 (for 2 to 6 NB). For ring joint flanges, blinds and spacers the hardness shall be as follows:
1.10

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Flange Material Carbon Steel 1 %Cr to 5% Cr Type 304, 316, 321, 347 Type 304L, 316L 1.11 1.12
Mm. Hardness of Groove (BHN) 140 150 160 140
For ring joint flanges, blinds and spacers, the hardness shall be recorded in the test report. Flanges, blinds, drip rings under NACE category shall meet the requirements given in MR-01-75 unless otherwise specified. All austenitic stainless steel flanges shall be supplied in solution annealed condition. I.G.C. Test for Stainless Steels:
1.13 1.14
1.14.1 For all austenitic stainless steel flanges, blinds, drip rings & Fig.8 flanges intergranular corrosion test shall have to be conducted as per following ASTM A262 Practice B with acceptance criteria of 60 mils/year (max.). OR ASTM A262 Practice E with acceptance criteria of No cracks as observed from 20X magnification & Microscopic structure to be observed from 250X magnification. 14.2 When specifically asked for in requisition for high temperature application of some grades of austenitic stainless steel (like SS309, 310, 316, 316H etc.) ASTM A262 Practice C with acceptance criteria of 15 mils/year shall have to be conducted. When testing is conducted as per Practice E, photograph of microscopic structure shall be submitted for record.
1.14.3 For the IGC test as described in 1.15.1 & 1.15.2 two sets of samples shall he drawn from each solution treatment lot; one set corresponding to highest carbon content and the other corresponding to the highest rating / thickness. 1.15 All types of 321 or 347 stainless steel flanges shall be in a stabilised heat treated condition. Stabilising heat treatment shall be carried out subsequent to the normal solution annealing. Soaking temperature and holding time for stabilising heat treatment shall he 900C and 4 hours respectively. AWWA C207 flanges shall be hub type. IBR REQUIREMENTS IBR Documentation:
1.16 2.0 2.1
2.1.1 Flanges coming under the purview of IBR (Indian Boiler Regulations) shall be accompanied with IBR Certificate original in Form III C duly approved and countersigned hy IBR authority / local authority empowered by Central Boiler Board of India. Photocopy of original certificate duly attested by the local boiler inspector where the supplier is located is the minimum requirement for acceptance. 2.2 For carbon steel flanges described as IBR. Chemical composition shall conform to the following: Carbon (max.) Others (S, P, Mn) : 0.25% : As prescribed in IBR Regulation
The chemical composition as indicated in this clause is not applicable for flanges other than IBR. Document No. 11-0330G01-01-09-02-009 SHEET 3 of 4 Rev 0

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3.0 3.1
SPECIAL REQUIREMENTS FOR HYDROGEN SERVICE Method of Manufacture
3.1.1 All carbon steel flanges having wall thickness 9.53 mm and above shall be normalized. The normalizing heat treatment shall he a separate heat treatment operation and not a part of the hot forming operation. 3.1.2 All alloy steel (Cr-Mo) flanges shall be normalized and tempered. The normalizing and tempering shall be a separate heat treatment operation and not a part of the hot forming operation. 3.2 Impact Test
3.2.1 For all carbon steels and alloy steels with wall thickness over 19 mm, Charpy-V Notch impact testing shall be carried out in accordance with paragraph UG-84 of ASME Section VIII, Div-l per heat of material and per heat treating batch. Impact test specimen shall be in accordance with ASTM A370. Impact Test shall be done at 0 C. The minimum average absorbed energy per set of three specimens shall be 27 J with an individual minimum per specimen of 22J. 4.0 4.1 MARKING AND DESPATCH All items shall be legibly and conspicuously stamped in accordance with the requirements of applicable ASME, API and MSS Standards. In addition, EIL item code, purchase order number & special conditions like IBR, CRYO, NACE H2 etc. shall also be stamped. All items coming under the purview of IBR, CRYO , NACE & H2(hydrogen) shall he painted in red stripes, light purple stripes, canary yellow stripes & sea green stripes (25 mm width) respectively for easy identification. Paint or ink for marking shall not contain any harmful metal or metal salts such as zinc, lead or copper which cause corrosive attack on heating. All items shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind. All items shall he protected from rust, corrosion and mechanical damage during transportation, shipment and storage. Rust preventive on machined surfaces to be welded shall be easily removable with a petroleum solvent and the same shall not be harmful to welding. Each end of flange shall he protected with the following materials: Flange face Bevelled end Threaded end Socket welding end 4.8 : Wood, metal or plastic cover : Wood, metal or plastic cover : Plastic plug : Plastic cover or plug
4.2
4.3
4.4 4.5
4.6
4.7
Each size of flanges, blinds, etc. shall be supplied in separate packaging marked with the purchase order number, item code number, material specification, size and rating.

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CLIENT JOB NO.
TECHNICAL NOTES FOR GASKETS

TOTAL SHEETS
4 018
DOCUMENT NO
11
0330G01
01
08
02
0 A REV
28.06.11 24.06.11 DATE
MH MH PREP
ASD ASD CHK
AD AD APPR
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TABLE OF CONTENT 1. GENERAL 4
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Abbreviations: AARH BHN CS MR PMI RTJ : : : : : : Average Arithmetic Root Height Brinnel Hardness Number Carbon Steel Material Requisition Positive Material Identification Ring Type Joint
TECHNICAL NOTES FOR GASKETS 1.0 1.1 GENERAL All gaskets shall conform to the codes/standards and specifications given in the requisition. Vendor shall strictly comply with MR/PR stipulations and no deviations shall be permitted. Process of manufacture, dimensions and tolerances not specified in requisition shall be in accordance with the requirements of the manufacturers standards. Testing Test reports shall be supplied for all mandatory tests for gaskets as per the standards specified in the requisition. Chemical composition and hardness of RTJ gaskets shall also be furnished in the form of test reports on samples. For Spiral wound material following shall be furnished: a) Manufacturers test certificate for filler material and spiral material as per the relevant material specifications. Manufacturers test certificate for raw materials and tests for compressibility/ seal-ability & recovery as per the relevant material specifications.
1.2
1.3 1.3.1
1.3.2
1.3.3
b)
1.4 1.5 1.6
Full face gaskets shall have bolt holes punched out. Filler material for spiral wound gaskets shall not have any colour or dye. All spiral wound gaskets shall be supplied with Outer ring. Material of the outer ring shall be CS unless otherwise specified in the MR. For spiral wound gaskets, material of Inner Compression ring shall be same as Spiral Strip material. In addition to the requirements as per code and as specified in the MR. inner rings shall be provided for the following: a) b) Sizes 26 and above. Class 900 and above.
1.7
1.8
Hardness of metallic RTJ gaskets shall not exceed the values specified below unless otherwise specified in MR:
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Ring Gasket Soft Iron Carbon steel 5Cr.1/2Mo 1.9 1.10
Material Maximum Hardness (BHN) 90 120 130
Face finish of metallic RTJ gaskets shall be 32 to 63 AARH. Gaskets of different types and sizes shall be placed in separate shipping containers and each container clearly marked with the size, rating, material specification and item code. All items shall be inspected and approved by Wood Group Kenny / owner / TPI Any additional requirements specified in the requisition, shall be fully complied with. Non-metallic ring gaskets as per ASME B16.21 shall match flanges to ASME B16.5 upto 24 (except 22 size) and to ASME B 16.47B above 24 unless specified otherwise. For 22 size, the matching flange standard shall be ASME B 16.47B unless specified otherwise. Spiral wound gasket as per ASME B16.20 shall match flanges to ASME B16.5 upto 24 (except 22size) and to ASME B16.47B above 24 unless specifically mentioned otherwise. For 22 size, the matching flange standard shall be ASME B 16.47B unless specified otherwise. The following abbreviations have been used in the Material Requisition for Spiral Wound Gaskets: (I) (0) CAF GRAFIL : : : : Inner Ring Outer Ring Compressed Asbestos Fibre Grafoil Filler
1.11 1.12 1.13
1.14
1.15
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TECHNICAL SPECIFICATION FOR INSULATING JOINTS
08 003
DOCUMENT NO
11
0330G01
01
09
02
0 A
28.06.11 24.06.11
ISSUED FOR TENDER ISSUED FOR IDC
MH MH
ASD ASD
AD AD
REV
DATE
DESCRIPTION
PREP
CHK
APPR
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TABLE OF CONTENTS
Sl.No.
DESCRIPTION
PAGE NO.
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
SCOPE ------------------------------------------------------------------------------------ 3 REFERENCE DOCUMENTS-------------------------------------------------------- 3 DEFINITIONS---------------------------------------------------------------------------- 4 MATERIALS------------------------------------------------------------------------------ 4 DESIGN & CONSTRUCTION REQUIREMENTS------------------------------ 5 INSPECTION AND TESTS---------------------------------------------------------- 6 TEST CERTIFICATES----------------------------------------------------------------- 7 PAINTING, MARKING AND SHIPMENT----------------------------------------- 7 SPARES AND ACCESSORIES----------------------------------------------------- 8 DOCUMENTATION-------------------------------------------------------------------- 8
Document No. TECHNICAL SPECIFICATION FOR MONOLITHIC INSULATING JOINTS

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1.0
SCOPE This specification covers the basic requirements for design manufacture, testing and supply of carbon steel insulating joints to be installed in onshore cross country pipeline systems used for transporting Natural Gas service. This specification does not cover the Insulating joints for sour hydrocarbons (liquid/gas) service as defined in NACE standard MR-01-75.
2.0 2.1
REFERENCE DOCUMENTS Reference has been made in this specification to the latest edition of, the following Codes, Standards and Specifications. API 1104 : Specification for welding pipelines and related facilities.
ASME B 31.3 ASME B 31.4
: Process piping. : Liquid transportation system for hydrocarbons, LPG, Anhydrous ammonia and Alcohols. : Gas Transmission and Distribution piping systems. : Boiler & pressure Vessel Code.
ASME B 31.8 ASME Section VIII ASME Section IX ASTM A 370
: Standard Test Methods and Definitions for Mechanical Testing of steel Products. : Auto catalytic Nickel Phosphorous coating on metals. : Butt Welding Ends : Metallic Materials-Types of inspection documents. : Standard marking systems for valves, Fittings, Flanges and union. : Quality standard for steel casting and forging for valves, flanges, fittings and other piping components Magnetic particle Examination method. : Specification for High Test Wrought welding fittings. : The electrical isolation of catholically protected pipelines. : Petroleum & Natural Gas industry Pipeline transportation system.
ASTM B 733 ANSI B 16.25 EN 1024 MSS-SP-25
MSS-SP-53
MSS-SP-75 NACE RP o286 ISO 13623
ISO 14313 2.2
: Petroleum & Natural Gas Industry, Pipeline transportation system pipeline valves. In case of conflict between the requirements of this specification and any code, Standard or Specification referred to in this Specification, the requirements of this specification shall govern.

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3.0
DEFINITIONS
Shall : This verbal form indicates requirements strictly to be followed in order to confirm to the standards and form which no deviation is permitted. : This verbal form indicates that among several possibilities one is particularly suitable without mentioning or excluding others or that a certain course of action is preferred but not necessarily required. : This verbal form indicates a course of action permissible within the limits of this standard. : This verbal form used for statements of possibility & capability , whether material, physical or casual.
Should
May
Can
4.0
4.1
MATERIALS Material for the pressure containing parts of the insulating joints shall be as indicated in the data sheets. Material for pups shall be equivalent or superior to the material of connecting pipeline, which is indicated in the data sheets. Pup piece material shall be such as to limit the thickness of pup piece to be welded with pipeline. Other part shall be as per Manufacturer's standard suitable for the service condition indicated in Insulating Joint Data Sheets and shall be subject to approval by purchaser. Insulating joints which are subjected to field welding by purchaser shall have carbon equivalent (CE) not exceeding 0.43 based on check analysis for each heat of steel calculated according to the following formula: Mn Cr + Mo + V Ni + Cu CE = C + ------ + ----------------- + ------------6 5 15
4.2
4.3
Charpy V-notch test shall be conducted on each heat of base material, weld metal and heat affected zone of all pressure containing parts such as body, welding ends in accordance with the impact test provisions of ASTM A 370 at a temperature of -20 C/-4 F. The charpy impact test specimens shall be taken in the direction of principal grain flow and notched perpendicular to the original surface of the plate of forging. Average impact energy value of three full sized specimens shall be 35 joules. Minimum impact energy value of individual specimen shall be 27 joules. No specimen shall exhibit less than 80% shear area. Carbon steel used for the manufacture shall be fully killed.
4.4
4.5
Hardness test shall be carried out as per ASTM A370 for each heat of steel used. The maximum hardness of base metal, weld metal and heat affected zone of all pressure parts shall be 248 HV10, unless specified otherwise. Insulation material shall be minimum 20 mm thick and shall comply section 5, NACE RP 0286.
4.6

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5.0
5.1
DESIGN & CONSTRUCTION REQUIREMENTS MECHANICAL
5.1.1
Insulating joints shall be of integral type fabricated by welding and with pups on either side as shown in data sheet. A corrosion allowance as indicated in data sheet shall be considered in design. Bolted and threaded joints are not acceptable. All materials used for the manufacture of the insulating joint shall be in accordance with clause 4.0 of this Specification. Insulating joints shall be designed using the design principles of ASME Section-VIII Div. 1. Insulating joint design and materials shall be capable of being vacuum tested to 1 millibar. The joint between pipe pup pieces and main forging shall be full penetration butt weld type. Weld design shall be such as resulting in a weld joint factor of 1.0. Butt weld ends shall have ends as per ASME B16.25. However, end preparation for butt welding ends having unequal thickness with respect to connecting pipe, shall be as per ASME B31.4/ B31.8 as applicable. The reinforcement of inside weld seam, in case pups fabricated from LSAW pipes, shall be removed for a distance of at least 50mm from each end to facilitate welding. Insulating joints shall allow free passage of scraper/ instrumented pigs. The internal bore shall be same as that of connecting pipe including its tolerances. The insulating joint shall be formed by sandwiching and locking in positions the insulating material in a bell and spigot type of joint. The joint shall be assembled in such a way that its various components are firmly locked in position and the completed joint is capable of withstanding stresses due to designed operating conditions and field hydrostatic testing. Insulating joints shall be suitable for aboveground or underground installations as indicated in the data sheets. All welds shall be made by welders and welding procedures qualified in accordance with the provisions ASME section IX. The procedure qualification shall include impact test and hardness test and shall meet the requirements of clause 4.3, 4.5 of this specification. Repair welding on parent metal is not allowed. Purchasers representative for each repair shall carry out repair of welds only after specific approval. Welders shall carry out the repair welding and welding procedures duly qualified as per ASME section IX and records for each repair shall be maintained. Internal diameter at the welding end shall not vary more than + 1, -3 mm from the nominal internal diameter. Out of roundness measured at the root face of the welding ends shall not be more than 0.5% of the specified inside diameter. ELECTRICAL The average dielectric strength of the insulating joint shall be minimum 15 kilo Volts. Two cleats as shown in data sheet shall be provided on the pups on either side of the insulating joint 2 2 for connecting 10 mm and 50 mm cables for measurement/ shorting purposes. Cleats shall be attached to the insulating joint by welding. Document No. TECHNICAL SPECIFICATION FOR MONOLITHIC INSULATING JOINTS
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5.1.2
5.1.3 5.1.4 5.1.5
5.1.6
5.1.7
5.1.8
5.1.9
5.1.10 5.1.11
5.1.12
5.1.13
5.1.14 5.2 5.2.1 5.2.2
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6.0
6.1
INSPECTION &TESTING The manufacture shall perform all inspection and tests as per the requirements of this specification and the relevant codes, prior to shipment at his works. Inspection & tests shall be performed to ascertain the requirements of this specification & not limited to the following: All insulating joints shall be visually inspected. Dimensional checks shall be carried out as per the purchaser 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 insulating joints shall be carried out as given below: a) 100% radiography shall be carried out on all butt & repair welds of pressure containing parts. Acceptance limits shall be as per API 1104.
6.1.1 6.1.2 6.1.3
6.1.4
Welds, which in purchaser's Representative 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 Appendix-12 and Appendix-6 respectively. b) All finished weld ends shall be 100% ultrasonically tested for lamination type defects for a distance of 50mm from the ends. Any lamination larger than 6.35 mm shall not be acceptable.
c)
All forgings shall be wet magnetic particle inspected on 100% of forged surfaces. Method and acceptance shall comply MSS-SP-53.
d) All fillet weld of thickness < 6mm shall be examined 100% by magnetic particle inspection and t 6mm shall be examined 100% by UT. Acceptance criteria for MPI & UT shall be as per ASME Sec.VIII Appendix-6 & Appendix-12 respectively. 6.1.5 Insulating joint shall be hydrostatically tested to a pressure as indicated in data sheet. The test duration shall be of 15 minutes.
2 After the hydrostatic test insulating joints shall be tested with air at 5 kg/cm for 10 minutes. The tightness shall be checked by immersion or with a frothing agent. No leakage shall be acceptable.
6.1.6
6.1.7
DIELECTRIC TEST a) Insulation resistance of each insulating joint shall be at least 50 mega-ohms when checked with1000 V DC. Insulating joint before and after the hydrostatic test, shall be tested for dielectric integrity for one minute at 5000 V A.C., 50 cycles and the leakage current before and after hydrostatic test shall be equal. Testing time voltage and leakage shall be recorded and certified. No repair shall be permitted to the insulating joints failed in the above mentioned tests.
b)
6.2
Purchaser reserves the right to perform stage wise inspection and witness test as indicated in Para 6.1 at Manufacturer's works prior to shipment. Manufacturer shall give reasonable notice of time and

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shall provide without charge reasonable access and facilities required for inspection to the purchaser's Representative. Inspection and tests performed/witnessed by the Purchaser's Representative shall in no way relieve the Manufacturer's obligation to perform the required inspection and test.
7.0
7.1
TEST CERTIFICATES Manufacturer shall submit following certificates to Purchaser's Representative. a) Test certificates relevant to the chemical analysis and mechanical properties including hardness of the materials used for construction of insulating joint as per this specification and relevant standards. Test reports on non-destructive testing. Test certificates for hydrostatic and air tests. Test certificate for electrical resistance test.
b) c) d)
e)
Test report for dielectric strength test.
8.0
8.1
PAINTING, MARKING AND SHIPMENT. Insulating joint surface shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot blasting to SP-6 in accordance with "steel structures painting council - Visual standard SSPC-VIS-l.". External surfaces of buried insulating joints shall be painted with three coats of suitable coal tar epoxy resin with a minimum dry film thickness of 300 microns. Manufacturer shall indicate the type of corrosion resistant paint used, in the drawings submitted for approval.
8.2
Insulating joints shall be marked with indelible paint with the following data:a. b. c. d. e. f. g. h. Manufacturer's name Suitable for- inch nominal diameter pipeline End thickness in mm Material Design Pressure/ Hydrostatic Test Pressure ANSI Class Rating Tag No. Year of Manufacture
8.3
Insulating joints shall be suitably protected to avoid any damage during transit. Metallic bevel protectors shall be provided to weld ends. Document No. TECHNICAL SPECIFICATION FOR MONOLITHIC INSULATING JOINTS
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8.4
Only those insulating joints, which have been inspected and certified by Purchaser, shall be shipped.
9.0
SPARES AND ACCESSORIES Not Applicable
10.0
10.1 10.2
DOCUMENTATION All documents shall be in English Language. At the time of bidding, Bidder shall submit the following documents:a) b) c) General arrangement drawing along with cross sectional view, overall dimensions and details of insulating materials recommended. Reference lists of previous supplies of insulating joint of similar specification. Clause wise list of deviation from this specification, if any.
10.3
Within two weeks of placement of order, the Manufacturer shall submit four copies of but not limited to the following drawings, documents and specifications for approval.
a) b) c)
Fabrication drawings and relevant calculations for pressure containing parts. Welding procedure and method of manufacture for all phases of manufacture. Quality Assurance Plan (QAP)
Once the approval has been given by purchaser any changes in design, material and method of manufacture shall be notified to the Purchaser whose approval in writing of all changes shall be obtained before the insulating joint are manufactured. 10.4 Within four weeks from the approval date Manufacturer shall submit one reproducible and six copies of the approved drawings, documents and specifications as listed in 9.3 of this specification. Prior to shipment, the manufacturer shall submit one reproducible and six copies of the test certificates as listed in Clause 6.0 of this specification.
10.5

