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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

1 of 245

TABLE OF CONTENT
S.No.

DOCUMENT TITLE

DOCUMENT NUMBER

Page No

1.0

PIPING MATERIAL SPECIFICATION

11-0330G01-01-08-02-001 Rev 0

2.0

MECHANICAL DESIGN BASIS

11-0330G01-01-09-02-001Rev 0

22

3.0

ASSORTED VALVES

11-0330G01-01-08-02-008Rev 0

33

4.0

DATA SHEET BALL VALVE

11-0330G01-01-08-03-002 Rev 0

69

5.0

QAP BALL VALVE

11-0330G01-01-08-10-002 Rev 0

75

6.0

DATA SHEET PLUG VALVE

11-0330G01-01-08-03-008 Rev 0

78

7.0

QAP PLUG VALVE

11-0330G01-01-08-10-004 Rev 0

86

8.0

DATA SHEET CHECK VALVE

11-0330G01-01-08-03-005 Rev 0

89

9.0

QAP CHECK VALVE

11-0330G01-01-08-10-005 Rev 0

95

10.0

ASSORTED PIPES

11-0330G01-01-08-02-011Rev 0

98

11.0

TECHNICAL NOTES FOR VALVES

11-0330G01-01-08-02-016 Rev 0

106

12.0

TECHNICAL NOTES FOR BUTT WELDED,


SOCKET WELDED & SCREWED FITTINGS

11-0330G01-01-08-02-017 Rev 0

117

13.0

TECHNICAL NOTES FOR BOLTS & NUTS

11-0330G01-01-09-02-010 Rev. 0

122

14.0

FLANGES, SPECTACLE BLIND & DRIP RINGS

11-0330G01-01-09-02-009 Rev 0

126

15.0

TECHNICAL NOTES FOR GASKETS

11-0330G01-01-08-02-018 Rev 0

130

16.0.

TECHNICAL SPECIFICATIONS FOR IJ

11-0330G01-01-09-02-003 Rev 0

134

17.0

WELDING SPECIFICATION FOR


FABRICATION OF PIPING

11-0330G01-01-09-02-011Rev 0

142

18.0

NON DESTRUCTIVE REQUIREMENTS OF


PIPING

11-0330G01-01-08-02-019 Rev 0

168

19.0

TECHNICAL SPECIFICATION FOR PAINTING

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

176

20.0

FLANGES & FITTINGS UPTO 16

11-0330G01-01-08-02-006 Rev

203

TABLE OF CONTENTS

Document No.

Rev

11 / 0330G01 / WGI/ GAIL / 01

SHEET 1 of 2
2 of 245

21.0

INSPECTION, FLUSHING AND TESTING OF


PIPING SYSTEM

22.0

STANDARD PIPING DRAWINGS

23.0

11-0330G01-01-08-02-009 Rev 0

208

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

216

TECHNICAL SPECIFICATION FOR PIG


SIGNALLER

11-0330G01-01-11-02-006 Rev 0

224

24.0

DATA SHEET FOR PIG SIGNALLER

11-0330G01-01-11-03-006 Rev 0

229

25.0

DATA SHEET FOR IJ

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

231

26.0

LIST OF VENDORS

11-0330G01-01-11-06-01 Rev 0

233

27.0

PIPING GENERAL ARRANGEMENT


DIAGRAMS

27.1

PIPING GAD FOR DISPATCH


STATION(HANUMAN JUNCTION)

11-0330G01-01-02-01-001 Rev B

242

27.2

PIPING GAD FOR SV-1

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

243

27.3

PIPING GAD FOR SV-2

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

244

27.4

PIPING GAD FOR RECIEVING STATION

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

245

TABLE OF CONTENTS

Document No.

Rev

11 / 0330G01 / WGI/ GAIL / 01

SHEET 2 of 2
3 of 245

GAIL (India) Limited


PIPELINE FROM HANUMAN JUNCTION TO VCL

CLIENT JOB NO.

TOTAL SHEETS

18

PIPING MATERIAL SPECIFICATION

DOCUMENT NO

11

0330G01

01

08

02

001

28-06-11

ISSUED FOR TENDER

MH

ASD

AD

24-06-11

ISSUED FOR IDC

MH

ASD

AD

REV

DATE

DESCRIPTION

PREP

CHK

APPR

4 of 245

TABLE OF CONTENT

CONTENT

PAGE No.