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CLIENT JOB NO.
26 011
WELDING SPECIFICATION FOR FABRICATION OF PIPING
TOTAL SHEETS
DOCUMENT NO
11
0330G01
01
09
02
0 A REV
28.06.11 24.06.11 DATE
MH MH PREP
ASD ASD CHK
AD AD APPR
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Abbreviations: ASME ASNT AWS BPVC CFH DWDI DWSI SWSI GTA GTAW IBR IQI NDT PQR RT SMAW UTS : : : : : : : : : : : : : : : : : American Society of Mechanical Engineers American Society for Nondestructive Testing American Welding Society Boiler & Pressure Vessel Code Cubic Feet per Hour Double Wall Double Image Double Wall Single Image Single Wall Single Image Gas Tungsten Arc Gas Tungsten Arc Welding Indian Boiler Regulations Image Quality Indicator Non Destructive Testing Procedure Qualification Record Radiographic Testing Shielded Metal Arc Welding Ultimate Tensile Strength
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TABLE OF CONTENT
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0
GENERAL APPLICABLE CODES & STANDARDS BASE MATERIALS WELDING CONSUMABLES SHIELDING & PURGING GAS EQUIPMENTS & ACCESSORIES WELDING PROCESSES EDGE PREPARATION ALIGNMENT & SPACING WEATHER CONDITIONS WELDING TECHNIQUE HEAT TREATMENT CLEANING OF THE WELD JOINT INSPECTION & TESTING REPAIRS OF WELDS DOCUMENTS TO BE SUBMITTED BY CONTRACTOR ATTACHMENT 1
4 4 4 4 5 5 6 6 6 7 7 8 9 9 12 12 27
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(This specification shall be used in conjunction with Welding Specification Charts). 1.0 GENERAL This specification shall be followed for the fabrication of all types to welded joints of piping system within the battery limits of the plant. The welded pipe joints shall include the following: a) b) c) d) e) f) All pipe joints, longitudinal butt welds, circumferential butt welds and socket welds. Attachments of forgings, flanges and other supports to pipes. Welded manifold headers and other sub-assemblies. Welded branch connections with or without reinforcing pads. Joints in welded/fabricated piping components. The attachments of smaller connections for vents drain drips and other instrument tappings.
Any approval granted by the Engineer-in-Charge or Owners inspector, shall not relieve the Contractor of his responsibilities and guarantee. This specification shall not be applicable for welding of pipelines for transportation of liquid petroleum, gas and other similar products in on shore and off shore 2.0 APPLICABLE CODES & STANDARDS All welding work, equipments for welding, heat treatment, other auxiliary functions and the welding personnel shall meet the requirements of the latest editions of the following accepted standards and procedures unless otherwise specified in the Welding Specification Chart and the Technical Notes attached thereof. In the case of conflicting requirements, the requirements mentioned in Welding Specification Chart/Technical Notes shall be applicable. i) ASME Code for Pressure Piping - ASME B31.3/ASME B31.8 ii) ASME Boiler & Pressure Vessel Code, Sec II Part C, Material Specifications: Welding Rods, Electrodes and Filler metals. iii) ASME Boiler & Pressure Vessel Code, Section V, Non destructive examination. iv) ASME Boiler & Pressure Vessel Code, Section VIII, Rules for Construction of Pressure Vessels. v) ASME Boiler & Pressure Vessel Code, Section IX, Welding and Brazing Qualifications. vi) The Indian Boiler Regulations - I.B.R. In the event of any differences due to the additional requirements mentioned in this specification, over and above those obligatory as per codes, this specification shall be binding. 3.0 3.1 BASE METAL In general, use of carbon steel, alloy steel and stainless steel is envisaged. The details of the material specifications are given in the Welding Specification Chart. The Contractor shall provide the manufacturers test certificates for every heat of the materials supplied by him. WELDING CONSUMABLES The Contractor shall provide, at his own expense, all the welding consumables necessary for the execution of the job such as electrodes, filler wires, argon etc. and these should bear the approval of the Engineer-in-Charge. The welding electrodes and filler wires supplied by the Contractor shall conform to the class specified in the Welding Specification Chart. The materials shall be of the make approved by the Engineer-in-Charge.
3.2
4.0 4.1
4.2
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4.3
Electrode qualification test records should be submitted as per the Exhibit-A (attached) in respect of the electrodes tested by the Contractor, for obtaining the approval of the Engineer- in-Charge. The Contractor shall submit batch test certificates, from the electrode manufacturers, giving details of physical and chemical tests carried out by them, for each batch of electrodes to be used. All electrodes shall be purchased in sealed containers and stored properly to prevent deterioration. The electrodes removed from the containers shall be kept in holding ovens at temperatures recommended by the electrode manufacturer. Out of the oven time or electrodes, before they are consumed, shall not exceed the limits recommended by the electrode manufacturer. The electrodes shall be handled with care to avoid any damage to the flux covering. All low hydrogen type of electrodes shall be rebaked at 350C for 1 hour minimum and stored in ovens kept at 80-100C before use. Recommendations of the electrode manufacturer shall be followed, if available. The electrodes, filler wires and flux used shall be free from rust, oil, grease, earth and other foreign matter which affect the quality of welding. Tungsten electrodes used shall conform to ASME Sec.II C SFA 5.12 specification. Thoriated Tungsten electrodes shall not be permitted due to possible radiation hazard. Instead, ceriated Tungsten Electrodes (EWCe-2 or equivalent) shall be used for GTA Welding. SHIELDING & PURGING GAS Argon gas used in GTA welding for shielding purposes shall be 99.995% pure. The purity of the gas shall be certified by the manufacturer. The rate of flow for shielding purposes shall be established through 3 procedure qualification tests. Normally this rate may be 0.34 0.57 M per hour. Argon gas with a purity level of 99.995% shall be used for purging. When GTAW process alone or a combination of GTAW and SMAW processes is recommended for the production of a particular joint, the purging shall be maintained during the root pass and for the first filling pass to minimize oxidation on the inner side of the pipe, unless otherwise specified in Welding Specification Chart. Initial purging shall be maintained for sufficient period of time so that at least 4-5 times the volume between the dams is displaced, in order to completely remove the entrapped air. In no case should the initial purging period be less than 10 minutes. High gas pressure should be avoided. After initial purging, the flow of the backing gas should be reduced to a point where only a slight positive pressure prevails. For systems, which have a small volume (up to 0.0425 M3 per hour) to be purged, a gas 3 flow rate of 0.17 M per hour is usually adequate. Systems of larger volume may require higher flow rates and these should be established during procedure qualification tests. Gas backing (purging) is not required for socket type of welded joints. Dams, used for conserving inert gas during purging, shall be removed after completion of the welding, and shall be accounted for. Wherever, removal of dams is not possible after welding, use of water-soluble dams should be made. EQUIPMENTS & ACCESSORIES The Contractor should have the arrangement of sufficient number of welding and cutting equipments, auxiliaries, and accessories of sufficient capacities so as to meet the target/schedule. All the equipments for performing the heat treatment, including transformers, thermocouples, pyro-meters, automatic temperature recorders (with suitable calibration arrangement etc.) shall be provided by the Contractor at his own expenses and these should bear the approval of the Engineer-in-Charge. WELDING SPECIFICATION FOR FABRICATION OF PIPING Document No. 11-0330G01-01-09-02-011 SHEET 5 of 26
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4.4
4.5
4.6
4.7
4.8
5.0 5.1
5.2 5.3
5.4
5.5
5.6 5.7
6.0 6.1
6.2
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6.3
Contractor shall make necessary arrangements at his own expense, for providing the radiographic equipments, radiographic films, processing equipment all other darkroom facilities and all the equipments/materials required for carrying out the dye-penetrant/magnetic particle test/ultrasonic testing for satisfactory and timely completion of the job. Redoing of any work, necessitated by faulty equipments or operation used by the Contractor will be done at his own expense. WELDING PROCESS Welding of various materials under this specification shall be carried out using one or more of the following processes with the approval of the Engineer-in-Charge. - Shielded Metal Arc Welding Process (SMAW). - Gas Tungsten Arc Welding Process (GTAW) The welding processes to be employed are given in the Welding Specification Chart. Any deviation desired by the Contractor shall be obtained through the express consent of the Engineer-in-Charge. Automatic and semi-automatic welding processes shall be employed only with the express approval of the Engineer-in-Charge. The welding procedure adopted and consumables used shall be specifically approved. A combination of different welding processes could be employed for a particular joint only after duly qualifying the welding procedure to be adopted and obtaining the approval of Engineer-in-Charge. EDGE PREPARATION General The edges to be welded shall be prepared to meet the joint design requirements by any of the following methods recommended: (a) Carbon Steel Gas cutting, machining or grinding methods shall be used. After gas cutting, oxides shall be removed by chipping or grinding. (b) Low Alloy Steels (containing up to 5% Chromium). Gas cutting, machining or grinding methods shall be used. After gas cutting, machining or grinding shall be carried out on the cut surface. (c) High alloy steel (> 5% Chromium) and stainless steels, nickel alloys: Plasma cutting, machining or grinding methods shall be used. After plasma cutting, cut surfaces shall be machined or ground smooth. Cleaning (a) The ends to be welded shall be properly cleaned to remove paint, oil, grease, rust, oxides, sand, earth and other foreign matter. The ends shall be completely dry before the welding commences. (b) On completion of each run, craters, welding irregularities, slag etc., shall be removed by grinding and chiseling. Wire brushes used for cleaning stainless steel joints shall have stainless steel wires and the grinding wheels used for grinding stainless steel shall be of a suitable type. Separate grinding wheels and wire brushes should be used for carbon steels and stainless steels.
6.4
7.0 7.1
7.2
7.3
7.4
8.0 8.1
8.2
9.0 9.1
ALIGNMENT & SPACING Components to be welded shall be aligned and spaced as per the requirements laid down in applicable code. Special care must be taken to ensure proper fitting and alignment when the welding is performed by GTAW process. Flame heating for adjustment and correction of ends is not permitted unless specifically approved by the Engineer-in-Charge.
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9.2
A wire spacer of suitable diameter may be used for maintaining the weld root opening while tacking, but it must be removed after tack welding and before laying the root bead. For pipes of wall thickness 5 mm and above, the ends to be welded shall be secured in position with the aid of couplers, yokes and C clamps, to maintain perfect alignment. Yokes shall be detached after the completion of weld, without causing any surface irregularity. Any irregularity caused on the pipe surface must be suitably repaired to the satisfaction of the Engineer-in-Charge. Tack welds, for maintaining the alignment, of pipe joints shall be made only by qualified welders using approved WPS. Since the tack welds become part of the final weldment they shall be executed carefully and shall be free from defects. Defective tack welds must be removed prior to the actual welding of the joints. Tacks should be equally spaced. Minimum number of tacks shall be: 3 tacks 4 tacks 6 tacks for 2 1/2 and smaller dia. pipes. for 3 to 12 dia. pipes. for 14 and larger dia. pipes.
9.3
9.4
9.5
9.6 10.0 10.1
Welding shall commence only after approval of fit-up by the Engineer-In-Charge. WEATHER CONDITIONS The parts being welded and the welding personnel should be adequately protected from rain and strong winds. In the absence of such a protection no welding shall be carried out. During field welding using GTAW process, particular care shall be exercised to prevent any air current affecting the welding process. WELDING TECHNIQUE Root Pass (a) Root pass shall be made with electrodes/filler wires recommended in the welding specification chart. For fillet welding, root welding shall be done with consumables recommended for filler passes. The preferred size of the electrodes is 2.5 mm diameter (12 SWG) but in any case not greater than 3.25 mm (10 SWG). (b) Upward technique shall be adopted for welding pipe held fixed with its axis horizontal. (c) The root pass of butt joints should be executed so as to achieve full penetration with complete fusion of the root edges. Weld projection inside the pipe shall be as per applicable code. It shall be limited 3mm map. When the applicable code does not place any restriction. (d) Any deviation desired from the recommended welding technique and electrodes indicated in the welding specification chart should be adopted only after obtaining express approval of the Engineer-inCharge. (e) Welding shall be uninterrupted. (f) While the welding is in progress care should be taken to avoid any kind of movement of the components, shocks, vibrations and stresses to prevent occurrence of weld cracks. (g) Peening shall not be used.
10.2
11.0 11.1
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11.2
Joint Completion (a) Joint shall be completed using the class of electrodes, recommended in the Welding Specification Chart. Size of the electrode shall not exceed 4 mm in diameter for stainless steels and alloy steels used for low temperature applications. (b) Two weld beads shall not be started at the same point in different layers. (c) Butt joints shall be completed with a cover layer that would affect good fusion at the joint edges and a gradual notch free surface. (d) Each weld joint shall have a workmanship like finish. Weld identification work shall be stamped clearly at each joint, just adjacent to the weld. Metal stamping shall not be used on thin pipe having wall thickness less than 3.5mm. Suitable paint shall be used on thin wall pipes for identification. (e) Rust preventive/protective painting shall be done after the weld joint has been approved.
11.3
Dissimilar Welds Where welds are to be produced between carbon steels and alloy steels, preheat and post weld heat treatment requirements shall be those specified for corresponding alloy steels and filler wire/electrodes shall correspond to ER 70 S-G or AWS E-7016/7018 type. For welds between two dissimilar Cr-Mo low alloy steels, preheat and post weld heat treatments shall be those specified for higher alloy steel and electrodes used shall correspond to those specified for steel of lower alloy content. For carbon steel or alloy steel to stainless welds, use of filler wire/electrodes E/ER-309/E-310/E NiCr Fe-3 shall be made. The welding procedure, electrodes/filler wires to be used shall be approved by the Engineer-in-Charge.
12.0 12.1
HEAT TREATMENT Preheating (a) No welding shall be performed without preheating the joint to 10C (50F) when the ambient temperature is below 10 degree. (b) Preheating requirements for the various materials shall be as per the Welding Specification Chart attached. (c) Preheating shall be performed using resistance or induction heating methods. Preheating by gas burners, utilizing oxy-acetylene or oxy-propane gas mixtures, with neutral flame may also be carried when permitted by the Engineer-in-Charge. (d) Preheating shall extend uniformly to at least three times the thickness of the joint, but not less than 50 mm, on both sides of the weld. (e) Preheating temperature shall be maintained over the whole length of the joint during welding. Temperature recorders shall be provided by the Contractor to record the temperature.
12.2
Post Heating In case of alloy steel materials such as Cr-Mo steels, if the post weld heat treatment is not performed immediately after welding, the weld joint and adjacent portion of pipe, at least 50 mm on either side of weld, shall be uniformly heated to 300C. This temperature shall be maintained for half an hour minimum, and then wrapped with mineral wool before allowing it to cool to room temperature. If the Post Heating temperature specified in the Welding Specification Charts exceeds 3 00C, the same shall be followed. Similarly, if the welding specification chart specifies post-heat time, the same shall be applicable. Post weld heat treatment as specified in the Welding Specification Chart shall be carried out later on.
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12.3
Post Weld Heat Treatment (PWHT) (a) Post weld heat treatment, wherever required for joints between pipes, pipes and fittings, pipe body and supports shall be carried out as per the welding specification chart, applicable codes standards and the instructions of the Engineer-in-Charge. In this regard procedure qualification to be done before carrying out PWHT in production welds. (b) The Contractor shall submit for the approval of the Engineer-in-Charge, well before carrying out actual heat treatment, the details of the post weld heat treatment procedure as per Exhibit B attached, that he proposes to adopt for each of the materials/assembly/part involved. (c) Post weld heat treatment shall be done in a furnace or by using an electric resistance or inductionheating equipment, as decided by the Engineer-in-Charge. (d) While carrying out local post weld heat treatment, technique of application of heat must ensure uniform temperature attainment at all points of the portion being heat- treated. Care shall be taken to ensure that width of heated band over which specified post weld heat treatment temperature attained is at least that specified in the relevant applicable standards/codes. Control of temperature shall be done using microprocessor/computer controlled system. The desired time-temperature cycle shall be entered into the microprocessor/computer. (e) Throughout the cycle of heat treatment, the portion outside the heated band shall be suitably wrapped under insulation so as to avoid any harmful temperature gradient at the exposed surface of pipe. For this purpose temperature at the exposed surface should not be allowed to exceed 50% of the peak temperature. (f) The temperature attained by the portion under heat treatment shall be recorded by means of thermocouple pyrometers. Adequate number of thermocouples should be attached to the pipe directly at equally spaced location along the periphery of the pipe joint. The minimum number of thermocouples attached per joint shall be 1 up to 6 dia., 2 up to 10 dia. and 3 for 12 dia. and above. However, the Engineer-in-Charge can increase the required number of thermocouples to be attached if found necessary. (g) Automatic temperature recorders, which have been suitably calibrated, shall be employed for measuring & recording temperature. Both, the actual time-temperature graph and the designed time temperature graph shall be available on every chart. The time-temp graph shall be submitted to Engineer-in-Charge immediately on completion of Stress Relieving Cycle. The calibration record of each recorder should be submitted to the Engineer-in-Charge prior to starting the heat treatment operations and his approval should be obtained. (h) Manufacturers test certificate shall be submitted for the thermocouples materials and record shall be maintained by the Contractor. (i) Immediately on completion of the Heat Treatment, the Post Weld Heat Treatment charts/records along with the hardness test results on the weld points, wherever required as per the Welding Specification Chart, shall be submitted to Engineer-in- Charge for his approval. (j) Each weld joint shall bear a unique identification number, which shall be maintained in the piping sketch to be prepared by the Contractor. The weld joint identification number should appear on the corresponding post weld heat treatment charts. The chart containing the identification numbers and piping sketch shall be submitted to the Engineer-in-Charge in suitable folders.
13.0
CLEANING OF THE WELD JOINT All weld joints shall be free from adherent weld spatters slag, sward, dirt or foreign matter. This can be achieved by brushing. For stainless steels, brushes with only stainless steel bristles shall be used.
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14.0 14.1
INSPECTION AND TESTING General (a) The Owners inspector shall have free access to all concerned areas, where the actual work is being performed. The contractor shall also accord the Owners Inspector all means and facilities necessary to carry out inspection. (b) The Owner is entitled to depute his own inspector to the shop or field where prefabrication and erection of pipe lines is in progress for (but not limited to) the following objectives: i) To check the conformance to relevant standards and suitability of various welding equipments and the welding performance. ii) To witness the welding procedure qualification. iii) To witness the welder performance qualification. iv) To check whether shop/field welding being executed is in conformity with the relevant specifications and codes of practice followed in piping construction. (c) Contractor shall intimate sufficiently in advance the commencement of qualification tests, welding works and acceptance tests, to enable the Owners inspector to be present to supervise them, as decided by the Engineer-In-Charge.
14.2
Welding Procedure Qualification Welding procedure qualification shall be carried out in accordance with the applicable requirements of ASME Sec. IX latest edition and/or other applicable codes and the job requirements. The contractor shall submit the welding procedure specification in format as per Exhibit-C (attached) immediately after the receipt of the order. Owners inspector will review, check and approve the welding procedure submitted and shall release the procedure for qualification tests. The procedure qualification test shall be carried out by the Contractor at his own expense. A complete set of test results in the format as per Exhibit-D attached) shall be submitted to the Owners inspector for his approval immediately after completing the procedure qualification test and at least 2 weeks before the commencement of actual work. Standard test as specified in the code shall be carried out in all cases. In addition to these tests, other tests like macro/micro examination, hardness tests, dye penetrant examination, Charpy V notch, Corrosion tests, impact tests etc. shall be carried out on specimens depending upon the type of base material, operating conditions and requirements laid down in the detailed drawings and specifications. It shall be the responsibility of the Contractor to carry out all the tests required to the satisfaction of the Owners inspector.
14.3
Welders Qualification (a) Welders shall be qualified in accordance with the ASME Section-IX or other applicable codes. The Owners inspector reserves the right to witness the test and certify/approve the qualification of each welder separately. Only those welders who have been approved by the Owners Inspector shall be employed for welding. Contractor shall submit the welder qualification test reports in the format as per Exhibit-E (attached) and obtain express approval before commencement of work. It shall be the responsibility of Contractor to carry out qualification tests of welders. For welding of the steam piping, falling under the purview of Indian Boiler Regulations, only those welders with IBR Certification, qualified by Boiler Inspectorate, and acceptable to the local Boiler Inspector authority shall be employed. (b) The welders shall always have in their possession an identification card containing information contained in Exhibit-G and shall produce it on demand by the Engineer In-Charge or his representative. It shall be the responsibility of the Contractor to issue the identify cards after it has been duly certified by the, owners Inspector. (c) No welder shall be permitted to work without the possession of the identify card.
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(d) If a welder is found to perform a type of welding or in a position for which he is not qualified, he shall be debarred from doing any further work. All welds performed by an unqualified welder shall be cut and redone by a qualified welder at the expense of the Contractor. 14.4 Visual Examination Visual Examination of all welds shall be carried out as per the latest editions of the applicable codes and specifications. All finished welds shall be visually inspected for parallel and axial alignment of the work, excessive reinforcement, concavity of welds, shrinkage cracks, inadequate penetration, unrepaired burnthrough, under cuts, dimensions of the weld, surface porosity and other surface defects. Undercutting adjacent to the completed weld shall not exceed the limits specified in the applicable standard/code. 14.5 Radiographic Examination (a) Contractor shall appoint agency for carrying out the radiography works at site from the list of agency (ies) enclosed in the bid document or separately supplied by owner. (b) The Radiographic Examination procedures to be adopted shall be submitted by the contractor as per Exhibit-F and shall be got approved from the Owners Inspector prior to employment. A person qualified to ASNT Level-II or ASNT Level-lII in Radiographic testing shall prepare the procedure. The Radiography Procedure shall be established to demonstrate that the required sensitivity can be consistently achieved under the most unfavorable parameters (e.g. source to film distance, geometric unsharpness, thickness etc.). The radiographic technique and procedure adopted shall conform of the requirements mentioned in Article 2 as well as Article 22 of ASME Sec.V. The IQI sensitivity obtained shall be equal to or better than the requirements mentioned in Article 2 of ASME Sec.V. Source side penetrameter shall be used in establishing radiographic procedure technique. The acceptance criteria shall be as per the relevant codes of Fabrication and over riding requirements if mentioned else where in the technical specifications of the contract. The Contractor shall be responsible for carrying out Radiography; rectification of defects and re-radiography of welds repaired/rectified at his cost. (c) The extent of Radiography shall be as per specifications to be supplied to the Contractor. For welds between dissimilar materials, the extent of Radiographic Examination shall be the more stringent of the two recommended for the materials being welded. Wherever random Radiography is called for, in a particular piping class, the dissimilar materials weld joints shall essentially be included. (d) Type of Radiation source and film to be used shall be as per Exhibit-H for carrying out radiographic examination. However if specifications (as given else where in the contract) for some critical material require usage of X-Radiation, then Radiography shall be done using X-Rays only. (e) The Contractor shall fulfill all the statutory and owners safety requirements while handling X-ray and Gamma-ray equipments. (f) In case of random radiography, the joints for Radiography shall be selected by the Owners Inspector and the Radiography shall be performed in his presence, if he instructs the contractor to do so. The contractor shall furnish all the radiographs, to the Owners Inspector immediately after processing along with evaluation by a person qualified to ASNT Level-II in Radiographic testing, inline with Article 2 of ASME Sec.V. The certificate of ASNT/ISNT Level II qualification of the NDT personnel shall be submitted to owners inspector for his approval prior to start of job. (g) The Contractor shall provide the Owners Inspector, all the necessary facilities at site such as a dark room with controlled temperature, illuminator (viewer) suitable for varying densities, a duly calibrated electronic densitometer with batteries, magnifying glass, tracing papers, ruler, marking pencils etc. to enable him to review the radiographs. (h) Where random radiography is specified, the first weld of each welder shall be completely radiographed. In the case of pipe of size 6 and below, the first two welds shall be completely radiographed.
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(i)
For each weld performed by a welder found unacceptable, two additional checks shall be carried out on welds performed by the same welder. This operation is iterative and the of two additional welds for each weld deemed unsatisfactory shall be continued till such time that two consecutive welds of satisfactory quality are found for every defective weld.
(j) The Contractor shall carry out these additional radiographic testing at his own expense. To avoid the possibility of too many defective welds by a single welder remaining undetected for a long period to time, the Contractor shall promptly arrange for Radiographic Examination so that there is no accumulation of defective joints. (k) Contractor shall quote rates for X-ray as well as Gamma Ray for joints indicated to be radiographed by X-ray in Table of Exhibit-H. 14.5.1 Check shots (a) Owner / Engineer- incharge or his representative shall select 5% of the total joints radiographed on a day for check shots. Contractor shall carry out check shots as directed. (b) Weld profiles of check shots shall be compared with weld profile observed in the earlier Radiographs. In the event of any one variation in the check shots and earlier Radiographs, contractor shall re-shoot the entire lot of joints radiographed by particular Radiography agency on the particular date. All the reshot films shall be compared with the originally submitted films. 14.6 Liquid Penetrant and Magnetic Particle Examination (a) Whenever such tests are specified, the tests shall be carried out on joints chosen by the Owners inspector, as per ASME Section V article 6 and 7 respectively. The tests are to be performed by a person possessing a valid ASNT/ISNT Level-II qualification in the method being used. (b) For austenitic stainless steels and other nonmagnetic materials, liquid (dye) penetrant test shall be carried out. For carrying out this test, the materials shall be brought within a temperature limit of 15 to 50C. 14.7 Hardness Test Hardness requirements for welds shall be as per the Welding Specification Chart/Non Destructive Examination Specification attached elsewhere in the contract. Hardness testing shall be carried out by Vickers Hardness Tester during welding procedure qualification and shall be cross sectional. For production welds, hardness testing shall be carried out by portable digital hardness testers. Poldi hardness tester shall not be permitted. Contractor shall produce documentary evidence/calibration certificate to the Owners Inspector and obtain approval of the hardness testing equipment. 14.8 Proof Tests Hydrostatic and pneumatic tests shall be performed as per the requirements laid down by respective flushing and Testing specification/applicable codes to demonstrate the soundness of the welds. The tests shall be conducted after fulfilling the requirement of visual examinations radiography etc. and after the entire work has been certified by the Owners inspector to be fit for being subjected to such tests. 15.0 REPAIRS OF WELDS (a) Defects ascertained, through the inspection methods, which are beyond acceptable limits shall be removed after the joint is completely radiographed by the process of chipping and grinding. (b) When the entire joint is judged unacceptable, the welding shall be completely cut and edges suitably prepared as per required alignment tolerances. The rewelded joint shall again be examined following standard practices. (c) No repair shall be carried out without prior permission of the Owners inspector. Document No. 11-0330G01-01-09-02-011 SHEET 12 of 26
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(d) Repairs and/or work of defective welds shall be done in time to avoid difficulties in meeting the construction schedules. 16.0 DOCUMENTS TO BE SUBMITTED BY CONTRACTOR (4 COPIES EACH) (a) Electrode and Welding Consumable Qualification Records as per Exhibit-A, for the Welding Consumables tested and approved for the work.
(b) Batch Test Certificates, for the Electrodes used, obtained from the Electrode Manufacturers. (c) Proposed Heat Treatment Procedure as per Exhibit-B. (d) Heat Treatment Charts. (e) Weld joint hardness test results. (f) Welding Procedure Specifications as per Exhibit-C immediately after receipt of the order. (g) Welding Procedure Qualification records as per Exhibit-D (h) Welder Performance Qualification records as per Exhibit-E immediately after conducting Welder Qualification Tests. (i) Radiography Procedure as per Exhibit-F and other NDT procedures. (j) Radiographic test Report along with Radiographs and other NDT reports. (k) Piping Sketch (Isometric) giving all the details regarding the pipe specifications, welded joints, joints radiographed magnetic particle, tested, ultrasonic tested, penetrant tested, joints heat treated, WPS used, welders identification number, etc.
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EXHIBIT - A Sheet 1 of 2 ELECTRODE QUALIFICATION TEST RECORD A: Tested at (Site name) Manufacturers Name Brand Name Batch Number & Size tested Classification & Code Intended for welding in position In combination with (if any) Code of Reference (used for testing) Special Requirements (if any) All-weld Tensile Test Base Material used Pre-heat temperature Post weld heat treatment details Visual examination Radiographic examination results Tensile test results Identification No. 1. 2. C: Impact Test Results Test Temperature Type of Specimens (Charpy) Specimen No. 2 3 4 5 D: Chemical Analysis Results Electrode Size Result Batch No. %C %S %P : : %Si %Mn %Cr %Ni %Mo Other U.T.S. Date: : : : : : : : :
B:
: : : : : : Yield Point Elongation Remarks
: : Impact Value
Notch in Size of Specimens Average
: :
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EXHIBIT - A Sheet 2 of 2 E: Fillet Weld Test Results Welding Positions Base Materials Size of electrode used Visual Inspection Results 1) 2) 3) Macro Test Results Fracture Test Results Remarks F: Other Test Results 1. Transverse tensile test In combination with Base material used Position of welding Preheat temperature Post weld heat treatment Radiography Identification No. 2. Guided Bend Test : : : : : : : : : : : U.T.S. : Fracture in Remarks : : : : :
Position
Identification No. 1 2 3 4 5
Root, Face or Side Bend
Remarks
G. Any other tests H. Conclusions
: :
PREPARED BY (CONTRACTOR)
REVIEWED BY (CONTRACTOR)
APPROVED BY (OWNER)
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EXHIBIT - B Sheet 1 of 1 STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION Contractor Name of the Heat treater Name of the Project 1. General Details Name of the Equipment: ________________________ (Tick mark applicable method) Maximum Permissible Temp at Uncovered Parent Metal Width of heated band _________ Width of Insulation __________ Material: __________________________ Type of Thermo couples 3. Heat Treatment Cycle Details Charging Temp C Rate of heating C / Hr. Soaking Temperature, C Soaking Time, Hrs. Rate of Cooling oC /Hr. Method of Cooling No. of Themo couples (dia wise) : _______________________________________________________________ : ____________________________________________________________ : _____________________________ Other Details Type of Heating: Elec. Res/ Induction Specification Reference No.
4.
Other details, if any
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EXHIBIT-C Sheet 1of 3 FORMAT FOR WELDING PROCEDURE SPECIFICATION (WPS)
Company Name ___________________________ By ____________________________ Welding Procedure Specification No. _______ Date ______Supporting PQR No. (S) _______ Revision No. ________________________ Date ______________ Welding Process (es) _________________________Type (s) ____________________________ (Automatic, Manual, Machines or Semi Auto)
JOINTS Joint Design Backing (Yes) ______________________________ (No) ____________________ Backing Material (Type) _______________________________________________ Sketches Production Drawings. Weld Symbols Written Description should show the general arrangement of the parts to be welded. Where applicable, the root specing and the details of weld groove may be specified. (At the option of the Manufacturer sketches may be attached to illustrate joint design weld layers and bead sequence e.g. for notch toughness procedures, for multiple process procedures, etc.)
BASE METALS P.No. _________ Group No. OR to P. No _______ Group No.
Specification type and grade _____________________________________________ to Specification type and grade ___________________________________________ OR Chem. Analysis and Mech. Prop. _______________________________________ to Chem. Analysis and Mech. Prop. ______________________________________ Thickness Range: Base Metal : Groove _______________________________ Fillet Deposited Weld Metal: Groove ____________________ Fillet Pipe Dia Range: Groove: _____________________________ Fillet Other
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EXHIBIT - C Sheet 2 of 3 FILLER METALS F.No. _________________________ Other _______________________________ A.No. _________________________ Other ________________________________ Spec. No. (SFA) AWS No. (Class) Size of filler metals (Electrodes, Cold Wire, Hot Wire etc.) Electrode-Flux (Class) Flux Trade Name Consumable Inset Each base metal/filler metal combination should be recorded individually. WPS NO. ______Rev. ___
POSITIONS: Position (s) of Groove Welding Progression : UP Position (s) of Fillet PREHEAT Preheat Temp. Min. Interpass Temp. Max. Down
POSTWELDED HEAT TREATMENT Temperature Range Time Range GAS Shielding Gas (es) Percent Composition (mixtures) Flow Rate
Preheat Maintenance
Gas Backing Trailing Shielding Gas Composition
ELECTRICAL CHARACTERISTICS Current AC or DC Amps (Range) Polarity Volts (Range)
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This information may be listed in a tabular form similar to that shown below). Tungsten Electrode Size and Type (Pure Tungsten, 2% Ceriated, etc) Mode of Metal Transfer for GMAW (Spray arc, short circuiting arc, etc.) Electrode Wire feed speed range
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EXHIBIT - C Sheet 3 of 3 TECHNIQUE String or Weave Bead ___________________________ Orifice or Gas Cup Size ___________________________ Initial and Interpass Cleaning (Brushing, Grinding, etc.) Method of Back Gouging ______ Oscillation ______________________ Contact Tube to Work Distance Multiple or Single Pass (per side) Multiple or Single Electrodes Travel Speed (Range) ________ Peening _____________________ Other Travel Speed Range
Weld Layer(s)
Process
Filler Metal
Current Type Polarity Amp. Range
Volt Range
Others
Class
Dia.
e.g. Remarks, Comments, Hot wire Addition, Technique Torch Angle, etc.
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EXHIBIT-D Sheet 1 of 2 FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR) RECORD ACTUAL CONDITIONS USED TO WELD TEST COUPON Company Name Procedure Qualification Record No. WPS No. Welding Process (es) Types (Manual, Automatic, Semi-Auto) Date
JOINTS Groove Design of Test Coupon