GENERAL NOTES

DEFINITIONS

CODES AND STANDARDS

ABBREVIATIONS

PIPING CLASS DESCRIPTION

PIPING CLASS 1A1

PIPING CLASS 3A1

11

PIPING CLASS 6A1

15

PIPING MATERIAL SPECIFICATION

Document No.

Rev

11-0330G01-01-08-02-001

SHEET 2 of 18
5 of 245

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

3.0

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.

Should

: 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.

May

: This verbal form indicates a course of action permissible within the


limits of this standard.

Can

: This verbal form is used for statements of possibility & capability,


whether material, physical or casual.

CODES AND STANDARDS


The latest revision of the following shall be considered as part of this specification.
ASME B 16.5

Steel Pipe Flanges and Flanged Fittings

ASME B 16.9

Factory made Wrought Steel Buttwelding Fittings

ASME B 16.11

Forged Steel Fittings, Socket Welding and Threaded

ASME B 16.20

Metallic Gaskets for Pipe Flanges.

ASME B 16.21

Non-Metallic Flat Gasket for Pipe Flanges

ASME B 16.47

Large Diameter Steel Flanges (26 throu 60)

ASME B 31.3

Process Piping

ASME B 31.4

Pipeline Transportation system for Liquid hydrocarbons & other Liquids

ASME B 31.8

Gas Transmissions and Distribution Piping System

ASME B 36.10

Welded and Seamless Wrought Steel Pipe

ASME B 46.1

Surface Texture

API 5L

Line Pipe

API 6D

Pipeline Valves

API 590

Steel Line Blank

PIPING MATERIAL SPECIFICATION

Document No.

Rev

11-0330G01-01-08-02-001

SHEET 3 of 18
6 of 245

4.0
4.1

API 600

Steel Gate Valves Flanges and Buttwelding Ends

API 602

Compact Steel Gate Valves

MSS SP 44

Steel Pipe line Flanges

MSS SP 75

Specification for High Test Wrought Butt Welding Fittings

MSS SP 97

Integrally Reinforced Forged Branch Outlet Fitting Socket Welding,


Threaded and Buttwelding Ends

ASTM A 105

Forging, Carbon Steel for Piping Components

ASTM A 193

Alloy Steel and Stainless Steel bolting Materials for High temp Service.

ASTM A 194

Carbon and Alloy Steel Nuts for Bolts for High Pressure and High
Temperature Service

ASTM A 320

Standard Specification for Alloy Steel and Stainless Steel Bolting


Materials

ASTM A 216

Steel Casting, Carbon, Suitable for Fusion Welding, for High


Temperature Service.

ASTM A 234

Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate
and Elevated Temperature

ASTM A 285

Pressure Vessel Plates, Carbon Steel, Low and Intermediate Tensile


Strength.

ASTM A 694

Forging, Carbon and Alloy Steel, for Pipe Flanges, Fitting, Valves and
Parts for High Pressure Transmission Service.

ASTM A 333

Low temperature service seamless pipe.

ASTM A 350

Forged Carbon and Low Alloy Steel requiring Notch Toughness Testing
for Piping Components

ASTM A 420

Piping Fittings of Wrought Carbon Steel and Alloy Steel for Low
Temperature Service.

ASTM A 860

Standard Specification for Wrought High Strength Low Alloy Steel Butt
Welding Fittings

ABBREVIATIONS
Flange Facing
RTJ
FF
RF

Ring Type Joint


Flat Face
Raised Face

PIPING MATERIAL SPECIFICATION

Document No.

Rev

11-0330G01-01-08-02-001

SHEET 4 of 18
7 of 245

4.2

Fittings
PE
BE
BW
PBE
POE
TBE
TOE
LR
SR

4.3

Butt-Weld
Flanged
Screwed
Slip-On
Socket Weld
Threaded
Weld Neck

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

Valve Description
BC
BB
ES
FB
MO
GO
NRS
OS&Y
RB
RS
SC
UB
UC
WB

4.6

Wall Thickness
SCH
STD
XS
XXS

4.5

Plain End
Bevel End
Butt Weld
Plain Both End
Plain One End
Threaded Both End
Threaded One End
Long Radius
Short Radius

Connections
BW
FLGD
SCRD
SO
SW
THRD
WN

4.4

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

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

PIPING MATERIAL SPECIFICATION

Document No.

Rev

11-0330G01-01-08-02-001

SHEET 5 of 18
8 of 245

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

PIPING MATERIAL SPECIFICATION

Document No.

Rev

11-0330G01-01-08-02-001

SHEET 6 of 18
9 of 245

RATING

PIPING SPECIFICATION

1A1
TEMPERATURE

( 0 TO 60 C)

PRESSURE
ITEM

PIPELINE

PIPES

ELBOWS 90 LR

150#

CODE

PIPELINE FROM HANUMAN JUNCTION TO


VCL

ANSI B 31.8

BASIC MATERIAL

(18.75 bar g)
SHORT

SIZE

RATING

DIMENSION

CODE

FROM-

AND/OR

STANDARD

THRU

SCHED.

PL

DESCRIPTION

MATERIAL

REMARKS

4"

BE

6.4 mm

API 5L

API 5L Gr. X42

6"

BE

6.4 mm

API 5L

API 5L Gr. X52

8"

BE

6.4 mm

API 5L

API 5L Gr. X56

0.50" - 1.50"

PE, SEAMLESS

S160

ASME B36-10

ASTM A 106 Gr.B

2"

BE, SEAMLESS

XS

ASME B36-10

ASTM A 106 Gr.B

3" - 16"

BE, SEAMLESS

S40

ASME B36-10

ASTM A 106 Gr.B

0.50" - 1.50"

SW

3000#

ASME B16.11

ASTM A105

2" - 16"

BW, 1.5D, 3D

0.50" - 1.50"

SW

3000#

2" - 16"

BW, 1.5D, 3D

ASME B16.9 ASTM A 234 Gr WPB

4-16"

BW, 3D

ASME B16.9 ASTM A 234 Gr WPB

ASME B16.9 ASTM A 234 Gr WPB

ELBOWS 45 LR

E45

ASME B16.11

ASTM A105

LR Bends 90

LR B

LR Bends 45

LR B 45

4-16"

BW, 3D

ASME B16.9 ASTM A 234 Gr WPB

REDUCERS

RC

2" - 16"

BW - ASME B16-25

MXM

ASME B16-9 ASTM A 234 Gr WPB

REDUCERS
ECCENTRIC

RE

2" - 16"

BW - ASME B16-25

MXM

ASME B16-9 ASTM A 234 Gr WPB

TEES EQUAL

0.50" - 1.50"

SW

3000#

ASME B16.11

2" - 16"

BW

ASME B16.11

CONCENTRIC

ASTM A105

ASME B16.9 ASTM A 234 Gr WPB

TEES RED

TR

0.50" - 1.50"

SW

3000#

2" - 16"

BW

MXM

ASME B16.9 ASTM A 234 Gr WPB

SOCKOLET

0.50" - 1.50"

SW

3000#

MSS-SP 75

ASTM A105

WELDOLETS

2" - 16"

BW - ASME B16-25

MXM

MSS-SP 75

ASTM A105

0.50" - 1.50"

SCRF

3000#

ASME B16.11

ASTM A105

2" - 16"

BW

0.50" - 1.50"

PBE, SEAMLESS

CAPS

NIPPLES
FULL
COUPLINGS

NA
FC

0.50" - 1.50"

SW

3000#

HALF

HC

0.50" - 1.50"

SW

3000#

ASTM A105

ASME B16-9 ASTM A 234 Gr WPB


ASME B36-10

ASTM A 106 Gr.B

ASME B16-11

ASTM A105

ASME B16-11

ASTM A105

COUPLINGS

NOTE: M=THICKNESS TO MATCH PIPE WALL THICKNESS

PIPING MATERIAL SPECIFICATION

Document No.

Rev

11- 0330G01-01-08-02-001

Sheet 7 of 18

10 of 245

PIPING SPECIFICATION

RATING

1A1
TEMPERATURE
PRESSURE
ITEM

PIPELINE FROM HANUMAN JUNCTION TO VCL


( 0 TO 60 C)

150#

CODE

ANSI B 31.8

BASIC MATERIAL

(18.75 bar g)
SHORT

SIZE

CODE

DESCRIPTION

RATING

DIMENSION

FROM-

AND/OR

STANDARD

THRU

SCHED.