(For combination qualification the deposited weld metal thickness shall be recorded for each Filler metal or process weld)
BASE METALS Material Sepc. Type of Grade P.No. to P.No. Thickness of Test Coupon Diameter of Test Coupon Other FILLER METALS Weld Metal Analysis A No. Size of Filler Metal Filler Metal E.No. SFA Specification AWS Classification Other ELECTRICAL CHARACTERISTICS POSITION Position of Groove Weld Progression (Uphill, Downhill) Other Current Polarity Amps. Tungsten Electrode Size Other GAS Type of Gas on Gases Composition of Gas Mixture Other POST WELD HEAT TREAT MENT Temperature Time Other
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EXHIBIT-D Sheet 2 of 2 TECHNIQUE PREHEAT Preheat Temp. Interpass Temp. Travel Speed String or Weave Bead Oscillation Multipass or Single Pass (per side) Single or Multiple Electrodes Other GUIDED BEND TESTS Type of figure no. Result
TOUGHNESS TEST Specimen no. Notch location Notch type Test temperature Impact value % shear Mils Break No Break Lateral exp. Drop weight
FILLET WELD TEST Result - Satisfactory: Yes ____ No Marco Results OTHER TESTS Type of Test Deposit Analysis Other Welders Name Test Conducted by Clock No. Stamp No Laboratory Test No. Penetration into Parent Metal: Yes No
We certified that the statements in this record are correct and test welds were prepared, welded and tested in accordance with the requirements of Section IX of the ASME Code. Date Manufacturer By (Detail of record of tests are illustrative only and may be moulded to conform to the type and number of tests required by codes and specifications). Document No. 11-0330G01-01-09-02-011 SHEET 21 of 26
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EXHIBIT - E Sheet 1 of 2 FORMAT FOR MANUFACTURER S RECORD FOR WELDER OR WELDING OPERATOR QUALIFICATION TESTS Welder Name Using WPS No. Variable Process Process Type Backing (metal, Weld metal, flux, etc) Material Spec. Thickness Groove Filler Diameter Groove Filler Filler Metal Spec. No. Class F.No. Position Weld Progression Gas Type Electrical Characteristics Current Polarity to to Check No. Rev. Record Actual Values Used in qualification Qualification Range Stamp. No.
The above welder is qualified for the following ranges
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EXHIBIT-E Sheet 2 of 2 Guided Bend Test Results Type and Fig. No. Result
Radiographic Test Results For alternative qualification of groove welds by radiography Radiographic Results Fillet Weld Test Results Fracture Test (Describe the location, nature and size of any crack of tearing of the specimen Length and Per Cent of Defects Macro Test Fusion Appearance - Fillet Size (ing) x Convexity or Concavity inches %
Test Conducted by _________________________ Laboratory - Test No. _________________ We certify that the statements in this record are correct and that the test welds were prepared. Welded and tested in accordance with the requirements of Section IX of the ASME Code. Date Organization By (Details of record tests are illustrative only and may be modified to conformation to the type & number of tests required by the Code). Note: Any essential variables in addition to those above shall be recorded.
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EXHIBIT - F RADIOGRAPHIC PROCEDURE QUALIFICATION RECORD FOR PIPE WELDING 1. Location 2. Date of Testing 3. Name of the Contractor/Agency 4. Material: Carbon steel/Alloy Steel/Stainless Steel 4 A. Technique: DWSI/SWSI/DWDI 5. Diameter & Thickness: 6. Type of Weld Joint: 7. Radiation Source: 8. Intensifying Screens/Lead Screens: 9. Geometric Relationship: 10. Limit of Film Coverage: 11. Film Type and Make: 12. Exposure Time: 13. Processing: 14. Density: 15. Sensitivity: 16. * Type of penetrameter: (Source side) 17. Type of penetrameter: (Film side) Signature of Contractor/Agency with Seal Approval of Wood Group Kenny / Owners inspector x x Ref. Para regarding recommended practice on placement of penetrameters Article 22, SE 142, ASME Sec. V. For Random Radiography lines placement of penetrameters as per Article 2, ASME, Sec. V is permitted.
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EXHIBIT - G WELDERS IDENTIFICATION CARD 1. Name: Photograph 2. Identification: 3. Date of Testing: 4. Process 5. Thickness range 6. Diameter range 7. F.No. 8. Date of approval of welding 9. Position(s)
Approved by:
Employers Signature with Seal
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EXHIBIT-H Type of Source and Films to be used for RADIOGRAPHY
SHOP WELDED JOINTS NOMINAL WALL THICKNESS (T) in mm T> 19 All Materials Carbon Steel All other materials Carbon Steel Other than Inspection Class IV All other materials and Carbon Steel of Inspection Class IV SOURCE Gamma Ray Gamma Ray Gamma Ray FILM : CEN Class C5 C4 C3
IN-SITU WELDS SOURCE Gamma Ray Gamma Ray Gamma Ray FILM : CEN Class C5 C4 C3
8 <T < 19
<8
Gamma Ray
C3
Gamma Ray
C3/C 1
X-Ray
C4
X-ray with C4 or Equivalent to be used. Gamma Ray (Se 75 Source only) with C3/C2 Equivalent may be allowed only if in the assessment of the owners inspector, Joints are inaccessible for Xray equipment and radiographic sensitivity is achieved.
Note: Integral to above table 1) Films slower than the above may have to be used, if required radiographic sensitivity is not achieved consistently. COMPARISON OF FILMS FROM DIFFERENT MANUFACTURERS CEN Classification --C5 C4 C3 C2 C1 --KODAK CX AA400 T200 MX125 M100 DR5O SR** AGFA D8 D7 D5 D4 D3 D2 --FUJI --1X100 1X80 1X50 --1X25 ---
* * Special films, extremely fine grain & very high resolution
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CLIENT JOB NO.
8 019
STANDARD SPECIFICATIONS FOR NON DESTRUCTIVE REQUIREMENTS OF PIPING
TOTAL SHEETS
DOCUMENT NO
11
0330G01
01
08
02
0 A REV
28.06.11 24.06.11 DATE
MH MH PREP
ASD ASD CHK
AD AD APPR
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TABLE OF CONTENT 1. GENERAL 2. VISUAL EXAMINATION 3. NON DESTRUCTIVE EXAMINATION 4. TABLE-I (with applicable Notes to Table-I) 3 3 6 6
NON DESTRUCTIVE EXAMINATION REQUIREMENT OF PIPING
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Abbreviations: DP/LP MP CS AS SS ASTM ASME IBR PMS : : : : : : : : : Dye/Liquid Penetrant Magnetic Particle Carbon Steel Alloy Steel Stainless Steel American Society for Testing & Materials American Society of Mechanical Engineers Indian Boiler Regulations Piping Material Specification
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1.0 1.1
GENERAL SCOPE This specification covers the general requirements for non destructive examination of shop & field fabricated piping.
1.2
RELATED CODES & ENGINEERING STANDARDS Referred codes / standards are as follows. Latest editions of the Codes/Standards referred to shall be followed. a) b) c) d) e) f) g) h) i) ASME Boiler & Pressure Vessel Codes, Section V & VIII (Div. 1) including addenda. ASME B31.3 ASME B16.5 ASME B16.34 Standard Piping Material Specification, 11-0330G01-01-08-02-001 Welding Specification Charts for Piping Classes Standard Specification for Fabrication & Erection of Piping ASTM E1O Welding Specification for Fabrication of Piping, 11-0330G01-01-09-02-011
2.0 2.1 a) b) c)
VISUAL EXAMINATION Weld shall be visually inspected wherever accessible in accordance with the following requirements: Internal misalignment Cracks or lack of fusion Incomplete penetration (For other than 100% radiography butt-weld) 1.5 mm or less not permitted Depth shall not exceed the lesser of 0.8mm or 0.2 times thickness of thinner component joined by butt-weld. The total length of such imperfections shall not exceed 38 mm in any 150 mm of weld length not permitted
d)
Surface porosity and exposed slag inclusions (For nom. wall thickness 4.7 mm and less) Concave root surface (Suck up)
e)
For single sided welded joints, concavity of the root surface shall not reduce the total thickness of joint, including reinforcement, to less than the thickness of the thinner of the components being joined. 2.5 mm or less. Document No. 11-0330G01-01-08-02-019 SHEET 4 of 8
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f)
Weld ripples irregularities
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g)
Lack of uniformity in bead width Lack of uniformity of leg length Unevenness of bead Weld undercutting
2.5 mm or less.
h)
2.5 mm or less.
i) j)
2.0 mm or less. 0.8 mm or 1/4 thickness of thinner components joined by butt weld, whichever is less. (shall be smooth finished) 1.5 mm or less 2.5 mm or less
k) l) m)
Overlap Bead deflection
External weld reinforcement and internal weld protrusion (when backing rings are not used) shall be fused with and shall merge smoothly into the component surfaces. The height of the lesser projection of external weld reinforcement or internal weld protrusion from the adjacent base material surface shall not exceed the following limits: Wall thickness of thinner component joined by butt weld (mm) 6.4 and under Over 6.4 -12.7 Over 12.7 -25.4 Over 25.4 Weld reinforcement or internal weld protrusion (mm) max 1.6 3.2 4.0 4.8
n) p)
Throat thickness of fillet welds: Nominal thickness of the thinner component x 0.7 or more. Flattening Flattening of a bend, as measured by difference between the nominal outside diameter and minimum or maximum diameter at any cross section shall not exceed 5 % of the nominal outside diameter of pipe.
q)
Reduction of wall thickness Reduction of wall thickness of a bend, as measured by difference between the nominal thickness and minimum thickness shall not exceed 10 % of the nominal wall thickness of pipe.
2.2
Welds having any of imperfections which exceed the limitations specified in various clauses of 2.1 shall be repaired by welding, grinding or overlaying etc. Number of times of repair welding for the same weld, however shall conform to applicable notes to Table 1-Note 6(b) b.5. NON DESTRUCTIVE EXAMINATION The type and extent of weld examination shall be in accordance with Table-1. All visual and supplementary methods of girth weld examination shall be in accordance with ASME B31.3 & the requirements of this standard specification. Welds between dissimilar materials shall be examined by method & to the extent required for the material having the more stringent examination. Document No. 11-0330G01-01-08-02-019 SHEET 5 of 8
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3.0 3.1
3.2
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4.0
TABLE-I (with applicable notes) TABLE 1: CLASS, TYPE & EXTENT OF WELD EXAMINATION INSPECTION CLASS: I
TYPE OF WELD EXAMINED
PRESS. SERVICE MATERIAL (NOTE 3) P.NO. TEMP. DEG.C CLASS B16.5/ B16.34
APPLICABLE PIPING CLASS
TYPE OF EXAMINATION
GIRTH BUTT WELD
SOCKET WELD (NOTE 2)
FAB. ATTACH - MENT WELD BRANC H WELD (NOTE 1)
FAB. WELDS OF MITRES / REDUC.
INSPN. CLASS
10
11
12
13
a) VISUAL 1A1, 3A1, 150# CARBON HYDROCARBON I VAPOURS & GAS SERVICES STEEL -29 1 TO 186 IJPTO 10.55 KG/CM2 c) LP, MP (NOTE4, 6, 9) 6A1 b) RADIOGRAPHY
100%
100%
100%
100%
100%
20%
100%
20%
20%
CURPO NICKEL
34
-29 TO 60
d) HARDNESS
NOTE-7
NOTE 7
NOTE-7
NOTE -7
NOTE-7
REMARKS FOR ABOVE TABLE: 1. MITRES & FABRICATED REDUCERS ARE PERMITTED ONLY IF SPECIFIED TN PMS.
Applicable Notes to Table-I 1. Branch welds shall consist of the welds between the pipe & reinforcing element (if any), nozzles & reinforcing element and the pipe & nozzle under the reinforcing element. Reinforcing element to be interpreted as pads, saddles, weldolets, sockolets etc. Seal welds of threaded joints shall be given the same examination as socket welds. Unless specifically stated, all materials shall be for Non-IBR service. Magnetic Particle & the Liquid Penetrant method of examination shall be in accordance with Section V of the ASME Boiler and Pressure Vessel Code, Article VII and VI respectively. The entire area of the accessible finished weld surface shall be examined. Selected root runs, subject to a maximum of 10%, before finished weld, may also be examined, at the discretion of the engineer-in-charge. a) Wherever MP / LP testing is specified, either MP or LP test may be used. But wherever only MP test is specified, LP method of examination may be used only if MP examination is impracticable in the field as concurred by site-in charge.
2. 3. 4.
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b) Random 10% of Liquid Penetrant / Magnetic Particle test shall mean testing, by applicable test, one weld for each ten welds or less made by the same welding procedure or operator or both. Similarly Random 20% shall mean testing, by applicable test, one weld for each five welds or less made by the same welding procedure or operator or both. c) When Liquid Penetrant examination is specified, the surface shall be free of peened discontinuities. Abrasive blast cleaning shall be followed by light surface grinding prior to Liquid Penetrant examination. d) Inspection shall be performed in the welds excluding those for which radiography has been done. 5. Radiography: a) Random 10% or 20% radiography shall mean examining not less than one from each 10 welds or less in case of Random 10% radiography or one from each five welds or less in case of Random 20% radiography made by the same welding procedure or welder or both. Irrespective of percentage, no. of welds to be radiographed shall be minimum 1. However first two welds made by each welder shall also be radiographed in case of Random radiography. Welds selected for examination shall not include flange welds and shall be radiographed for their entire length. However, where it is impossible or impracticable to examine the entire weld length of field welds for either random or 100% radiography, and if the same impossibility is agreeable to sitein- charge, then a single 120 deg. exposure of the weld length may be given a Magnetic Particle test or Liquid Penetrant test. However in such cases for ferro-magnetic materials, only MP test shall be acceptable for classes higher than 600#. b) In-process examination shall not be substituted for any required radiographic examination. c) Number of radiographs per one circumferential weld shall be as per ASME Sec.V Articles 2 and 22. 6. When radiography or other non destructive inspection is specified, acceptance criteria for repairs or defects shall be as follows: a) In case of 100% examination, any unacceptable weld shall be repaired and reinspected. b) If required random examination reveals a defect requiring repair, then: b.1 Two additional examinations of same type shall be made of the same kind of item (if welded joint, then by the same welding procedure or operator or both). b.2 If the group of items examined as required by b.1 above is acceptable, the items requiring repair shall be repaired or replaced and reexamined as required and all items represented by this additional examination shall be accepted. b.3 If any of the items examined as required by b.1 above reveals a defect requiring repair, two further comparable items shall be examined for each defective item found by examination. b.4 If all the items examined as required by b.3 are acceptable, the items requiring repair shall be repaired or replaced and reexamined as required, and all items represented by this further examination shall be accepted. b.5 Number of times repair welding could be done for the same weld before acceptance shall be as follows: Material C.S. upto 300 # C.S.above300# Killed steel b.6 b.7 No. of times repair welding is allowed 3 or less 2 or less 2 or less
Welds not found acceptable for allowed number of times of repair as per b.5 above shall be replaced and reexamined. If any of the items examined as required by b.4 above reveals a defect requiring repair, all items represented by these examinations shall be either: - repaired or replaced and reexamined as required. - fully examined and repaired or replaced as necessary, and reexamined as necessary. NON DESTRUCTIVE EXAMINATION REQUIREMENT OF PIPING Document No. 11-0330G01-01-08-02-019 SHEET 7 of 8
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7.
Hardness Test: a) Hardness test shall be in accordance with ASTM specification E10. Hardness tests of the heat affected zone shall be made at a point as near as practicable to the edge of the weld. One test per weld shall be performed. Hardness test where specifically called out in Table-I of this specification or in PMS, shall be carried out irrespective of thickness and to the extent (%age) as mentioned therein. All welds which are given heat treatment shall be hardness tested. Hardness test shall be performed after final heat treatment. A minimum of 10% of welds of hot formed and hot bent materials in each heat treatment batch which are furnace heat treated and 100% of those which are locally heat treated, shall be hardness tested. For C-0.5 Mo steels, a minimum of 10% of welds shall be hardness tested. Hardness test requirement not covered in b) & e) above shall be as per ASME B3l .3. The hardness limit applies to the weld and heat affected zone. Following hardness values shall be maintained: Base Metal Group Maximum Hardness (BHN/RC) CS 238BF1N/RC22
b) c) d)
e) f) g)
8.
For IBR service lines, following IBR requirements shall apply in addition to the notes 4, 5, 6, 7, 12 and Table I. In case of conflict between above notes and these requirements, the more stringent ones shall apply. IBR piping shall be erected of IBR inspector approved material and construction procedure. Erected piping shall be hydrotested, inspected and approved by IBR inspector. a) Piping over 102 mm (4) bore: 10% of welds made by each welder on a pipeline with a minimum of two welds per welder, selected at random, shall be subjected to radiography. Piping 102 mm (4) bore and under, but not less than 38 mm (1-1/2) bore: Two percent of welds made by each welder on a pipeline with a minimum of one weld per welder, selected at random, shall be subjected to radiography or may be cut for visual examination and tests. Piping less than 38 mm (1.5) bore: Special tests are not normally required but 2% of welds by each welder on a pipe line may be cut out from the pipeline for the visual examination and bend tests. Retests: If any test specimen is unsatisfactory, two further weld specimens for retests shall be selected from the production welds and subjected to tests. In the event of failure of any retest specimens, the production welds carried out by this welder subsequent to the previous test shall be given special consideration.
b)
c)
d)
9.
For fabricated fittings LP test shall be done on the final pass of welding only, in addition to visual examination. For mitres and fabricated reducers, LP / MP test shall be done on root pass in addition to radiography applicable to circumferential joint of respective piping class. For branch connections, LP/MP test shall be done on root pass and final pass. As per TAC requirements, 10% of the butt weld joints shall be radiographed; however, 50% of these butt weld joints shall be field weld joints.
10.
11. 12.
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CLIENT JOB NO.
TECHNICAL SPECIFICATION FOR PAINTING

TOTAL SHEETS
27 007
DOCUMENT NO
11
0330G01
01
09
02
0 A REV
28.06.11 24.06.11 DATE
MH MH PREP
ASD ASD CHK
AD AD APPR
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TABLE OF CONTENT
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0
GENERAL .............................................................................................................................. 3 CODES & STANDARDS ........................................................................................................ 3 CONDITIONS OF DELIVERY ................................................................................................ 4 COMPOSITION OF THE PAINT PRODUCTS USED............................................................. 4 IDENTIFICATION ................................................................................................................... 5 SURFACE PREPARATION STANDARDS ............................................................................ 6 PREPARATION OF THE SURFACES ................................................................................... 6 METALLISATION................................................................................................................. 10 CARRYING OUT THE PAINTWORK ................................................................................... 10
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1.0 1.1
GENERAL These technical specifications shall be applicable for the work covered by the contract, and without prejudice to the provisions of various codes of practice, standard specifications etc. It is understood that contractor shall carry out the work in all respects with the best quality of materials and workmanship and in accordance with the best engineering practice and instructions of Engineer-In-Charge. Wherever it is stated in the specification that a specific material is to be supplied or a specific work is to be done, it shall be deemed that the same shall be supplied or carried out by the contractor. Any deviation from this standard without written deviation permit from appropriate authority will result in rejection of job.
1.2 1.2.1 1.2.2
SCOPE Scope of work covered in the specification shall include, without being limited to the following. This specification defines the requirements for surface preparation, selection and application of primers and paints on external surfaces of equipment, vessels, machinery, piping, ducts, steel structures, external & internal protection of storage tanks for all services, MS Chimney without Refractory lining and Flare lines etc. The items listed in the heading of tables of paint systems is indicative only, however, the contractor is fully responsible for carrying out all the necessary painting, coating and lining on external and internal surfaces as per the tender requirement. Extent of Work
1.2.3
1.2.3.1 The following surfaces and materials shall require shop, pre-erection and field painting: a. All uninsulated C.S. & A.S. equipment like columns, vessels, drums, storage tanks(both external & internal surfaces), heat exchangers, pumps, compressors, electrical panels and motors etc. b. All uninsulated carbon and low alloy piping, fittings and valves (including painting of identification marks), furnace ducts and stacks. c. All items contained in a package unit as necessary.
d. All structural steel work, pipe, structural steel supports, walkways, handrails, ladders, platforms etc. e. Flare lines, external surfaces of MS chimney with or without refractory lining and internal surfaces of MS chimney without refractory lining. f. Identification colour bands on all piping as required including insulated aluminium clad, galvanised, SS and nonferrous piping.
g. Identification lettering/numbering on all painted surfaces of equipment/piping insulated aluminium clad, galvanized, SS and non-ferrous piping. h. Marking / identification signs on painted surfaces of equipment/piping including hazardous service. i. Supply of all primers, paints and all other materials required for painting (other than Owner supplied materials) Over insulation surface of equipments and pipes wherever required. Painting under insulation for carbon steel, alloy steel and stainless steel as specified. Painting of pre-erection/fabrication and Shop primer.
j. k. l.
m. Repair work of damaged pre-erection/fabrication and shop primer and weld joints in the field/site before and after erection as required. TECHNICAL SPECIFICATION FOR PAINTING Document No. 11-0330G01-01-09-02-007 SHEET 3 of 27
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n. All CS Piping, equipments, storage tanks and internal surfaces of RCC tanks in ETP plant. 1.2.3.2 The following surfaces and materials shall not require painting in general. However, if there is any specific requirement by the owner, the same shall be painted as per the relevant specifications: a. Uninsulated austenitic stainless steel. b. Plastic and/or plastic coated materials c. Non-ferrous materials like aluminum. 1.2.4 Documents
1.2.4.1 The contractor shall perform the work in accordance with the following documents issued to him for execution of work. a. Bill of quantities for piping, equipment, machinery and structures etc. b. Piping Line List. e. Painting specifications including special civil defence requirements. 1.2.5 Unless otherwise instructed, final painting on pre-erection/ shop primed pipes and equipments shall be painted in the field, only after the mechanical completion, testing on systems are completed as well as after completion of steam purging wherever required. Changes and deviations required for any specific job due to clients requirement or otherwise shall be referred to Wood Group Kenny for deviation permit. CODES & STANDARDS Without prejudice to the specifications of the contract, the following codes and standards shall be followed for the work covered by this contract. IS: 5 IS: 101 IS: 161 IS: 2074 IS: 2339 IS: 2379 IS: 2932 Colors for ready mixed paints and enamels. Methods of test for ready mixed paints and enamels, Heat resistant paints. Specifications for ready mixed paint, red oxide zinc chrome priming. Aluminum paint for general purposes in dual container. Color code for identification of pipelines. Specification for enamel, synthetic, exterior (a) undercoating. (b) Finishing.
1.2.6
2.0
3.0
CONDITIONS OF DELIVERY Packaging Every recipient will be fitted with a hermetically-sealed lid with an opening that is sufficiently large to allow the contents to be stirred: the outside and inside are protected against oxidation, and, the lid, are marked with a strip of color identical to the contents.
4.0
COMPOSITION OF THE PAINT PRODUCTS USED a) Quality The composition and quality of the products may not differ from batch to batch. A batch is all of the products of a specified manufacture. If the analyses of products bring to light that the TECHNICAL SPECIFICATION FOR PAINTING Document No. 11-0330G01-01-09-02-007 SHEET 4 of 27
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composition does not conform to the specifications of the paint manufacturer, the OWNER may refuse to use this batch of products. The paint products must comply with the following conditions x They must have the viscosity necessary for the described use and the established condition: use of the brush - paint roller (spray gun only for special cases and in the workshop)
b) Quality control - Sampling While the works are in progress on the construction site, the OWNER may carry out sampling on the paint being used for the purpose of checking conformity. The paint products must be made available free of charge to the laboratory or the approved supervisory body in sufficient quantities so that all the tests can be carried out on the same batch. If analyses reveal a non-conformity in the composition of the products used (tolerance of + 3 % of the dosage of every component), the OWNER may refuse application of the product under consideration, halt the work and have the nonconforming product already applied removed. Before proceeding the work, a product that does conform will be required. The only Purpose of the analysis is to reveal any nonconformity of the composition of the products. Their purpose is therefore not to assess the quality of the different components. The analyses concerned are not acceptance tests of the products supplied and in no way affect the obligations of the contractor specified in the contract towards the OWNER. 5.0 IDENTIFICATION Every recipient will bear the following information: x x x x x x Name of the manufacturer Date and number of manufacture Name of the product type Batch no Net weight of the produced or the contents of the recipient Date of the expiry.
At the time of delivery, this packaging must bear labels in conformity with the legal stipulations in force. Leaving the site after work After completion of a job a general clean-up shall be carried out by the Contractor to remove all debris, materials or irregularities that his work has brought to the site so that it is left tidy: The restoration work includes among other things: x x x x The removal of abrasives. The removal of the different protective coverings. The Contractor will make the required repairs to any damage after refitting the supports. The removal of paint and cleaning of the stains on the floor.
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6.0
SURFACE PREPARATION STANDARDS Following standards shall be followed for surface preparations: 1 2 3 4 5. Swedish Standard Institution- SIS-05 5900-1967 Steel Structures Painting Council, U.S.A. (Surface Preparation Specifications (SSPC-SP) British Standards Institution (Surface Finish of Blast-cleaned for Painting) BS-4232. National Association of Corrosion Engineers. U.S.A. (NACE). IS-1477-1971 (Part-1) - Code of Practice for Painting of Ferrous metals in Buildings. (Part 1, Pre-treatment) a) The contractor shall arrange, at his own cost to keep a set of latest edition of above standards and codes at site. The paint manufacturer's instruction shall be followed as far as practicable at all times. Particular attention shall be paid to the following: x x x x Proper storage to avoid exposure as well as extremes of temperature. Surface preparation prior to painting. Mixing and thinning. Application of paints and the recommended limit on time intervals between coats. c) Any painting work (including surface preparation) on piping or equipment shall be commenced only after the system tests have been completed and clearance for taking up painting work is given by the OWNER, who may, however, at his discretion authorize in writing, the taking up of surface preparation or painting work in any specific location, even prior to completion of system test.
b).
7.0 7.1
PREPARATION OF THE SURFACES General Specifications The cases that occur in practice on building sites, with regard to painted surfaces, can be broken down as follows: x x x Material of which the oxide content disappears by natural oxidation. Material that has already been covered with a layer of paint in the workshop. Material that is covered with old paint layers that show different degrees of weathering.
Good preparation oldie surface is the best guarantee for good anti-corrosion protection. Paintwork may never begin until the surface to be treated is dry and is independent of the base coat and cleared of dirt, dust, rust, scale, grease, salt attack, cement powder, cement mud-scale, sand, oil, etc. Based on the environmental conditions of coastal and saline nature, the Painting specification for station pipes defines the complete requirements like: x x Surface preparation standards like NACE etc. Sand blasting process TECHNICAL SPECIFICATION FOR PAINTING Document No. 11-0330G01-01-09-02-007 SHEET 6 of 27
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Color Codes for piping Paint materials types and their DFT measurement. Selection and application of paints on external surfaces.
The pipeline passes through the coastal and marine environment, the Table-4 of this specification to be followed for the painting works. The method of preparation of the surface will be implemented in accordance with the preparation methods described below: x x x Cleaning (bright blast-cleaning); Mechanical cleaning; Manual derusting.
The Contractor should have the required material at his disposal to clean the surfaces to be coated thoroughly in accordance with the preparation methods regardless of the form or the condition of such surfaces. The cleaning devices that might be damaged during the surface preparation shall be screened off by the Contractor. 7.2 Sandblasting Before beginning cleaning by blasting, the person carrying out the work will take the following measures: x x x x x x x Clear the steel surface of oil and/or grease; Ensure that each flange collar (section where the sealing is applied) is properly screened off against the blasting and the subsequent works; Check that no blasting grains can act into the pipes during this process. Any openings not sealed off must be screened off; Where there are valves, regulators and other devices, the manufacturer's identification plate will be dismantled so that all surfaces can be treated. The plate will then be put back again. Screen off all non-metal structures such as rubber where there is a filter; With valves, operators and other devices, care should be taken to ensure that no metal filings or paint get into the apparatus: The OWNER reserves the right to carry out part or all of these works himself.
To prevent rust forming quickly as the result of humidity on the blasted surface, cleaning by blasting may only be carried out when the temperature of the steel surface is at least 3C higher than the dew-point of the ambient air. Blasting may not be carried out if the relative degree of humidity exceeds 80%. The choice of the type of blasting medium used depends on local circumstances such as the possible presence of gas and the material to be blasted. The abrasive to be used must conform to the local low i.e. it may contain no carbon and less than 1% free silicon dioxide. The Sa 3 will always be requested and must at least reach Sa 2 during the initial stage of the paintwork. For blasting followed by metallisation, the surface preparation degree to be achieved is always Sa 3. The degree of cleanliness to be obtained will be inspected in accordance with the Swedish standard SVENSK STANDARD ISO 8501-1-1988 SS 05.5900. x Sa 3: surface blasted down to the bare metal; when the surface is inspected with a magnifying glass, scale, rust and foreign bodies must be completely removed and it should be possible to raise a metallic -shine on the treated surface. TECHNICAL SPECIFICATION FOR PAINTING Document No. 11-0330G01-01-09-02-007 SHEET 7 of 27
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Sa 2 1/2: blasted very carefully. Scale, rust and foreign bodies must be removed in such a way that anything left behind will only be visible as nuances (shading) or strips.
The blast-cleaning will be carried out by means of compressed air free of water and oil. After the blasting and before painting, the surface should be completely cleaned of blasting material and so forth with a soft brush, a dry cloth or dry compressed air. 7.3 Mechanical cleaning If sandblasting is not permitted or if the metal structures are not easily accessible for blasting or blasting for one reason or another is technically unfeasible, mechanical derusting can be used instead. With mechanical cleaning by means of chipping, rotating steel brushes and sanding discs, a degree of cleanliness St. 3 should be reached. St 3: removal of the old paint layers of which the adhesion leaves something to be desired and/or of which the paint layer no longer fulfils the requirements. If parts are present that are so corroded that St 3 is difficult to achieve, this should be notified to the OWNER representative prior to the start of the works.
N.B: St. 3 : means removal of every old paint layer. Retouching means local polishing with St. 3 or Sa 3 followed by application of the desired painting system. After mechanical cleaning, the surface should be made dust-flee with a cloth or a so brush, washed with an organic solvent and thoroughly dried off with a dry cloth (e.g. with 1.1.1. Trichoroethane such as Solvethane, Chloroethene). 7.4 Manual Derusting Manual derusting with the aid of scrapers. steel brushes, sandpaper etc. shall only be permitted in exceptional cases for local repairs. Any deviation there from must be requested from the OWNER/ OWNERs Representative. With manual derusting, a surface preparation degree St 3 must be obtained. The length of the handles of the equipment used may not exceed 50 cm. 7.5 Preparation of a surface covered with a layer of paint in the workshop. This layer is in general applied by the manufacturer, for example, on valves, regulators etc. Layers of this kind will be checked for their proper adhesion in accordance with ASTM D 3359, method A (Standard Test Method for measuring adhesion by tape test). The adhesion should be at least . If the paint layer shows less adhesion or is incompatible with the rest of the system it should be completely removed. If the paint layer is not removed, the Contractor accepts it in the state in which the coating is found and the guarantee remains in force. The adhesion does not have to be examined if system 63 has already been applied in the workshop on behalf of the OWNER. The Contractor, who must provide for the protection on the construction site, must therefore obtain the information regarding the treatment of the surface and the quality of the paint that was used and must, moreover, examine the adhesion of the layer on the construction site, the percentage of damage and weathering as well as the value of the preparation of the surface in the workshop together with the thickness thereof that must be supplemented if necessary.
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a)
Galvanized surface Galvanized surfaces, both old and new will be carefully roughened up. Every foreign body (concrete splatters, chalk marks, grease and oil stains, etc.) will be removed. Thereafter, rub the surfaces with abundant water and, if necessary, with cleaning products. To this end, nylon brushes will be used for every kind of dirt as well as for removing zinc salt residue. Thereafter, the surfaces will be treated in accordance with system 21. Where the zinc layer is lacking, it will be derusted manually to a degree of cleanliness St 3, after which a primer coat will be applied in accordance with system 22.
b) x x
Metallised surfaces treated with an impregnation layer degrease with the desired degreasing product: clean under high pressure or with a product prescribed by the paint supplier.
If the paint layer adheres well and is applied on a clean base, the painting system described may be continued. If the percentage of damage and weathering does not exceed 5 % m. retouching may be considered. These partial repairs will be carried out. If on the other hand, the percentage of damage does exceed 5 %/m or if the layer applied in the workshop comes loose the Contractor must draw the attention of the OWNER to this and carry out the complete application system. 7.6 Preparation of surfaces covered with earlier paint layers that show different degrees of weathering. If the surfaces do not show deep weathering limited to the spread of rust by small pitted areas or nonpenetrative rust in spots, it will very often be sufficient to clean the surfaces with abrasives or with an abrasive disc, then to rub them down with steel wool, remove the dust and wash off. If thick rust appears, in spots, scale rust and active rust canker, this should be removed with needle hammers or stripped away directly by blasting, removing the dust and washing oft. 7.7 Preparation of concrete or cement plaster surfaces Remove unsound paint layers and loose components with scrapers, blades or rotating steel brushes. Thoroughly clean the entire surface with water containing ammonia. Thoroughly remove moss, algae and fungal growths. Where these growths have been removed, treat the area with a fungicide in accordance with the instructions for use. Once the entire area is completely dry, brush off the dead residue of moss, algae and fungus with a hard brush. In the case of reinforcement steel that has been laid bare, remove as rust, dust and grease as possible and treat with a printer coat. When painting concrete surfaces, they must first be checked for cracks. Cracks larger than 0.3 mm must be repaired with an appropriate system in accordance with the type and extent of the repairs (e.g. injection with epoxy mortar). Repair damage such as cracks and bursts to concrete parts with a two-component mortar or preferably with micro-mortars. Finally check the alkalinity of the surface with the aid of litmus paper and neutralize it if necessary. 7.8 Use of solvents It is sometimes necessary to use solvents when the surfaces to be painted are streaked with grease or oil. In this case a suitable organic solvent should be applied. The operation should be carried out with the aid of clean brushes or rags and clean solvent. All the legal specifications in connection with solvents etc. must be adhered to. The OWNER/OWNER's Representative will be informed in advance of any toxicity or flammability. All measures must be taken to prevent any risk of fire and to nick out any possibility of poisoning (ventilation). The Contractor will provide drip collectors to keep the environment free of pollution.
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7.9
Condition of the metal after stripping The Contractor must call in a representative of the OWNER/OWNER's representative or of the Approved supervisory Body responsible for checking the condition of the metal during stripping and informing the OWNER/OWNER's representative immediately of any damage that he might have noticed. x x x Deep corrosion of the plates - rivets - bolts Faulty welding Fittings that appear to be dangerous because of their age. Removing coating from surface pipelines The Contractor must have the equipment necessary for the removal of asphalt from the pipe without damaging the latter (scratching, impact, etc,). The Contractor undertakes to carry out the work in accordance with an approved procedure.
7.10
8.0 8.1
METALLISATION Applying the metallisation Metallisation must be carried out in accordance with ISO 2063, Metallisation is carried out as rapidly as possible after blasting in order to limit corrosion of the pipes (max. 3 hours later). With metallisation, a surface preparation degree Sa 3 is compulsory. The roughness of the blasted surfaces should be from 25 to 50 R Max. x x The metallising is always carried out on dry parts in good weather conditions (maximum relative humidity 80 %); For metallisation, a wire composed of 85 % zinc and 15 % aluminum with a minimum guaranteed degree of purity of 99.5 % is used (subject to other specifications). The application thereof is always carried out in accordance with the conditions of the manufacturer and may at all times be submitted to the OWNERs representative. The sealant should be applied maximum 3 hours alter metallisation. The sealant must be thinned and applied as per the present specifications. A visual inspection whereby the sealant completely covers the metallisation will suffice here. When evaluating the metallisation, a negative deviation from the minimum coating thickness, to 80 for 20% of the measurements will be permitted.
x x x 9.0 9.1
CARRYING OUT THE PAINTWORK Conditions for carrying out paintwork Painting may not be carried out in unsuitable conditions. All preparatory work and painting may only he carried out in dry weather and at a minimum temperature of 10C, except for special eases requested by the OWNER's Representative. Unless otherwise stipulated in the specifications of the paint supplier, application of the paint is forbidden if it is forecast that the temperature will fall to below 0C before the paint is dry. The temperature of-the surface to be painted must be at least 3C higher than the dew point of the ambient air. Application of the paint is also not permitted if there is a danger that the coat of paint will not be dry before dew or condensation sets in. The work must be stopped: TECHNICAL SPECIFICATION FOR PAINTING Document No. 11-0330G01-01-09-02-007 SHEET 10 of 27
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x x
If the temperature of the surface to be painted is higher than that described by the supplier. In rain, snow, mist or fog or when the relative humidity is higher than 80 %.
Coats that have not yet dried and have been exposed to frost, mist, snow or rain and might thereby be damaged must be removed after drying and the surfaces must be repainted at the expense of the Contractor. Working in direct sunlight or in hot weather must be avoided, The first coat of paint must be applied maximum 3 hours after the preparation of the surface of the relative humidity of the air is between 50% and 80%. This time span may be increased to 6 hours if the relative humidity is less than 50%. In all cases, the preparation of the surface must exhibit degree Sa 3 and at the very least the appearance of degree Sa 2 at the time of painting. The coats of paint may only be applied on carefully cleaned surfaces that must be dry and free of grease and dust. 9.2 Special conditions Painting may be carried out when the Contractor can be sure that the instructions of the paint supplier have been scrupulously followed with regard to the parameters in the following (non-exhaustive) list: x x x x x Ambient temperature. Surface temperature. Relative humidity. Dew point. Drying times.
The Contractor must in this respect be able to produce the instructions for the paint on the site. The OWNER/CONSULTANT will guarantee 100% supervision in this regard during the execution of the work. In addition, the paintwork may only be carried out to a minimum ambient temperature of 5C and/or to a maximum relative degree of humidity of 85 %. Application of the paint is also not permitted if there is a danger that the coat of paint will not be dry before dew or condensation sets in. 9.3 Paint Materials Manufacturers shall furnish the characteristics of all paints indicating the suitability for the required service conditions. Primer and finish coats shall be of class-I quality and shall conform to the following: a) Primer (P-1) Red oxide Zinc Chromate Primer Type and Composition Single pack, Modified phenolic alkyd medium pigmented with red oxide and zinc chromate. 30 - 35% 25 microns/coat (min) 12-13 M/Lit/coat TECHNICAL SPECIFICATION FOR PAINTING Document No. 11-0330G01-01-09-02-007 SHEET 11 of 27
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Volume solids DFT Covering capacity
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b)
Primer (P-2) High build chlorinated rubber zinc phosphate primer Type and Composition Single pack, Chlorinated rubber medium Plasticised with unsaponifiable plasticiser pigmented with zinc phosphate 35- 40% 50 MICRONS/COAT (MIT) 7-8 M/Lit/Coat
Volume solids DFT Covering capacity c) Primer (P-3) High build zinc phosphate primer
Type and Composition
Single Pack, Synthetic medium, pigmented with zinc phosphate. 40-45% 35-50 microns/coat 10-12 M/Lit/coat Upto 100 C (dry)
Volume solids DFT Covering capacity Heat resistance d) Primer (P-4) Etch Primer / Wash Primer Type and Composition
Two pack Poly vinyl butyral resin medium cured with phosphoric acid solution pigmented with zinc tetroxy chromate. 7-8% 8-10 microns/coat 7-8 M/lit/coat
Volume solids DFT Covering capacity e) Primer (P-5) Epoxy Zinc Chromate Primer Type and Composition
Two pack, Polyamide cured epoxy resin medium pigmented with zinc chromate. 40%(min) 35 microns/coat (min) 11-12 M2/lit/Coat
Volume solids DFT Covering capacity f) Primer (P-6) Epoxy Zinc Phosphate Primer
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Two pack, Polyamide cured Epoxy resin medium pigmented with zinc phosphate. 40% 35 microns / coat (min) 11-12 M/lit/coat
Volume solids Covering capacity
g)
Primer (P-7) Epoxy high build M10 Paint (Intermediate Coat) Type and composition Two pack Poly Polyamide cured epoxy resin medium pigmented with micaceous iron oxide. Volume solids 7- 8% 50% 100 microns/coat (min) 5.0 M/lit/coat
Volume Solids DFT Covering capacity h) Primer (P-8)
Epoxy Red Oxide zinc phosphate primer Type and Composition Two pack. Polyamine cured epoxy resin pigmented with Red oxide and Zinc phosphate. 42% 30 microns/coat (min) 13-14 M/lit/coat
Volume solids DFT Covering capacity i) Primer (P-9)
Epoxy based tie coat (suitable for conventional alkyd based coating prior to application of acrylic polyurethane epoxy finishing coat) Type and Composition Two pack, Polyamide cured epoxy resin medium suitably pigmented. 50-60% 50 microns/coat (min) 10-12 M/Lit/Coat
Volume solids DFT Covering capacity j) Finish Coats (F-1) Synthetic Enamel Type and Composition
Single pack, Alkyd medium pigmented with superior quality water and weather resistant pigments 30-40% 20-25 microns/coat Document No. 11-0330G01-01-09-02-007 SHEET 13 of 27
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Volume solids DFT
Rev 0
Covering capacity k) Finish coat (F-2) Acrylic Polyurethane paint Type and Composition
16-18 M/lit/Coat
Two pack, Acrylic resin and iso-cyanate hardener suitably pigmented. 40% (min) 30-40 microns / coat 10-12 M/lit/ coat
Volume Solids DFT Covering Capacity l) Finish Coat (F-3) Chlorinated Rubber Paint Type and Composition
Single pack, Plasticised chlorinated rubber medium with chemical & weather resistant pigments. 30% 30 microns/coat (min) 1 0.0 M / lit /coat
m)
Finish Coat (F-4) High build chlorinated rubber M10 paint. Type and Composition Single pack Chlorinated rubber based high build pigmented with micaceous iron oxide. 40-50% 65-75 microns/coat 6.0-7.0 M / lit / coat
Volume solids DFT Covering capacity n) Finish coat (F-5)
Chemical Resistant Phenolic based Enamel Type and Composition Volume solids DFT Covering capacity Single pack phenolic medium suitably pigmented. 35-40% 25 microns/ coat 15.0 M /lit/ coat
o)
Finish Coat (F-6) Epoxy High Building Coating
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Two pack. Polyamide cured epoxy resin medium suitably pigmented. 60-65% 100 microns/coat (min) 6.0-6.5 M / lit / coat
p)
Finish Coat (F-7) High build Coal Tar Epoxy Type and Composition Volume solids DFT Covering capacity Two pack, Polyamine cured epoxy resin blended with Coal Tar. 65% (min) 100-125 microns/coat 6.0-6.5 M / lit / coat
q)
Finish Coat (F-8) Self-priming epoxy high build coating (complete rust control coating) Type and Composition Two packs. Polyamide-amine cured epoxy resin suitably pigmented. Capable of adhering to manually prepared surface and old coatings. 65-80% 125-150 microns/coat 4-5 M / lit / coat
Volume solids DFT Covering capacity r) Finish Coat (F-9) Inorganic Zinc Silicate coating Type and Composition
Two packs, self cured Ethyl silicate solvent based Inorganic Zinc coating. 60% (min) 65-75 microns/coat 8-9 M / lit / coat
s)
Finish coat (F-10) High build Black Type and Composition Single pack. Reinforced bituminous composition phenol based resin. 55-60% Document No. 11-0330G01-01-09-02-007 SHEET 15 of 27
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Volume solids
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DFT Covering capacity t) Finish Coat (F-11)
100 microns/coat (min) 5.50-6.0 M / lit / coat
Heat Resistant Aluminium Paint Suitable up to 250C. Type and Composition Duel container (paste & medium). Heat resistant spec varnish medium combined with aluminium flakes. 20-25% 20 microns/coat (min) 10-12 M / lit/ coat
Volume solids DFT Covering capacity u) Finish Coat (F-12)
Heat Resistant Silicon Paint suitable up to 400 C. Type and Composition Volume solids DFT Covering capacity v) Finish Coat (F-13) Synthetic Rubber Based Aluminium Paint Suitable up to 150C. Type and Composition Single Pack, Synthetic medium rubber medium combined with leafing Aluminium, 25 microns/coat 9.5 M /lit/ coat Single pack Silicone resin based with aluminium flakes. 20-25% 20 microns/coat (min) 10-12 M/lit/coat
DFT Covering capacity
Notes 1 Covering capacity and DFT depends on method of application Covering capacity specified above is theoretical. Allowing the losses during application, min specified DFT should be maintained. All paints shall be applied in accordance with manufacturer's instructions for surface preparation, intervals, curing and application. The surface preparation quality and workmanship should be ensured. Selected chlorinated rubber paint should have resistance to corrosive atmosphere and suitable for marine environment, All primers and finish coats should be cold cured and air-drying unless otherwise specified. Technical data sheets for all paints shall be supplied at the time of submission of quotations. In case of use of epoxy tie coat, manufacturer should demonstrate satisfactory test for inter coat adhesion. In case of limited availability of epoxy tie coat (P-9) alternate system may be used taking into the service requirement of the system. TECHNICAL SPECIFICATION FOR PAINTING Document No. 11-0330G01-01-09-02-007 SHEET 16 of 27
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2.
3.
4 5. 6.
Rev 0
7.
In case of F-6, F-9, F-1 1 & F-1 2 Finish Coats, No Primer are required.
MANUFACTURERS The paints shall conform to the specifications given above and Class-I quality in their products range of any of the-following manufacturers: i) ii) iii) iv) v) vi) Asian Paints (India) Ltd, Bombay Paints Berger Paints India ltd. Gaodlass Nerolac Paints Ltd. Jenson & Nicholson Shalimar Paints
STORAGE All paints and painting material shall be stored only in rooms to be provided by contractor and approved by OWNER/ OWNER 's Representative for the purpose. AlI necessary precautions shall be taken to prevent fire. The storage building shall preferably be separate from adjacent, building. A signboard bearing the words given below shall be clearly displayed outside: PAINT STORAGE No NAKED LIGHT highly -inflammable COLOR CODE FOR PIPING: i) ii) iii) For identification of pipelines, the color code as per Table -1 shall be used. The color code scheme is intended for identification of the individual group of the pipeline. The system of color coding consists of a ground color and color bands superimposed on it. Colors (Ground) as given in Table-2 shall be applied throughout the entire length of uninsulated pipes, on the metal cladding & on surfaces. Ground color coating of minimum 2m length or of adequate length not to he mistaken as color band shall be applied at places requiring color bands. Color bands shall be applied as per approved procedure. Line coating shall meet DIN 30670 standard for external coating and API 5L RP 2 for internal coating. The thickness for the epoxy should be 180 microns, adhesive 200 microns and balance should be PE The minimum coating thickness on weld seam shall be 3.2 mm and minimum coating thickness on body should be 3.2. Minimum thickness for liquid epoxy for internal coating should be 100 20 microns. Max design temperature for coating should be considered +80 C
V) VI) VII) VIII)
COLOR CODE: A) B) C) D) E) F) G) Ball Valve (Above Ground) : Off White Globe Valve (Above Ground) : Oxford Blue-RAL 5005, IS-519941005 Check Valve(Above Ground) : Oxford Blue-RAL 5005, IS-519941005 Launcher / Receiver : Yellow Golden Jib Crane / Trolley : Yellow Golden All underground valves shall have epoxy base coating after surface finish of SA 2:5 Valves and above ground pipes need to be properly blasted to achieve surface finish of Sa 2:5 before the application of paints. IDENTIFICATION SIGN i) Colors of arrows shall be black or white and in contrast to the color on which they are superimposed. Document No. 11-0330G01-01-09-02-007 SHEET 17 of 27
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ii)
Product names shall be marked at pump inlet, outlet and battery limit in a suitable size as approved by OWNER. Size of arrow shall be either of the following: Color Bands Minimum width of color band shall be as per approved procedure.
iii) a)
b)
Whenever it is required by the OWNER to indicate that a pipeline carries a hazardous material, a hazard marking of diagonal stripes of black and golden, yellow as per IS:2379 shall be painted on the ground color.
IDENTIFICATION OF EQUIPMENT All equipment shall be stenciled in black or white on each vessels, column, equipment, painting as per approved procedure. INSPECTION AND TESTING 1. All painting materials including primers and thinners brought to site by contractor for application shall be procured directly from manufactures as per specifications and shall be accompanied by manufacturer's test certificates Paint formulations without certificates are not acceptable. The painting work shall be subject to inspection by OWNER/ OWNER's Representative at all times. In particular, following stage wise inspection will be performed and contractor shall offer the work for inspection and approval at every stage before proceeding with the next stage.
2.
In addition to above record should include type of shop primer already applied on equipment e.g. Red oxide zinc chromate or zinc chromate or Red lead primer etc. Any defect noticed during the various stages of inspection shall be rectified by the contractor to the entire satisfaction of OWNER/ OWNER's Representative before proceeding further. Irrespective of the inspection, repair and approval at intermediate stages of work. Contractor shall be responsible for making good any defects found during final inspection/guarantee period/defect liability period as defined in general condition of contract. Dry film thickness (DFT) shall be checked and recorded after application of each coat and extra coat of paint should be applied to make-up the DFT specified without any extra cost to OWNER. PRIMER APPLICATION i. The contractor shall provide standard thickness measurement instrument with appropriate range(s) for measuring. Dry film thickness of each coat, surface profile gauge for checking of surface profile in case of sand blasting. Holiday detectors and pinhole detector and protector whenever required for checking in case of immerse conditions. ii. At the discretion of OWNER/ OWNER's Representative, contractor has to provide the paint manufacturers expert technical service at site as and when required. For this service, there should not be any extra cost to the OWNER. Final Inspection shall include measurement of paint dry film thickness, check of finish and workmanship. The thickness should be measured at as many points/ locations as decided by OWNER/ OWNER's Representative and shall be within +10% of the dry film thickness. The contractor shall produce test reports from manufacturer regarding the quality of the particular batch of paint supplied. The OWNER shall have the right to test wet samples of paint TECHNICAL SPECIFICATION FOR PAINTING Document No. 11-0330G01-01-09-02-007 SHEET 18 of 27
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iii.
iv.
Rev 0
at random for quality of same. Batch test reports of the manufacturer's for each batch of paints supplied shall be made available by the contractor. PAINT SYSTEMS The paint system should vary, with type of environment envisaged in and around the plants. The types of environment as given below are considered for selection of paint system. The paint system is also given for specific requirements. a) b) c) Normal Industrial Environment, Table 2. Corrosive industrial Environment, Table3 Coastal & Marine Environment, Table 4 Primers and finish coats for any particular paint systems shall be from same manufacturer in order to ensure compatibility.
Notes 1.
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Table 1
Colour Coding Scheme for Pipes and Equipment