WN FLANGES

FW

0.50"-16"

RF,125 AARH

150#

ASME B16-5

BLIND

FB

0.50"-16"

RF,125 AARH

150#

ASMEB16-5

FF

0.5" - 16"

RF,125 AARH

150#

ASME B16-48

FSB

16"

RF,125 AARH

150#

ASME B16-48

0.5" - 16"

REMARKS

MATERIAL

ASTM A105

ASTM A105

FLANGE

FLANGES

ASTM A105

FIG 8

SPCR &

ASTM A105

BLND

STUD BOLTS

ASME B18-2

Bolt: A193 B7
Nut: A194 Gr.2H

GASKETS

0.5" - 16"

150#, SPIRAL

SPIRAL

B-16.20 ASME B16.5

WOUND
GATE

(5 mm thick)
VG

VALVE

PLUG
VALVE

SP. WND
metallic with
Graphite Filler

0.50 - 1.50

SW , B16.11

800#

API 602

ASTM A105

2''-16''

FLG, B16.5,
RF/125 AARH

150#

API 600

ASTM A 216 Gr WCB

0.50 - 1.50

SW,BS-5353

800#

ASME B16.10

ASTM A105

2''-16''

FLG/BW,API6D

150#

ASME B16.10

ASTM A 216 Gr WCB

PV

NOTE: M=THICKNESS TO MATCH PIPE WALL THICKNESS

PIPING MATERIAL SPECIFICATION

Document No.

Rev.

11-0330G01-01-08-02-001

Sheet 8 of 18

11 of 245

PIPING SPECIFICATION

1A1
TEMPERATURE
PRESSURE
ITEM

BALL

RATING

PIPELINE FROM HANUMAN JUNCTION TO VCL


( 0 TO 60 C)

150#

CODE

ANSI B 31.8

BASIC MATERIAL

(18.75 bar g)
SHORT

SIZE

CODE

VBA

DESCRIPTION

RATING

DIMENSION

FROM-

AND/OR

STANDARD

THRU

SCHED.

0.50'' - 1.50'' SW:ASME B16-11

800#

REMARKS

MATERIAL

ASME B16-10

VALVES

BODY:

FULL BORE

ASTM A105

FIRE SAFE

BALL:

WRENCH OPERATED.

SS 316

2"-3"

BW:ASME B16-5

150#

BODY:

FULL BORE

ASTM A216 Gr. WCB

FIRE SAFE

ASME B16-10

BALL:

WRENCH OPERATED.

(A 216 Gr. WCB)


+ 0.003" ENP
4"-16"

BW:ASME B16-5

150 #

BODY:

FULL BORE

ASTM A216 Gr. WCB

FIRE SAFE

ASME B16-10

BALL:

GEAR OPERATED.

(A 216 Gr. WCB)


+ 0.003" ENP
GLOBE

VGL

0.50'' - 1.50''

VALVES

SW

800#

ASME B16-10

BODY:

ASME B16-11

ASTM A 105

HANDWHEEL
FIRE SAFE

TRIM:
ASTM A182 F6
2" - 16"

FLGD RF

150#

ASME B16-10

ASME B16-5

BODY:
ASTM A 216 Gr. WCB

HANDWHEEL
FIRE SAFE

TRIM:
ASTM A182 F6
LIFT CHECK

0.50'' - 1.50''

VALVES

SW

800#

ASME B16-10

BODY:

ASME B16-11

HORIZONTAL INSTALLATION

ASTM A 105
TRIM:
ASTM A182 F6

VCH
2"-16"
SWING CHECK
VALVE

FLGD RF

150#

ASME B16-10

ASME B16-5

BODY:
ASTM A 216 Gr. WCB
TRIM:

HORIZONTAL INSTALLATION
VERTICAL INSTALLATION FLOW
UPWARDS

ASTM A182 F6
NOTE: M=THICKNESS TO MATCH PIPE WALL THICKNESS

PIPING MATERIAL SPECIFICATION

Document No.

Rev.

11-0330G01-01-08-02-001

Sheet 9 of 18

12 of 245

PIPING SPECIFICATION

RATING

1A1
TEMPERATURE ( 0 TO 60 C)
PRESSURE

150#

PIPELINE FROM HANUMAN JUNCTION CODE


ANSI B 31.8
TO VCL
BASIC MATERIAL

(18.75 bar g)

BRANCH TABLE

1/2" 3/4"

H
E

1"

1.1/2"

2"

3"

4"

6"

8"

1/2"

3/4"

1"

1.1/2" T

10"

S I

12"

14"

16"

2"

3"

4"

6"

8"

10"

12"

14"

16"

LEGEND
T : TEE
S: SOCKOLET - SW
W : WELDOLET - BW

PIPING MATERIAL SPECIFICATION

Document No.

Rev.

11-0330G01-01-08-02-001

Sheet 10 of 18

13 of 245

RATING

PIPING SPECIFICATION

3A1
TEMPERATURE

PIPELINE

PIPES

ELBOWS 90 LR

ELBOWS 45 LR

PIPELINE FROM HANUMAN JUNCTION TO VCL


(49 bar g)

SHORT

SIZE

RATING

DIMENSION

CODE

FROM-

AND/OR

STANDARD

THRU

SCHED.

PL

E45

DESCRIPTION

MATERIAL

4"

BE

6.4 mm

API 5L

API 5L Gr. X42

6"

BE

6.4 mm

API 5L

API 5L Gr. X52

8"

BE

6.4 mm

API 5L

API 5L Gr. X56

0.50" - 1."

PE, SEAMLESS

XXS

ASME B36-10

ASTM A 106 Gr.B

1.5"

PE, SEAMLESS

XS

ASME B36-10

ASTM A 106 Gr.B

2"

BE, SEAMLESS

XS

ASME B36-10

ASTM A 106 Gr.B


ASTM A 106 Gr.B

3" - 16"

BE, SEAMLESS

S40

ASME B36-10

0.50" - 1.50"

SW

3000#

ASME B16.11

ASTM A105

2" - 16"

BW, 1.5D, 3D

ASME B16.9

ASTM A 234 Gr WPB

0.50" - 1.50"

SW

3000#

ASME B16.11

ASTM A105

2" - 16"

BW, 1.5D, 3D

ASME B16.9

ASTM A 234 Gr WPB

LR Bends 90

LR B

4-16"

BW, 3D

ASME B16.9

ASTM A 234 Gr WPB

LR Bends 45

LR B 45

4-16"

BW, 3D

ASME B16.9

ASTM A 234 Gr WPB

RC

2" - 16"

BW - ASME B16-25

MXM

ASME B16-9

ASTM A 234 Gr WPB

RE

2" - 16"

BW - ASME B16-25

MXM

ASME B16-9

ASTM A 234 Gr WPB

0.50" - 1.50"

SW

3000#

ASME B16.11

ASTM A105

2" - 16"

BW

MXM

ASME B16.9

ASTM A 234 Gr WPB

0.50" - 1.50"

SW

3000#

ASME B16.11

ASTM A105

2" - 16"

BW

MXM

ASME B16.9

ASTM A 234 Gr WPB

SW

3000#

MSS-SP 75

ASTM A105

REDUCERS

300#
ANSI B 31.8

BASIC MATERIAL

( 0 TO 60 C)

PRESSURE
ITEM

CODE

REMARKS

CONCENTRIC
REDUCERS
ECCENTRIC

TEES EQUAL

TEES RED

TR

SOCKOLET

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

FC

0.50" - 1.50"

SW

3000#

ASME B16-11

ASTM A105

HC

0.50" - 1.50"

SW

3000#

ASME B16-11

ASTM A105

0.50" - 1.50"

COUPLINGS
HALF
COUPLINGS

NOTE: M=THICKNESS TO MATCH PIPE WALL THICKNESS

PIPING MATERIAL SPECIFICATION

Document No.

Rev.

11- 0330G01-01-08-02-001

Sheet 11 of 18

14 of 245

RATING

PIPING SPECIFICATION

3A1
TEMPERATURE
PRESSURE
ITEM

CODE

PIPELINE FROM HANUMAN JUNCTION TO VCL

300#
ANSI B 31.8

BASIC MATERIAL

( 0 TO 60 C)
(49 bar g)
SHORT

SIZE

CODE

FROM-

DESCRIPTION

THRU

RATING

DIMENSION

AND/OR

STANDARD

MATERIAL

REMARKS

SCHED.