SI. No. 1 a) b) 2 a) b) c) d) e) 3
Content Plant Air Instrument Air GASES Charge Gas Regeneration Gas Residue Gas LPG Acetylene ALL EQUIPMENT
Ground Color
First Color Band -
Second Color Band
COMPRESSED AIR Sky Blue Silver Grey Sky Blue French Blue
Canary Yellow Canary Yellow Canary Yellow Canary Yellow Canary Yellow
Signal Red White White Brilliant Green Dark violet
Smoke Grey Dark Violet French Blue White -
a) Such as vessels. columns, Light Grey exchangers, etc. containing nonhazardous fluids. b) All equipment containing hazardous Canary Yellow fluids c) Pipe carrying hazardous fluids Bar is to be replaced by Hazardous Marking as per IS: 2379 Clause 7.1C
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Table 2 Normal Industrial Environment (Above Ground)
Sl. Description No. 1.0 1.1
Temp. Range
Surface Preparation
Primer
Finish Coat
Total DFT
Remarks
External surface of equipment's and piping. -Do-10 to 20 SSPC-SP-3 One coat P-2 50 microns / coat (min) Two coats P1, 25 microns/ coat (min.) Two coats P3, 50 microns/ coat (min) Covered in Finish coat One coat F-4 65 microns/ coat (min) Two coats F3, 30 Microns/coat (min) Two coats of F-1, 20 microns/coat (min) 175 Primer and Finish coat can be applied at ambient temp. -
1.2
-Do-
21 to 60
SSPC-SP-6
90
1.3
-Do-
61 to 80
SSPC-SP-6
Two coats of F-13, 25 microns/coat (min)
150
1.4
-Do-
81 to 250
SSPC-SP-6
Three coats of F-11, 20 microns/ coat (min)
60
1.5
-Do-
251 to 400
SSPC-SP-10
Covered in Finish coat.
Three coats of F-12, 20 microns/ coat (min)
60
Paint application at ambient temp. curing at elevated temp. during start-up. -do-
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Table- 3 Corrosive Industrial Environment (Above Ground) SI. Description No. 1.0 I.1 Temp. Range Surface preparation Primer Finish Coat Total DFT Remarks
External surface of un-insulated and other equipment - do -10 20 to SSPC-SP-3 Two coat P-2, 50 microns) coat (min.) Two coats P-5, 35 microns / coat (min.) Covered in finish coat Two coat F3, 30 microns / coat (min.) Two coats F- 6, 100 microns coat (min.) Three coats F- 12, 20 Microns / coat (min.) 160 Primer and paint application at ambient temp. Paint application at ambient temp.
1.2
- do -
21 80
to
SSPC-SP10
270
I.3
- do -
81 400
to
SSPC-SP-3
60
Paint application. at ambient temp, and curing at 250'C for 4 hours,
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Table 4 Coastal and Marine Environment (Above Ground) SI. No. 1.0 1.1 Description Temp. Range Surface Preparation Primer Finish Coat Total DFT Remarks
External surface of equipments and piping. -do-10 to 60 SSPC-SP-3 Two coats P-2, 50 micron/ coat (min) Two coats F3, 30 Microns/coat (min.) 160 Primer and Finish coat application at Ambient temp. -do-
1.2
do -
61 80
to
SSPC-SP10
1.3
- do -
81 to 400
SSPC-SP-I0
Two coats P-5. 35 Microns. coat (Min.) One coat F-9, 83 Microns/ Coat(Min.)
Two coats of F-6, 100 Microns/Coat (min.) -
270
85
1.4 - do -
i) Upto 80
SSPC-SP10
One coat F-9, 6.5 microns / coat (Min) -do-
One coat of F-2. 30 Microns/coat (min.) -do-
95
Paint application at Ambient temp. Primer is acting as primer cum finish coat. Paint application at ambient temp. Paint application at ambient temp. Primer is acting as primer cum finish coat.
ii) 8l to 400
SSPC-SP10
85
1.9.4
Precautions to be taken Neither the environment of the site nor the marking labels of devices may be covered with paint and they must be kept free of paint splashes. To this end, it is advisable to use removable masking tape. Paint splashes, leaks, etc. on any adjacent installations such as measuring apparatus, valves, pipes. sources of light, insulation, heat insulators, walls, concrete, etc, must immediately be wiped up and the damage repaired before the paint is dry. Otherwise, the OWNER will be obliged to have the cleaning carried out at the expense of the Contractor. The paint recipient will only be opened at the time of use (unless otherwise specified by the manufacturer). The product will be mixed in the recipient with the aid of suitable tools and thus homogenized. Document No. 11-0330G01-01-09-02-007 SHEET 23 of 27
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1.9.5
Method of application Normally, three methods of application will be used on the construction site for the paint products. i.e. with a brush, with a roller or with a spray gun.
x x x x
The brush method makes it possible to obtain good penetration of the paint over irregularities in the metal. Only this method will be used for application of the base coats, for retouching and for protrusions, welded areas, riveted joints or bolted joints: The roller method may be used on large flat surfaces for the intermediate and topcoats. The spray gun method must be used in accordance with the instructions of the manufacturer and carried out by qualified personnel. The Contractor must guarantee that all safety measures have been taken for such work. The spray gun method may only he used on site for places that arc difficult to reach with the brush. In this case, a request must be made to the OWNER/ OWNER's Representative for a deviation. All paintwork will be carried out with good brushes or rollers that are suitable for the type of paint being used and for the form of the material to be painted and fitted with short handles. The maximum length of the brush and roller handles will be 50 cm; longer handles may only be used for places that are absolutely inaccessible. The maximum width of a brush will be 13 cm.
1.9.6
Application of the coating Application of the paint will be carried out in accordance with best practice in order to obtain a homogeneous and continuous layer. The OWNER or the Approved Supervisory body demands that painting of a layer will only be started after acceptance by them of the surface preparation or of the previous layer of paint. The layers of paint must have a uniform thickness. They must he spread in such a way that all concave parts are dried out and that the surface is completely covered and has a glossy appearance without leaving brush marks and without exhibiting bubbles, foam, wrinkles, drips, craters, skins or gums that arise from weathered paint, Each layer must have the color stipulated in the tables of the present specifications, which clearly differs from the previous layer, taking account of the Color of the top layer, all of which for the purpose of being able to identify the number of coats and their order of sequence. If the color of the coats is not mentioned in the tables the color difference in consecutive coats must, if possible, he at least 100 RAL. The color of the top layer is given in the table. The coating power should be such that the underlying layer is not visible. Only 1 layer per day may be applied, unless otherwise specified by the OWNER or the Approved Supervisory Body. The drying times prescribed by the paint manufacturer must be strictly observed in relation to the environmental conditions before proceeding with the application of the next layer. The dry coating thickness indicated in the description of the paint systems are minimum thickness. In this connection, the Contractor is obliged to contact the paint manufacturer and conform to his guidelines. The Contractor must respect the thickness specified by the supplier.
1.9.7
Transporting treated items In the case of works being carried out in a workshop, the metal structures will be surrounded by ventilated contraction film that prevents damage during transportation. This film may only be applied after complete polymerization of the paint. Document No. 11-0330G01-01-09-02-007 SHEET 24 of 27
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1.10 1.11
GROUND-LEVEL TRANSITION POINT Polyester protection system The Contractor will provide system 02 over the entire length of the pipes above ground and below ground and up to a height of 20 cm and a depth of 40 cm. perpendicular to the ground level mark. In each case, he must ensure that the jointing below the asphalt is in good condition and assures' faultless adhesion. He will apply the following products over the entire surface area, prepared in accordance with is Sa 3: 1) 2) The primer of system 01. Reinforced polyester 20 cm above the ground level marker and 5 cm on the asphalt cleaned beforehand (application of reinforced polyester is carried out in accordance with the work method prescribed by the manufacturer). Moreover, in the case of PE, in contrast to asphalt, he will apply a polygon primer to PE immediately before applying the reinforced polyester. He will then apply the other coats of system 01a to the surface section and thus cover the reinforced polyester with about 5 cm. For new constructions, the polygon primer will be applied to PE and then subsequently processed as described under point 2.
3)
4)
1.11.1 USE OF SCAFFOLDING Mounting, maintenance and dismantling of scaffolding for carrying out adaptation and/or paintwork to surface gas pipes or gas transport installations in use; x x x 1.12 The Contractor will specify the cost of scaffolding in the price list. The supplementary rental price for delays attributable to the Contractor will be charged to him: In his price quotation the Contractor should present the OWNER with diagrams of the scaffolding that he intends to install for carrying out the works of the OWNER.
QUALITY CONTROLS AND GUARANTEE
1.12.1 The Contractor is responsible for checking the weather conditions to ascertain whether the paintwork can be carried out within the technical specifications. The Contractor should have the required calibrated monitoring apparatus for this purpose on site (with calibration certificates). The personnel who will have to use this apparatus should have the training for this purpose. The OWNER or his representative and possibly the approved supervisory body indicated by the OWNER will maintain supervision during the works and inspect the works with random checks. A daily report will be drawn up in relation to the department that maintains supervision of these works. The supplementary inspection and the supervision by the OWNER or the approved supervisory body do not diminish in any way the liability of the Contractor. The proper execution of the work and the materials used may be checked at any time. 1.12.2 Reference Surfaces At the start of the works. the OWNER or the approved supervisory body will indicate a few surfaces that the Contractor will prepare and cover in accordance with the recognized method of operation under the inspection and to the satisfaction of all parties ; the OWNER or his representative, the approved supervisory body. the contractor and possibly the paint manufacturer. These reference surfaces will serve as a point of comparison for the good adhesion of the paint on the installations as a whole. The TECHNICAL SPECIFICATION FOR PAINTING Document No. 11-0330G01-01-09-02-007 SHEET 25 of 27
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parties will together work out a system for the identification of these surfaces in order to be able to monitor the conditions of the coatings over time. If the paintwork on a section of the installations is in a worse condition than the reference surfaces, the Contractor may be obliged to treat these parts again. 1.12.3 Measures to be taken in the event of a dispute If on delivery of the works no agreement can be reached between the Contractor and the OWNER regarding the conformity of the works to the requirements of these specifications, an Approved Supervisory Body will he Called in. The Approved Supervisory Body will then carry out inspections' on site whereby the following assessment criteria wilt be used: x x x x x x x x x The Swedish standards ISO 8501-1 1988 SS 05.5900 concerning the degree of cleanliness of the areas derusted by blasting, by machine or by hand. The wet film thickness of the paint will be measured in accordance with ISO 2808 or ASTM DI 212; The dry layer thickness of the film will be measured electronically, will complete statistical information. in accordance will, ISO 2808 or ASTM D 1186. The thickness of each layer will he measured in accordance with ISO 2808. ASTM 4138 or DIN 50986. Adhesion tests will be carried out in accordance with ISO 2409. ASTM 3359 or DIN 53151. Traction tests will he carried out in conformity with ISO 4624 or ASTM D 4541. The rugosity will be measured electronically in accordance with DIN 4768; The non-porosity will be measured with a test tension depending on the type of coating, the layer thickness and after consultation with the Paint manufacturer. Any defects in the paint film may be inspected visually by means of a magnifying glass or microscope. If necessary a photographic report may be drawn up in accordance with ASTM Standard D 4121-82,
The final judgement of the Approved Supervisory Body is irrevocable and binding for the Contractor and the OWNER. In the event of non-conformity of the works with the criteria of these specifications, all costs arising from the inspection by the Approved Supervisory Body shall be borne by the Contractor. 1.12.4 Guarantee a) General Principles The Contractor declares that he is aware of: x x The maximum operating temperature of the surfaces to be covered. The maximum permitted degree of humidity of the bearing surface. The properties of the environment to which the surfaces to be covered are: subject.
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b)
Summary of the Guarantee. The contractor fully guarantees the following without reservation:
The observance of all stipulations of the specifications for paintwork regarding, among other things: o o o The preparation of the surfaces. The thickness of each layer. The total thickness of the covering.
x x
The uniformity of the materials used. The repair of all defects before delivery of the works.
The Contractor will carry out the requested repair work as promptly as possible.
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SPECIFICATION FOR FITTINGS AND FLANGES UPTO 400mm (16) NB
5 006
DOCUMENT NO
11
0330G01
01
08
02
0 A REV
28.06.11 24.06.11 DATE
MH MH PREP
ASD ASD CHK
AD AD APPR
203 of 245
TABLE OF CONTENT
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0
SCOPE ........................................................................................ Error! Bookmark not defined. REFERENCE DOCUMENTS.................................................................................................. 3 MANUFACTURER'S QUALIFICATION ................................................................................. 3 MATERIALS.......................................................................................................................... 4 DESIGN AND MANUFACTURE ............................................................................................ 4 INSPECTION AND TESTS..................................................................................................... 5 TEST CERTIFICATES ........................................................................................................... 5 MARKING .............................................................................................................................. 5 DOCUMENTATIONS ............................................................................................................. 5
SPECIFICATION FOR FITTINGS AND FLANGES UPTO 16
Rev 0
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1.0
SCOPE This specification covers the minimum requirements for the design, manufacture and supply of following items to be installed in pipeline system handling hydrocarbons in liquid or gaseous phase: - Seamless fittings 400 mm (16) NB and smaller, such as tees, elbows, reducers and caps. - Flanges 400 mm (16) NB and smaller, such as welding neck flanges and blind flanges The specification does not cover the above mentioned items which are to be installed in pipeline system handling sour hydrocarbons (liquid / gas) service as defined in NACE standard MR-01-75-98.
2.0
REFERENCE DOCUMENTS Reference has been made in this specification to the latest edition of the following codes, standards and specifications: ASME B 16.5 ASME B 16.9 Steel Pipe Flanges and flanged Fittings Factory-Made Wrought Steel Butt Welding Fittings Forged Steel Fittings, Socket Welding and Threaded Process Piping Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia and Alcohols ASME B 31.8 ASTM A 370 API 590 MSS-SP-25 MSS-SP-44 MSS-SP-75 MSS-SP-97 Gas Transmission and Distribution Piping Systems Mechanical Testing of Steel Products Steel Line Blanks Standard Marking System for Valves, Fittings, Flanges and Union Steel Pipeline Flanges Specification for High Test Wrought Welded Fittings Forged Carbon Steel Branch Outlet Fittings-Socket Welding, Threaded and Butt Welding Ends
ASME B 16.11 ASME B 31.3 ASME B 31.4 -
3.0
MANUFACTURERS QUALIFICATION Manufacturer, who intends bidding for fittings, must possess the records of a successful proof test, in accordance with the provisions of ASME B 16.9/ MSS-SP- 75, as applicable. These records shall be submitted at the time of bidding.
4.0 4.1
MATERIALS The basic material for fittings and flanges shall be as indicated in the Material Requisition Additionally; the material shall also meet the requirements specified hereinafter. Each heat of steel used for the manufacture of fittings and flanges shall have carbon equivalent (CE) not greater than 0.45 % calculated from check analysis in accordance with following formula: Mn + Cr + Mo +V + Ni +Cu 6 5 15 Carbon contents on check analysis shall not exceed 0.22%. CE= C + Document No. 11-0330G01-01-08-02-006 SHEET 3 of 5
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4.2
Rev 0
4.3
Unless specified otherwise, Charpy V-notch test shall be conduced for each heat of steel, in accordance with the impact test provision of ASTM A370 at 0C temperature. The average absorbed impact energy values of three full- sized specimens shall be 27 joules. The minimum impact energy value of any one specimen of the three specimens analysed as above, shall not be less than 80% of the above- mentioned average value. For flanges and fittings specified to be used for other hydrocarbon service, the Charpy V-notch test requirements as stated above are not applicable, unless required by the specified material standard as a mandatory requirement. When Low Temperature Carbon Steel (LTCS) materials are specified in Purchase Requisition for flanges and fittings, the Charpy V-notch test requirements of applicable material standard shall be complied with.
4.4
For flanges and fittings, specified to be used for Gas service or High Vapour Pressure (HVP) liquid service, hardness test shall be carried out in accordance with ASTM A 370. Hardness testing shall cover at least 10% per item, per size, per heat, per manufacturing method. A full thickness cross section shall be taken for this purpose and the maximum hardness shall not exceed 248 HV10. For flanges and fittings, specified to be used for other hydrocarbon services, the hardness requirements stated above are not applicable.
4.5 5.0 5.1
In case of RTJ flanges, the groove hardness shall be minimum 140 BHN DESIGN AND MANUFACTURE Flanges such as welding neck flanges and blind flanges shall conform to the requirement of ASMEB16.5. Fittings such as tees, elbows and reducers shall be seamless type and shall conform to ASME B 16.9 for sizes 50 mm (2) NB and above and ASME B16.11 for sizes below 50mm (2) NB. Fittings such as weldolets, sockolets, nippolets, etc., shall be manufactured in accordance with MSS-SP-97 Type, face and face finish of flanges shall be as specified in Material Requisition / Purchase Requisition. Flanges and fittings manufactured from bar stock are not acceptable. All butt weld ends shall be bevelled as per ASME B 16.5/ASME B 16.9/MSS-SP-97 as applicable. Repair by welding on flanges and fittings are not permitted. INSPECTION AND TESTS The Manufacturer shall perform all inspection and tests as per the requirement 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: Visual inspection. Dimensional checks. Chemical composition, mechanical properties and hardness examination. All finished wrought weld ends shall be 100% ultrasonically tested for lamination type defects. Any lamination larger than 6.35 mm shall not be acceptable.
5.2
5.3
5.4 5.5 5.6 5.7 6.0 6.1
6.1.1 6.1.2 6.1.3 6.1.4
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6.1.5 6.2
All other tests not specially listed but are required as per applicable standard / specification. Purchasers Inspector may also perform stage-wise inspection and witness tests as indicated in Clause 6.1 at Manufactures Works prior to shipment Manufacturer shall give reasonable notice of time and shall provide, without charge, reasonable access and facilities required for inspection to the Purchasers Inspector. Inspection and tests performed/ witnessed by the Purchasers Inspector shall in no way relieve the Manufacturers obligation to perform the required inspection and tests.
7.0
TEST CERTIFICATES Manufacturer shall submit following certificates to Purchasers Inspector: a) Test certificates relevant to the chemical analysis and mechanical properties of the materials used for construction as per this specification and relevant standards b) Test reports on non-destructive testing. c) Certificates for each fitting stating that it is capable of withstanding without leakage a test pressure, which results in a hoop stress equivalent to 100 % of the specified minimum yield strength for the pipe with which the fitting is to be attached without impairment of serviceability.
8.0 8.1
PAINTING, MARKING AND SHIPMENT After all inspection and tests required have been carried out; all external surfaces shall be thoroughly cleaned to remove grease, dust and rust and shall be applied with standard mill coating for protection against corrosion during transit and storage. The coating shall be easily removable in the field. Ends of all fittings and weld neck flanges shall be suitably protected to avoid any damage during transit. Metallic or high impact plastic bevel protectors shall be provided for fittings and flanges. Flange face shall be suitably protected to avoid any damage during transit. All flanges and fittings shall be marked as per applicable dimension/manufacturing standard. DOCUMENTATION Prior to shipment, the Manufacturer shall submit six copies of the test certificates as listed in clause 7.0 of this specification. All documents shall be in English Language only
8.2
8.3 9.0 9.1
9.2
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STANDARD SPECIFICATION FOR INSPECTION, FLUSHING AND TESTING OF PIPING SYSTEMS
8 009
DOCUMENT NO
11
0330G01
01
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ABBREVIATIONS: PMI NDT P&ID A.S. C.S. C.I. S.S. LTCS NACE Positive Material Identification Non Destructive Testing Process and Instrumentation Diagram Alloy Steel Carbon Steel Cast Iron Stainless Steel Low Temperature Carbon Steel National Association of Corrosion Engineers
INSPECTION, FLUSHING AND TESTING OF PIPING SYSTEMS
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TABLE OF CONTENT
1.0 2.0 3.0 4.0 5.0
SCOPE ................................................................................................................................... 4 DEFINITION 4
INSPECTION.......................................................................................................................... 4 FLUSHING ............................................................................................................................. 4 TESTING ................................................................................................................................ 5
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1.0
SCOPE This specification covers the general requirements for inspection, flushing and testing of piping systems. However testing of steam lines falling under IBR shall also be governed by Indian Boiler Regulations. Flushing and testing of all piping systems shall be witnessed by the Engineer-In-Charge.
2.0
DEFINITIONS
Shall
: This verbal form indicates requirements strictly to be followed in order to confirm to the standards and from which no deviation is permitted. : This verbal form indicates that among several possibilities one is particularly suitable without mentioning or excluding others or that a certain course of action is preferred but not necessarily required. : This verbal form indicates a course of action permissible within the limits of this standard. : This verbal form used for statements of possibility & capability, whether material, physical or casual.
Should
May
Can
3.0
INSPECTION During various stages and after completion of fabrication and erection, the piping system shall be inspected by the Engineer-In-Charge to ensure that: - Proper piping material has been used. - Piping has been erected as per drawings and instructions of Engineer-In-Charge. - All supports have been installed correctly. - Test preparations mentioned in this specification have been carried out.
4.0
FLUSHING Flushing of all lines shall be done before pressure testing. Flushing shall be done by fresh potable water or dry compressed air, wherever water flushing is not desirable, to clean the pipe of all dirt, debris or loose foreign material Required pressure for water flushing shall meet the fire hydrant pressure or utility water pressure. For air flushing, the line / system will be pressurized by compressed air at the required pressure which shall be 50 psi maximum. The pressure shall then be released by quick opening of a valve, already in line or installed temporarily for this purpose. This procedure shall be repeated as many times as required till the inside of the pipe is fully cleaned. In line instruments like control valves, orifice plates, rotameters, safety valves and other instruments like thermowells which may interfere with flushing shall not be included in flushing circuit. The screens / meshes shall be removed from all permanent strainers before flushing. Screens/meshes shall be reinstalled after flushing but before testing.
During flushing temporary strainers shall be retained. These shall be removed, cleaned and reinstalled after flushing but before testing. INSPECTION, FLUSHING AND TESTING OF PIPING SYSTEMS Document No. 11-0330G01-01-08-02-009 SHEET 4 of 8
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In case of equipment such as column, vessel, exchanger etc. form part of a piping circuit during flushing, this shall be done with the approval of Engineer-In-Charge. However, equipments thus included in the circuit shall be completely drained and dried with compressed air after flushing is completed. During flushing discharged water/air shall be drained to the place directed by the Engineer-In-Charge. If necessary, proper temporary drainage shall be provided by the contractor. Care shall be taken during flushing so as not to damage/spoil work of other agencies. Precautions shall also be taken to prevent entry of water/foreign matter into equipments, electric motors, instruments, electrical installations etc. in the vicinity of lines being flushed. The contractor shall carry out all the activities required before, during and after the flushing operation, arising because of flushing requirements, such as but not limited to the following Dropping of valves, specials, distance pieces, inline instruments and any other piping part before flushing. The flanges to be disengaged for this purpose shall be envisaged by the contractor and approved by the Engineer-In-Charge. These flanges shall be provided with temporary gaskets at the time of flushing. After flushing is completed and approved, the valve distance pieces, piping specials etc. shall be reinstalled by the contractor with permanent gaskets. However, flanges at equipment nozzles and other places where isolation is required during testing, only temporary gaskets shall be provided. Records in triplicate shall be prepared and submitted by the contractor for each piping system for the flushing done in the Performa provided/approved by the Engineer-in-Charge. 5.0 5.1 TESTING Extent of Testing With the exclusion of instrumentation, piping systems fabricated or assembled in the field shall be tested irrespective of whether or not they have been pressure tested prior to site welding of fabrication. To facilitate the testing of piping systems, vessels and other equipments may be included in the system with the prior approval of Engineer-In-Charge if the test pressure specified is equal to or less than that for the vessels and other equipments. Pumps, compressors and other rotary equipments shall not be subjected to field test pressure. Lines which are directly open to atmosphere such as vents, drains, safety valves discharge need not be tested, but all joints shall be visually inspected. Wherever necessary, such lines shall be tested by continuous flow of fluid to eliminate the possibility of blockade. However, such lines if provided with block valve shall be pressure tested up to the first block valve. Seats of all valves shall not be subjected to a pressure in excess of the maximum cold working pressure of the valve. Test pressure applied to valves shall not be greater than the manufacturers recommendation nor less than that required by the applicable code. Where allowable seat pressure is less than test pressure, test shall be made through an open valve. Instruments in the system to be tested shall be excluded from the test by isolation or removals, unless approved otherwise by the Engineer-In-Charge. Restrictions which interfere with filling, venting and draining such as orifice plates etc. shall not be installed unless testing is complete. Control valves shall not be included in the test system. Where bypasses are provided test shall be performed through the bypass and necessary spool shall be used in place of the control valve. Pressure gauges which are part of the finished system, but cannot withstand test pressure shall not be installed until the system has been tested. Where piping systems to be tested are directly connected at INSPECTION, FLUSHING AND TESTING OF PIPING SYSTEMS Document No. 11-0330G01-01-08-02-009 SHEET 5 of 8
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the battery limits to piping for which the responsibility rests with other agencies, the piping to be tested shall be isolated from such piping by physical disconnection such as valve or blinds. 5.2 General Requirements / Test Preparation for Testing Testing shall be carried out with permanent gaskets installed unless specified otherwise or instructed by the Engineer-in-Charge. No pressure test shall be carried out against closed valve unless approved by the Engineer-in-Charge. The Engineer-in-Charge shall be notified in advance by the Contractor, of the testing sequence and program, to enable him to be present for witnessing the test. The Contractor shall be fully responsible for making arrangements with the local boiler inspector to witness the tests for steam lines falling under IBR. IBR certificates for these tests shall be obtained in the relevant IBR forms and furnished to the Engineerin-Charge. Before testing, all piping shall be cleaned by flushing to make it free from dirt, loose scale, debris and other loose foreign materials. All piping systems to be hydrostatically tested shall be vented at the high points and the systems purged of air before the test pressure is applied. Wherever in the line any void exists due to any reasons, like absence of control valves, safety valves, check valves etc. it shall be filled with temporary spools. All joints welded, screwed or flanged shall be left exposed for examination during the test. Before pressuring the lines, each weld joint shall be cleaned by wire brush to free it from rust and any other foreign matter. Where a system is to be isolated at a pair of companion flanges, a blank shall be inserted between the companion flanges. Minimum thickness of the blank shall be designed in accordance with applicable design code. Open ends of piping system where blanks cannot be used, such as pumps, compressors, turbines or wherever equipment or pipe spools have been recovered or disconnected prior to hydrostatic testing, shall be blinded off by using standard blind flanges of same rating as the piping system being tested. Pressure gauges used in testing shall be installed as close as possible to the lowest point in the piping system to be tested, to avoid overstressing of any of the lower portions of the system. For longer lines and vertical lines, two or more pressure gauges shall be installed at locations decided by the Engineer-inCharge. For lines containing check valves any of the following alternatives shall be adopted for pressure testing: Whenever possible pressurize up-stream side of valve. Replace the valve by a temporary spool and reinstall the valve after testing. Provide blind on valve flanges and test the upstream and downstream of the line separately and remove the blind after testing. At these flanges, temporary gaskets shall be provided during testing and shall be replaced by permanent gaskets subsequently. For check valves in lines 1 1/2 and below flapper or seat shall be removed during testing (if possible). After completion of testing the flapper/seat shall be refitted. Gas lines when hydrostatically tested shall be provided with additional temporary supports during testing as directed by the Engineer-in-Charge. Piping which is spring or counter-weight supported shall be temporarily supported, where the weight of the fluid would overload the support. Retaining pins for spring supports shall be removed only after testing is completed and test fluid is completely drained. Document No. 11-0330G01-01-08-02-009 SHEET 6 of 8
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When testing any piping system, air or steam of approximately 2 kg/cm2g may be used as preliminary test to detect missing gaskets etc. as this avoids the necessity of draining the line to make repairs. However, steam shall not be used for this purpose, if the steam temperature is more than the design temperature of the line. For jacketed pipes testing of core pipes shall be done on individual pieces where the pipe is continuously jacketed, before it is jacketed. The outer jacket shall be tested separately as a system. For piping with discontinuous jacketing the core pipe and the jacket shall be tested as separate continuous systems. 5.3 5.3.1 Testing Media, Test Pressure and Test Pressure Gauges Testing Media
In general all pressure test shall be hydrostatic using iron free water, which is clean and free of silt. Maximum chlorine content in water for hydrostatic testing for S.S. piping shall be 15-20 ppm. Air shall be used for testing only if water would cause corrosion of the system or overloading of supports etc. in special cases as directed by Engineer-in-Charge. Where air/water tests are undesirable, substitute fluids such as gas oil, kerosene, methanol etc. shall be used as the testing medium, with due consideration to the hazards involved. These test fluids shall be specified in the line list given to the contractor. 5.3.2 Test Pressure The hydrostatic/pneumatic test pressure shall be as indicated in the line list or as per the instruction of Engineer-in-Charge. The selection of the piping system for one individual test shall be based on the following: Test pressure required as per line list. Maximum allowable pressure for the material of construction of piping. Depending upon the above requirements and based on construction progress, maximum length of piping shall be included in each test. 5.3.3 Test Pressure Gauge All gauges used for field testing shall have suitable range so that the test pressure of the various systems falls in 40% to 80% of gauge scale range. Gauge shall be of a good quality and in first class working condition. Prior to the start of any test or periodically during the field test program, all test gauges shall be calibrated using a standard dead weight gauge tester or other suitable approved testing apparatus. Any gauge showing an incorrect zero reading or error of more than 2% of full scale range shall be discarded. The Engineer-in-Charge shall check the accuracy of master pressure gauge used for calibration. 5.4 5.4.1 Testing Procedure Hydrostatic Test All vents and other connections used as vents shall be left open while filling the line with test fluid for complete removal of air. In all lines for pressurizing and depressurizing the system, temporary isolating valves shall be provided if valves vents, drains do not exist in the system. Pressure shall be applied only after the system / line is ready and approved by the Engineer-incharge.
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Pressure shall be applied by means of a suitable test pump or other pressure source which shall be isolated from the system as soon as test pressure is reached and stabilized in the system. A pressure gauge shall be provided at the pump discharge for guidance in bringing the system to the required pressure. The pump shall be attended constantly during the test by an authorized person. The pump shall be isolated from the system whenever the pump is to be left unattended. Test pressure shall be maintained for a sufficient length of time to permit thorough inspection of all joints for leakage or signs of failure. Any joint found leaking during a pressure test shall be retested to the specified pressure after repair. Test period shall be maintained for a minimum of three hours. The pump and the piping system to be tested are to be provided with separate pressure indicating test gauges. These gauges are to be checked by the standard test gauge before each pressure test. Care shall be taken to avoid increase in the pressure due to temperature variation during the test. 5.4.2 Air Test When testing with air, pressure shall be supplied by means of a compressor. The compressor shall be portable type with a receiver, after cooler and oil separator. Piping to be tested by air shall have joints covered with a soap and water solution so that the joints can be examined for leaks. All other details shall be same as per hydrotesting procedure (specified above) 5.5 Completion of Testing After the hydrostatic test has been completed, pressure shall be released in a manner and at a rate so as not to endanger personnel or damage equipments. All vents and drains shall be opened before the system is to be drained and shall remain open till all draining is complete, so as to prevent formation of vacuum in the system. After draining, lines / systems shall be dried by air. After testing is completed the test blinds shall be removed and equipment/ piping isolated during testing shall be connected using the specified gaskets, bolts and nuts. These connections shall be checked for tightness in subsequent pneumatic tests to be carried out by the contractor for complete loop / circuit including equipments (except rotary equipments). Pressure test shall be considered complete only after approved by the Engineer-in-Charge. Defects, if any, noticed during testing shall be rectified immediately and retesting of the system / line shall be done by the contractor at his cost. 5.6 Test Records Records in triplicate shall be prepared and submitted by the contractor for each piping system, for the pressure test done in the Performa provided/approved by the Engineer-in-Charge. Records shall also be submitted for the PMI.
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TECHNICAL SPECIFICATION FOR PIG SIGNALLER DOCUMENT NO 11 0330G01 01
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TABLE OF CONTENTS
Sl.No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0
DESCRIPTION SCOPE CODES, STANDARDS AND DOCUMENTS GENERAL REQUIREMENTS BASIC DESIGN DATA DESIGN CRITERIA MATERIALS FABRICATION INSPECTION & TESTING
PAGE NO. 3 3 3 3 3 4 4 4
TECHNICAL SPECIFICATION FOR PIG SIGNALLER

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1.0
SCOPE This specification covers the minimum requirements for the design, manufacture, testing and supply of Pig Signallers, used for the detection of passage of intelligent and instrumented gauging pigs, to be installed in pipeline systems handling hydrocarbons in liquid or gaseous phase including Liquefied Petroleum GAS (LPG).
2.0
MATERIAL The material used in manufacture of the main components of the Pig Signaller shall be as under: All metallic parts except scarfed welding base : SS 316 Other components shall be as per Manufacturers Standard, suitable for the service conditions indicated in Data Sheet, which will be subject to approval by Purchaser. Welding base shall have Carbon Equivalent analysis, calculated as per the following formula: (CE) not greater than 0.45 on check
CE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni +Cu)/15 3.0 DESIGN AND CONSTRUCTION REQUIREMENT 3.1 Pig Signallers shall be bi-directional type, non intrusive & magnetic type and shall be designed as per ASME B 31.8.
3.2
Pig Signallers shall be designed to meet the requirements of pipeline material, diameter, wall thickness and service conditions indicated in the Data Sheet.
3.3 3.4
Pig Signallers shall be provided with a visual indicator to indicate the passage of pigs. All welds shall be made by welders and welding procedures qualified in accordance with the provisions of ASME Section IX.
3.5
When indicated in Data Sheet, Pig Signallers shall be fitted with sealed, weather proof and explosion proof microswitch for remote signal indication. The area classification and rating of microswitch shall be as indicated in Data Sheet.
4.0
INSPECTION AND TESTS 4.1 4.2 4.3 4.4 Manufacturer shall perform all inspection and tests required to supply the Pig Signallers as per the requirements of this specification. NDT shall be performed on each weld. 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. Manufacturers shall perform functional tests to establish satisfactory performance of both manual and electrical indications.
5.0
TEST CERTIFICATES Manufacturer shall submit the test certificates for material compliance as per the relevant material standards and certificates for functional tests.

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6.0
PAINTING, MARKING AND SHIPMENT 6.1 Exterior surface of the Pig Signaller shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion resistant paint. In case of Pig Signallers with extension, the buried portion shall be coated with three coats of coal tar epoxy resin. The minimum dry film thickness shall be 300 microns. A corrosion resistant metal tag shall be permanently attached with each unit, with the following marking: Manufacturers name. Suitable for installation in mm dia. Pipeline ANSI Rating Tag No. Each unit shall be suitably protected to avoid any damage during transit. Care shall be exercised during packing to prevent any damage to the welding ends. All machined surfaces subject to corrosion shall be well protected by a coat of grease or other suitable materials.
6.2
i) ii) iii) iv) 6.3 . 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 8.2 i) ii) iii) All documents shall be in English language. At the time of bidding, Manufacturer shall submit the following documents: General arrangement drawings with overall dimensions. Clause wise list of deviations from this specification, if any. 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. 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. Fabrication drawings! sectional arrangement reference numbers and material specification. Assembly drawing with overall dimensions Welding and testing procedure. Cable connection details and cable specification. drawings showing all parts with
8.3
i)
ii) iii) iv)

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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..4 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. Prior to shipment, Manufacturer shall submit one reproducible and six copies of the following: Test Certificates as per clause 5.0 of this specification Manual for installation, erection instructions, maintenance and operation instructions.
8.5 i) ii)

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DATA SHEET FOR PIG SIGNALLER
CLIENT JOB NO. TOTAL SHEETS 2
DOCUMENT NO
11
0330G01
01
11
03
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ISSUED FOR TENDER ISSUED FOR IDC
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DESCRIPTION
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CLIENT:
GAIL(India) Limited
TAG NO.:
QUANTITY:
02
SIZE:
TYPE DESIGN CONDITIONS OF PIPELINE PRESSURE TEMPERATURE DESIGN CODE ANSI RATING HYDRO TEST PRESSURE OPERATING CONDITIONS PRESSURE TEMPERATURE FLUID HANDELED INSTALLATION ELECTRICAL AREA CLASSIFICATION
NON INTRUSIVE / MAGNETICALLY COUPLED
72 Kg/cm2 g 0 to 65 C ASME B 31.8
600#
138 Kg/cm2 g
31Bar g 5 to 35 C NATURAL GAS / R-LNG ABOVE GROUND ZONE-1,GAS GROUP IIA & IIB, TEMP CLASS-T3
PIPELINE DIAMETER ON WHICH PIG SIGNALLER TO BE MOUNTED O.D. QUANTITY S.NO. (mm) 1 8 2
PIG SIGNALLER MATERIAL SPECIFICATION PART Body internals MICRO SWITCH DETAILS RATING POTENTIAL FREE CONTACT OF RATING 24DC,5A,SPDT/ 240 V A.C , 2A SPDT. WEATHER PROOF TO IP55 & FLAME PROOF Exd. ENCLOSURE CERTIFIED FOR AREA CLASSIFICATION NPTF SPECIFIED MATERIAL MFR.STD. SS-316 MATERIAL OFFERED
ENCLOSURE
CABLE CONNECTION
DATA SHEET FOR PIG SIGNALLER

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DOCUMENT NO. 11-0330G01-01-11-03-006 SHEET 2 OF 2
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GAIL (India) Limited PIPELINE FROM HANUMAN JUNCTION TO VCL DATA SHEET FOR MONOLITHIC INSULATING JOINT DOCUMENT NO 11 0330G01 01 CLIENT JOB NO. TOTAL SHEETS 09 03 2 003
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PROCESS DATA
PIPE CLASS : FLUID : 6A1 NATURAL GAS ANSI RATING : FLUID SYMBOL : 600# NG
DESIGN CONDITIONS : PRESSURE : 92 TEMPERATURE : 0 to 65 OPERATING CONDITIONS : PRESSURE : * TEMPERATURE : * PIPELINE DETAILS MATERIAL: API 5L X-56 (PSL-2) THICKNESS : 6.4 mm CONSTRUCTION DATA DESIGN AND CONSTRUCTION CODE ALLOWABLE STRESS VALUE CORROSION ALLOWANCE CONSTRUCTION MATERIAL BODY PUP PIECE INSULATION INSULATING JOINT SEALING GASKETS INSULATING SPACER INSULATING FILLER ADHESIVE SEALENT EXTERNAL COATING INTERNAL COATING TESTING INESPECTION AND CERTIFICATES: HYDROTEST PNEUMATIC TEST DIELECTRIC STRENGTH TEST INSULATION ELECTRICAL RESISTANCE DIMENSIONAL STANDARD END CONNECTION CHARPY IMPACT TEST HARDNESS TEST NDT MARKING
Kg/cm2 g C Kg/cm2 g C OUTSIDE DIA (O.D) : 10 / 8inch
: : : : : : : : :
:
ASME SEC VIII. DIV. 1 APP. 2 ASME IX AND ASME B 31.8 50% SMYS (DESIGN FACTOR : 0.5)
0.5 mm
MSS SP-75 WPHY Gr60/56 / ASTM A-694,F-60 / F56 API 5L Gr. X-56 (*) (*) (*) (*) (*) (*) (*) 1.5 X Design pressure, holding period 1.5 hour 5 Kg/cm2 for 10 min 5 000 VAC, 50 Hz Holding time at least one minute > 50M ohm (1000VDC) 1000 VDC,50 HZ Holding time at least one minute > 50 ohm ANSI B 16.9 BUTT WELDED ENDS AS PER ANSI B 16.25 As per Specification As per Specification As per Specification Manufacture name Heat number Tag number Grade symbol
: :
Note:
(*) To be selected by Vendor in his bid and submitted for approval.

1. For the welding end, the maximum out of roundness shall be 5 mm. 2. Suitable Pup-piece to be provided at each end and bevel end preparation shall be as per Fig: 14 & 15 of ASME B 31.8 1999 edition.
DATA SHEET FOR MONOLITHIC INSULATING JOINT

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DOCUMENT NO. 11-0330G01-01-09-03-003 SHEET 2OF 2
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CLIENT JOB NO.
LIST OF VENDOR
TOTAL SHEETS
8 01
DOCUMENT NO
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Document No. LIST OF VENDERS 11-0330G01-01-11-06-01 TOTAL SHEET 8

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LIST OF RECOMMENDED VENDORS S.NO 1 1 Ishwardas Aggarwal & Sons (Trader) ITEM NAME OF VENDOR ADDRESS 39, Lalit House, 3rd floor, Sant Tukaram Road, Iron Market, Mumbai - 400 009 116, P.D. Mello Road, Near Camace Bridge, Mumbai - 400 009 Apex Tubes Pvt. Ltd. 1/6 B, Asaf Ali Road New Delhi - 110 002 526/36, Maulana Azad Road, 2nd floor, Gulawadi Circle, Mumbai - 400 004 176, Magazine street, darukhana, Mazagaon, Mumbai 400 010 P.B. No. 3081, 276/278, Samuel street, 2nd floor, Vadgadi, Mumbai 400 003 PHONE NO FAX NO QUALIFIED FOR SIZE
(+91)22-342 2566 (+91)22-342 3762
M.J. Patel & company (Trader)
Apex Tubes Pvt. Ltd (Manufacturer & Trader)
011 - 3236408
Steel Tube (India) (Trader)
(+91)22-389 5908 (+91)22-3895906 (+91)22-381 2564
Nagardas Kanji Shah (Trader)
(022) 3721066)/ 3724157
(022) 3781032
6 Station Piping (Seamless Pipes) Trader 7
Jyoti Industries
(022) 3435091/92
(022) 3421 391
The Bengal Mill stores supply co (Trader)
205, Magnanial Chambers, Baburao (022)3430105, Bobde Marg, Iron Market, Mumbai 3430107, 3434918 400 009 M-2, sundaram, sion college, Mumbai 40 022 (022) 409 2016, 409 6036
(022) 3414763
Radiant Engineering Co.
(022) 409 4822
Tianjin Pipe corporation
PO box 17537, Jebel Ali Free zone, Dubai, U.A.E
97148833799
97148833899
10
Milsubihsi
11 12 13 14 15
Trub Chomulov TENARIS Valcvony Vallurorec Maneshman Tubes Brazil Virgo Engineers Ltd, Pune Virgo Engineers, J/517, MIDC, Bhosari, Pune - 411026 10, Navdurga Indl. Estate, Opp Forge Blower, Naroda Road, Ahmedabad 25 B-161-162 INDUSTRIAL ESTATE,GOKUL ROAD ,HUBLI ,KARNATKA 580030 020 - 2747 4481 020-2747 0772 Upto 24" class 600 upto 12" class 600
17
Flow Chem Industries
79 - 220 4773
79 - 220 1401
18
Micro Finish Valves
upto 12" class 600
20
BALL VALVES
L&T / Audco valves Cooper Cameron Valves (singapore) Pte. Ltd BOHMER Ball Valves
Chennai No.2, Gul Circle, Jurong Industrial Estate, singapore - 629560 Gedulderweg, 95 45549 Sprockhovel Germany Hlucinska, 41 747 22 Doinin Benesov Czech Republic
Upto 24" 600#
21
0065 865 2887
0065 861 7109
Upto 48" 600#
22
(+49) 2324 70010 (-49) 2324 700179
Upto 48" 600#
23
MSA
(+420) 553 881111 (+420) 553 651236 Document No.
Upto 48" 600# Rev. 0
LIST OF VENDORS
11-0330G01-01-11-06-01 SHEET 1 of 8
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LIST OF RECOMMENDED VENDORS S.NO 1 24 RMA Maschinen - und Armalurenbau Fulhaber & Truttenbach SCHUCK ARMATUREN (ex BORSIG) SUD ROBINETTERIE INDSUTRIE (SRI) TORMENE GAS TECHNOLOGY (VALVITALIA) BALL VALVES 28 29 VIAR VALVOLE BREDA ENERGIA SESTO INDUSTRIA FLOW CONTROL TECHNOLOGIES (TYCO flow control) PETRO VALVES Oststrasse, 17 77694 Kehl Germany Dailerstrasse 4-7 89555, Steinheim Germany 279 -305, Bvd D, Casanova 13309 Marseille, France Via L. Campolongo, 97 35020 Due Carrare PD ITALY Via L. Cadorna, 6 21041 Albizzate VA ITALY (+49) 78 518680 (+49) 78 5186813 upto 30" 600# ITEM NAME OF VENDOR ADDRESS PHONE NO FAX NO QUALIFIED FOR SIZE
25 26
(+49) 73 29 950 0 (+49) 73 29950161 (+33) 495 055050 (+33) 495 055070 (+39) 059 919 9511 (+39) 0331 99 2985
upto 30" 600# upto 30" 600#
27
(+39) 049 9125455
upto 30" 600#
(+39) 0331 992992
upto 30" 600# upto 30" 600#
Viale Sarca, 336 20126 Milano ITALY (+39) 0264 4771 (+39) 02 64477542 23, Deuzieme avenue 13743 Vitrolles FRANCE Viale G Borri, 42 21053 Catellanza VA ITALY (+33) 442 103600 (+91) 11 647 1469 (+39) 0331 334 111 (+33)442103636 G39 (+91) 11 646 1550 (+39) 0331 675830
30
upto 30" 600#
31 32 33 34 35 36 37 Gas Over Oil Actuators
upto 48" 600#
Contractor shall ensure that each valve manufacturer shall have valid API 6D license and in case of firm order the license shall be valid till complete execution of supplies. M/s BIFI M/s Rotork fluid system PC Intertecnik M/s Bettis Flow Chem Industries Italy Italy Germany Belgium 10, Navdurga Indl. Estate, Opp Forge Blower, Naroda Road, Ahmedabad 25 101, Samrudhi, Sattar Taluka Society, Opp old high court lane, Ahmedabad Plot No. R-241, TTC Industrial area, MIDC, Rabale, New Bombay - 400 701 104, Eric House 16th Road Chembur, Mumbai - 400 071 B-161-162 INDUSTRIAL ESTATE,GOKUL ROAD ,HUBLI ,KARNATKA 580030 Chennai 79 - 220 4773 79 - 2204773/ 3623 79 - 220 1401 upto 12" 600#
38
Shreeraj Industries
upto 12" 600# Upto 12" class 600 of split body type upto 12" 600#
39
Steel Strong Valves (P) Ltd.
40 Globe Valve 41 42
Ornate Valves Pvt. Ltd, Mumbai
Micro Finish Valves L&T / Audco valves
upto 12" class 600 Upto 24" 600#
43 SD -115/116 Ghatkopar Industrial Estate, L.B.S. marg Ghatkopar (West) Mumbai 400 086 197, SIDCO Industrial Area, Ambatturm, Chennai 600 098 Chennai Plot No. R-241, TTC Industrial area, MIDC, Rabale, New Bombay - 400 022 - 27699489/90 701 Spring loaded type upto 12" 600# of split body type
44
Niton valve Industries Pvt. Ltd
022- 500 8315
022 - 5007654
Upto 24" 600#
45
Econo Valves Pvt Ltd
044 6251829/ 6254371
044 - 6257501
46
L&T / Audco valves
47 Check/ Non Return Valve 48
Steel Strong Valves (P) Ltd.
022 - 27695537
49
Micro Finish Valves
B-161-162 INDUSTRIAL ESTATE,GOKUL ROAD ,HUBLI ,KARNATKA 580030 10, Navdurga Indl. Estate, Opp Forge Blower, Naroda Road, Ahmedabad 25
upto 12" 600 #
50
Flow Chem Industries
79 - 220 4773
79 - 220 1401
upto 12" 600# (lift type, wafer type & Swing type) Rev. 0
Document No. LIST OF VENDORS 11-0330G01-01-11-06-01 SHEET 2 of 8
235 of 245
LIST OF RECOMMENDED VENDORS S.NO 1 51 Ornate Valves Pvt. Ltd, Mumbai 104, Eric House 16th Road Chembur, Mumbai - 400 071 1201, GIDC Estate, Phase IV Vithal Udyog Nagar Anand 388 112 SD -115/116 Ghatkopar Industrial Estate, L.B.S. marg Ghatkopar (West) Mumbai 400 086 147, Karapakkam Village, Chennai-600096 Navi Mumbai 32, Sivaji Marg,Post Box 6223,Near Moti Nagar, New Delhi 908, Ansal Bhawan,16 Kasturba Gandhi Marg,New Delhi Germany Grobe Strabe 14, 27356 Rotenburg, "+49 4261 4081" Germany Mark S Clarkelaan 13 a, Haven No. M 512, 4761 RK Zevenbergen, The Netherlands Premier estate, Leys road, Brockmoor Brierley Hill, DY5 3UT West midlands, UNITED KINGDOM Unit 3 Rowan Court, Crystal Drive, Smethwick, B66 1RB West Midlands, UNITED KINGDOM Ten bergstraat 4, 2830 Wildebroek, BELGIUM Schaarbeeklei 189, 1800 Vilvoorde, BELGIUM M.S.FITTINGS MFG. CO.(P)LTD.,H.O 17 WESTERN STREET, KOLKATTA 13 Ferro tubes & Forging Industries, C 1/129, GIDC Estate, vaghodia, Baroda-391760 496/1 GIDC Industrial Estate, Makarpura, Baroda-390010, pipefit@pipefit.net 315/317, Navratan 69,P D Mello Road Near Camac Bridge, Mumbai400009 Airut Manai(1st floor) 27 whites Road, Chennai-600014 Alliance fittings & forgings inc., A-468/469,T.T.C Industrial Area Swastik Lloyds Engineering Pvt. Ltd.,5 B Islam pura Street, Mumbai-400004 748/8,GIDC,Indi.Estate Makarpura, Baroda-390010 526/36,Maulana Azad Road,2nd Floor, (Gulawadi Circle), mumbai400004 D1,Sipcot Industrial Park, Irungaltukottai-602105, Tamil nadu "+31 168 33 43 44" "+49 4261 3090" Upto 30" class 600 fittings & flow tee Upto 30" class 600 fittings & flow tee Upto 30" class 600 fittings & flow tee Upto 30" class 600 fittings & flow tee Upto 30" class 600 fittings & flow tee Upto 30" class 600 fittings & flow tee Upto 24"class 600 011-25931302 011-25438624 upto 12" 600# Lift & Swing type upto 8" 600# (wafer type) ITEM NAME OF VENDOR ADDRESS PHONE NO FAX NO QUALIFIED FOR SIZE
52
Check/ Non Return Valve
Arpita Enterprise
02692 - 36187
53
Niton valve Industries Pvt. Ltd
022- 500 8315
022 - 5007654
Upto 24" 600# (Lift & Swing Type)
54 55 56
FMC Sanmar Ltd Protego Equipments Pvt. Ltd. Larsen & Tubro
044-492-5455
044-492-6114
Pressure Relief Valve
57
SEBIM valves India Pvt. Ltd.
011-23312110,23318360
011-23712155
58 59
RMG regal + GmbH,Germany INTERFORGE
60
KURVERS Piping
"+31 168 33 43 49"
61
MEREK Engineering
"+44 121 544 9938"
"+44 121 544 9132"
62 63 64
PETROFIT PHOCEENINE (Groupe Genoyer) VAN LEEUWEN BUIZEN MS Fittings Mfg. Co. Pvt. Ltd., Kolkatta Ferrous Alloy Forgings(P) Ltd.
0121 544 9938 "+32 3 860 73 70" "+32 2 255 40 00"
0121 544 9132 "+32 3 860 73 71" "+32 2 253 20 92"
65
033-2362902, 2362903
033-2252103
66
02668-62479
Upto 12"
67
Pipe Fit Engineers
0265-2636 547/545 "+91 22 342 3382-83, 91 22 343 7716 ,345477, 3446975" 044 8523375
0265-2636 546
Upto 24"class 600
68 69 Pipe fittings (Elbows, Tees,Reducers)
Teekay Tube Steward & Lloyds Alliance Fittings & forgings , Navi Mumbai Swastik Lloyds Engineering Pvt. Ltd., Mumbai Tube Products Incorporate.,Baroda
(022)349162 044 8522877 022-2788 1134/ 5590 2273
Upto 24"class 600
70
022-2788 1333/1916
Upto 12" Class 600
71
022-3860222/23
022-7402779
Upto 12" Class 600
72
0265-5545211 /214
0265-2831031
upto 36" 600#
73
Steel Tubes (India)
022-3895908/ 3822821 04111-256284, 256714
022-3895906
Upto 24"class 600
74
Eften Engineering Pvt. Ltd.
04111-256714
Upto 8"class 600
75
Dylan Belgie
Lerenveld 20, 2547 Lint, Belgium Dynamicalaan 4-8, 2610 Anlwerpen, Belgium Hohenzollernstrasse 24, 45128 Essen, Germany
32 3 488 4880
32 3 488 4880
Upto 30" class 600 fittings & flow tee Upto 30" class 600 fittings & flow tee Upto 30" class 600 fittings & flow tee Rev. 0
76
FBF
32 3 820 5880
32 3 828 2822
77
Ferrostaal(Mangroup)
49 201 818 01
49 201 818 2822
236 of 245
LIST OF RECOMMENDED VENDORS S.NO 1 78 Pipe fittings (Elbows, Tees,Reducers) Sawan Engineers 201, Palace Plaza,lalbaug Road, 0265-243 3003/553 Near kashivishwanath Temple,Baroda8303 390001, Email :sawanengg@sify.com 111,DLF Industrial Estate,14th Mile stone, Mathura Road Faridaba-121003 Parvati chambers,Opp Apsara cinema-pratap Nagar Road, Baroda-390004 201,Palace Plaza, Lalbaug Road,Near kashivishwanath Temple, Baroada-390001 Kanjur Village Road, Kunjan Marg east Mumbai- 400042 Ms Fittings Mfg.Co. Pvt.Ltd.Kolkata, H.O.17 Westeren street, Kolkata-13 748/8,GIDC,Indi.Estate Makarpura, Baroda-390010 P.O.Box20,Near Hapur Road,Opp Power House Ghaziabad 496/1,GIDC,Indi.Estate Makarpura, Baroda-390010 38B, MayapurI Indl Area Phase-1 New Delhi-110064 A-292, Mahipal Pur Ext. NH-8, New Delhi-110037 S-6, 1 st Floor, Uphar Market Complex, Green Park, New Delhi Hadaspur Industrial Estate, pune, Maharashtra 0265-243 5196 upto 24" class 600 ITEM NAME OF VENDOR ADDRESS PHONE NO FAX NO QUALIFIED FOR SIZE
79
Ferrous Alloy Forging(P) Ltd.
upto 24" 600# 0265 258 1125 upto 12" 600# 0265-2435196 upto 18" 600#
80
Sanghvi Forging & Engineering Ltd
0265-258 0644 /1658
81 Sawan Engineers 82 Flanges 83 Ms Fittings Mfg.Co. Pvt.Ltd.Kolkata Tube Products Incorporate, Baroda Choudhary Hammer Works, ECHJAY Forgings Ltd.
0265-2433003/ 3096008 225782461 225782830
225784962
upto 30" 600#
033-2352902, 2362903
033-2252103
upto 24" 600#
84
0265-5545211 /214 120-4744921 0265-2636547 /545
0265-2831031 120-4792897
upto 36" 600# upto 24" 600#
85 86
Pipe Fit Engineers 87 Punjab Steel Works 88 89 90 91 92 93 94 95 Motors Pumps Flow More pumps Pvt. Ltd. Becon Weir ltd. Kirloskar Pneumatic Co. Ltd. Roto pump ABB Comproton Greaves Ltd. Bharat bijli Kirloskar Pneumatic Co. Ltd.
0265-2636546
upto 24" 600#
011-5130960 011-30623710 011-4175561 2062870133
115137432
upto 24" 600#
14, mathura Road, Faridabad-121003 Vandana Building, 11 Tolstoy Marg, New Delhi 110001 Hadaspur Industrial Estate, pune, Maharashtra 147,karapakkam Village, Chennai-600096 32,Shivaji Marg,Post Box No.6223,Near Moti Nagar New Delhi 908,Ansari Bhawan,16, Kasturba Gandhi Marg, New Delhi-11000 011-23354514
2062870133
96 FMC Sanmar Ltd 97 Larsen & Tubro 98 Pressure Safety Relief Valves SEBIM Valves India Pvt. Ltd RMG Regal+ Messtech Gmbh TYCO SANMAR LTD Yokogawa Blue star Pressure /Level/Temeprature transmitters
044-4925455
044-4926114
011-5931302 011-3312110, 3318360
011-5438624
011-3712155
99 100 101
Germany
102
Tata Honey well ltd.
103
Fisher Rosemount Document No. LIST OF VENDORS 11-0330G01-01-11-06-01 SHEET 4 of 8 Rev. 0
237 of 245
LIST OF RECOMMENDED VENDORS S.NO 1 104 Invensys India/Emerson process ITEM NAME OF VENDOR ADDRESS PHONE NO FAX NO QUALIFIED FOR SIZE
105 Pressure /Level/Temeprature transmitters
H. Guru
106
A. N Instrument
107 General Instrumants 108 Wika 109 ICA 110 Instrumentation Panel 111 Pyrotech Controls 112 Enclotek 113 Instrument Fittings including manifold, needle valve etc Rittal
Swagelock Parkar
114
115
Impulse tubing
Sandvik
116
Daniel
117 USM Meter 118
RMG
FMC
119
Instromet A-273 Ansal chambers-1 3,Bhikaji cama place, New Delhi
120 Signal Repeater 121
MTL India Pvt. Ltd
011-26715408/6180
011-2671681
P&F
122 Indication Lamp 123
Concord
L&T
124 24 V DC Power supply 125 126 127 RTD With Thermowell 128 129 130 MCT
SITOP
PHEONIX Pyroelectric Instruments General Instruments ALTOP A.N.Instruments Signet International Document No. LIST OF VENDORS 11-0330G01-01-11-06-01 SHEET 5 of 8 Rev. 0
238 of 245
LIST OF RECOMMENDED VENDORS S.NO 1 131 MCT NEIMEX ITEM NAME OF VENDOR ADDRESS PHONE NO FAX NO QUALIFIED FOR SIZE
132 Alarm Anunclator 133
IIC
Procon
134 Selector Switch 135
KAYCEE
SALZER
136
Flame Proof Control Gears Pvt. Ltd
137 Junction Box 138
Flame Proof Equiments Pvt. Ltd
Flex pro Electricals pvt. Ltd,Navsari
139 140 141 142 143 144 145 146 147 Quick Opening and closing
CEAG PEERLESS GRINELL PECO SIIRTEC HUBER YALE GD ENGG TUBE TURN(USA) Honeywell
148 Digital Indicator 149
ABB
YOKOGAWA
150 151 152 153 154 155 156 157 158 159 Isolating Barrier 160 Instrumentation Signal Control Cable Switch Socket & Plugs
MASIBUS B.C.H. Baliga CGL MDS Delton CORDS KEI Polycabs Associate cables MTL India Pvt. Ltd A-273 Ansal chambers-1 3,Bhikaji cama place, New Delhi 011-26715408/6180 011-2671681
P&F Document No. LIST OF VENDORS 11-0330G01-01-11-06-01 SHEET 6 of 8 Rev. 0
239 of 245
LIST OF RECOMMENDED VENDORS S.NO 1 161 Control switch Gear ITEM NAME OF VENDOR ADDRESS PHONE NO FAX NO QUALIFIED FOR SIZE
162
Electromac
163
Cable Glands
Commet
164
Baliga
165
Flameproof Control Gear
166
Lugs Instrument fitting SWAGELOK
Dowells
167
Parker
168
IL Paighat
169
Fisher
170
Foxboro
171
Control Valve
Valtex
172
Dresser valves(India)
173
Schlumberger(Actaris)
174
Masoneilan
175 Gas Chromatgraph 176
Daniel
RMG
177 Electronic Controllers (Flow/Level/Pressure &Temp)
Foxbro
178
Honeywell
179
ABB
180 Terminal Block 181 182 183 184 Filtering/ Pack Element 185 186 187
Elemex
Phoenix Contact(India) Pvt.Ltd. PECO FILTAN FACET VELCON ACS BURGESS MANNING Document No. LIST OF VENDORS 11-0330G01-01-11-06-01 SHEET 7 of 8 Rev. 0
240 of 245
LIST OF RECOMMENDED VENDORS S.NO 188 189 190 191 192 193 ITEM NAME OF VENDOR Raychem Denso SHAIC International Co. Sparco Multiplast Parixit Industries
Meteor private Limited Street 121-122 Ansal Bhawan K G Marg New Delhi- 110001 Ms. Bala Srinivasan,79 Valmiki Street Chennai,Tamil Nadu India Corporate Headquarter: via del Lavoro, 16, 41030 Bastiglia (Modena), Italy 878/1, GIDC Estate, Makarpura Baroda - 390 010, Gujrat India Largo Industrie, 30/33 240/20, Torre Boldone BE Italy SHANGHAI FIORENTINI GAS EQUIPMENT CO.LTD 4493 LONG DONG AVENUE , PUDONG NEW AREA , SHANGHAI , CHINA. ZIP - 201201
ADDRESS
PHONE NO
FAX NO
QUALIFIED FOR SIZE
Hot Shrink Sleeve
Warning Mat
194 195 196 Insulation Joints
IGP Engineers Pvt. Ltd.
ALFA ENGINEERING srl
ADVANCE Electronics System
197
Zunt Italina
198
Shanghai Fiorentini gas equipment
199 200 201 202 203 204 205 206 207 208 209 210
TD WILLIAMSON LTD. FORAIN S.r.l. Skelton Hall
Swindon Wittshire SN3 5HF ENGLAND Via G. Boeri, 11 20141, Milano, ITALY
70, Carwood Road Sheffield S4 7SD England 120,Maker chamber, V-221, Nariman EQUIP ENGINEERS INDIA PVT. LTD. point, Mumbai-2 443, Anna Salai, Teynampet, CHENNAI Scraper Traps (Pig 600 018 Launchers & Receivers) GEA Energy System (India) Ltd. Nottinghamshire S82 PY ENGLAND GD ENGINEERING Gastech Engineering Pvt. Ltd., B-20, 1st Gastech Floor, Lajpat Naagr-II, New Delhi-110024 Multitex Engg Karol Bagh, Delhi Control Plus V K Vikram Tata Projects Ltd. Indian Register of Shipping Bax counsel Insepection Bureau Pvt. 303, Madhava,Bandra Kurla Complex, 022-26591526,022022-26591526 Ltd. Bandra(E),Mumbai-400051 26590236 22,Sarvodaya Society,Nizampura,Baroda-390002 0265-2392863 0265-2785952
211
212
Bureau VeritasQl
The Leela Galleria,5th floor,Andheri022-26956300 Kurla Road,Andheri(E),Mumbai-400059
022-26956309
213 Third Party Inspection Agency
Germanischer Lloyd
304-305, Anna Salai,Teyanampet,Chennai-600018 Velosi Certification Services(I)Pvt.Ltd.,212,Shivkrupa Complex Centre,Off Ghokhale 404,Mayuresh Chambers,Sector11,CBD Belapur(E),Navi Mumbai400614
044-24320335
044-24328186
214
Velosi Certification Serrvices,Mumbai ABS Industrial Verification Ltd., Mumbai
022-25376770
022-25426777
215
022-27578780 /1 /2 022-27578784 / 5 011-26167539, 26102121 079-26575550
216
Certification Engineers International EIL Bhavan,5th floor,1,Bhikaji Camma Ltd. Place,New Delhi-110066 Dalal Mott MacDonald 501, Sakar -II, Ellisbridge,Ahemedabad380006 E-7,Chand Society, Juhu Road, Juhu, Mumbai-4000049 SGS India Pvt. Ltd.,SGS House,4B,A.S.Marg,Vikhroli (W),Mumbai-400083
011-26101419
217
079-6575558
218
International Certification Systems
022-26245747
022-226248167
219
SGS
022-25798421 to 28 022-25798431 to 33
Rev. 0
241 of 245
242 of 245
243 of 245
244 of 245
245 of 245

Volime II of II Mechanical Piping-GAIL

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Volime II of II Mechanical Piping-GAIL

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GAIL (India) Limited

PIPELINE FROM HANUMAN JUNCTION TO VCL

BID DOCUMENT FOR PIPELINE LAYING & TERMINAL WORKS

OPEN DOMESTIC COMPETITIVE BIDDING

13.0 14.0 15.0 16.0. 17.0

11-0330G01-01-09-02-010 Rev. 0 11-0330G01-01-09-02-009 Rev 0 11-0330G01-01-08-02-018 Rev 0 11-0330G01-01-09-02-003 Rev 0

122 126 130 134

11-0330G01-01-09-02-007Rev. 0 11-0330G01-01-08-02-006 Rev

Document No. TABLE OF CONTENTS 11 / 0330G01 / WGI/ GAIL / 01 SHEET 1 of 2

INSPECTION, FLUSHING AND TESTING OF PIPING SYSTEM STANDARD PIPING DRAWINGS

1-08-007 TO 10, 1-08-017, 1-08026, 1-08-027, 1-08-028

24.0 25.0 26.0 27.0

11-0330G01-01-11-03-006 Rev 0 11-0330G01-01-09-03-003 Rev 0 11-0330G01-01-11-06-01 Rev 0

229 231 233

27.2 27.3 27.4

11-0330G01-01-02-01-002 Rev B 11-0330G01-01-02-01-003 Rev B 11-0330G01-01-02-01-004 Rev B

243 244 245

Document No. TABLE OF CONTENTS 11 / 0330G01 / WGI/ GAIL / 01 SHEET 2 of 2

GAIL (India) Limited

CLIENT JOB NO.

PIPING MATERIAL SPECIFICATION

28-06-11 24-06-11 DATE

ISSUED FOR TENDER ISSUED FOR IDC DESCRIPTION

ASD ASD CHK

Document No. PIPING MATERIAL SPECIFICATION 11-0330G01-01-08-02-001 SHEET 2 of 18

API 600 API 602 MSS SP 44 MSS SP 75 MSS SP 97

ASTM A 105 ASTM A 193 ASTM A 194

ASTM A 333 ASTM A 350

Document No. PIPING MATERIAL SPECIFICATION 11-0330G01-01-08-02-001 SHEET 4 of 18

SAW SMLS 5.0

Submerged Arc Welded Seamless

Document No. PIPING MATERIAL SPECIFICATION 11-0330G01-01-08-02-001 SHEET 6 of 18

150# ANSI B 31.8

PIPELINE FROM HANUMAN JUNCTION TO VCL

RATING AND/OR SCHED.

4" 6" 8"

6.4 mm 6.4 mm 6.4 mm S160 XS S40 3000# M 3000# M M M MXM

0.50" - 1.50" 2" 3" - 16"

0.50" - 1.50" 2" - 16"

ASME B16.9 ASTM A 234 Gr WPB ASME B16.11 ASTM A105

0.50" - 1.50" 2" - 16"

LR Bends 90 LR Bends 45 REDUCERS CONCENTRIC REDUCERS ECCENTRIC TEES EQUAL

4-16" 4-16" 2" - 16"

ASME B16-9 ASTM A 234 Gr WPB

0.50" - 1.50" 2" - 16"

SW BW SW BW SW BW - ASME B16-25 SCRF BW PBE, SEAMLESS SW SW

3000# M 3000# MXM 3000# MXM 3000# M M 3000# 3000#

ASME B16.9 ASTM A 234 Gr WPB ASME B16.11 ASTM A105

0.50" - 1.50" 2" - 16"

SOCKOLET WELDOLETS CAPS

0.50" - 1.50" 2" - 16" 0.50" - 1.50" 2" - 16"

NIPPLES FULL COUPLINGS HALF COUPLINGS

0.50" - 1.50" 0.50" - 1.50" 0.50" - 1.50"

150# ANSI B 31.8

PIPELINE FROM HANUMAN JUNCTION TO VCL

CODE BASIC MATERIAL

SPCR & BLND

Bolt: A193 B7 Nut: A194 Gr.2H

GASKETS SPIRAL WOUND GATE

B-16.20 ASME B16.5

SP. WND metallic with Graphite Filler (5 mm thick)

SW , B16.11 FLG, B16.5, RF/125 AARH SW,BS-5353