WN FLANGES

FW

2"-16"

RF, 125 AARH

300#

ASME B16-5

FLG SW

FS

0.50 - 1.50

RF, 125 AARH

300#

ASME B16-5

BLIND

FB

0.50"-16"

RF, 125 AARH

300#

ASME B16-5

FF

0.5" - 16"

FF, 125 AARH

300#

ASME B16-48

FSB

16"

FF, 125 AARH

300#

ASMEB16-48

0.50" - 16''

ASTM A105

ASTM A105

ASTM A105

FLANGE

FLANGES

ASTM A105

FIG 8

SPCR &

ASTM A105

BLND

STUD BOLTS

ASME B18-2

Bolt: A193 B7
Nut: A194 Gr.2H

GASKETS

0.5" - 16"

SPIRAL, 300#

SPIRAL

B-16.20 ASME B16.5

WOUND

GATE

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

VG

0.50 - 1.50

SW

VALVE

800#

API 602

ASTM A105

300#

API 600

ASTM A 216 Gr WCB

B16.11
2" - 16"

FLGD, B-16.5,
RF/125 AARH

PLUG
VALVE

VP

0.50" - 1.50"

SW, BS -5353

800#

ASME B16-10

ASTM A105

2" - 16"

FLG/ BW, API 6D

300#

ASME B16-10

ASTM A 216 Gr WCB

NOTE: M=THICKNESS TO MATCH PIPE WALL THICKNESS

PIPING MATERIAL SPECIFICATION

Document No.

Rev.

11-0330G01-01-08-02-001

Sheet 12 of 18

15 of 245

PIPING SPECIFICATION

3A1

RATING

PIPELINE FROM HANUMAN JUNCTION TO VCL

TEMPERATURE ( 0 TO 60 C)
PRESSURE
ITEM

CODE

ANSI B 31.8

BASIC MATERIAL

(49 bar g)
SHORT

SIZE

CODE

FROM-

VBA

0.50 - 1.50

DESCRIPTION

THRU
BALL

300#

RATING

DIMENSION

AND/OR

STANDARD

MATERIAL

REMARKS

SCHED.
SW, ASME B16-11

300#

VALVES

ASME B16-10

BODY:

FULL BORE

BS 5351

ASTM A105

FIRE SAFE

BALL:SS 316

WRENCH OPERATED.

BODY SEAT: RPTFE


2"

FLGD RF:ASME B16-5

300#

or BW :ASME B16-5

ASME B16-10

BODY:

BS 5351

ASTM A216 Gr. WCB

FULL BORE, FIRE SAFE, WRENCH OPERATED

BALL:
(A 216 Gr. WCB)
+ 0.003" ENP
BODY SEAT: RPTFE
3" - 4"

FLGD RF:ASME B16-5

300#

or BW :ASME B16-5

ASME B16-10

BODY:

BS 5351

ASTM A216 Gr. WCB


(A 216 Gr. WCB)
+ 0.003" ENP
BODY SEAT: RPTFE

6"-16''

FLGD RF:ASME B16-5

300#

or BW :ASME B16-5

VGL

0.50 - 1.50

SW, ASME B16-11

300#

VALVES

FULL BORE
FIRE SAFE
WRENCH OPERATED.

ASME B16-10

BODY:

BS 5351

ASTM A216 Gr. WCB

FULL BORE

(A 216 Gr. WCB)


+ 0.003" ENP

FIRE SAFE

BODY SEAT: RPTFE


GLOBE

DOUBLE BLOCK AND BLEED

ASME B16-10

BODY:

BS 5352

ASTM A 216 Gr. WCB

DOUBLE BLOCK AND BLEED

GEAR OPERATED.
HANDWHEEL
FIRE SAFE

TRIM:
ASTM A182 F6
2" - 4"

FLGD RF:ASME B16-5

300#

ASMEB16-10

BODY:

BS 1873

ASTM A 216 Gr. WCB

HANDWHEEL
FIRE SAFE

TRIM:
ASTM A182 F6
6" - 16"

FLGD RF:ASME B16-5

300#

ASME B16-10

BODY:

BS 1873

ASTM A 216 Gr. WCB

GEAR OPERATED
FIRE SAFE

TRIM:
ASTM A182 F6
LIFT CHECK

0.50 - 1.50

SW, ASME B16-11

300#

VALVES

ASME B16-10

BODY:

BS 5352

ASTM A 105

HORIZONTAL INSTALLATION

TRIM:
ASTM A182 F6
VCH

2"-16''

FLGD RF:ASME B16-5

300#

ASME B16-10

BODY:

BS 1868

ASTM A 216 Gr. WCB

SWING
CHECK
VALVE

HORIZONTAL INSTALLATION
VERTICAL INSTALLATION FLOW UPWARDS

TRIM:
ASTM A182 F6

NOTE: M=THICKNESS TO MATCH PIPE WALL THICKNESS

PIPING MATERIAL SPECIFICATION

Document No.

Rev.

11-0330G01-01-08-02-001

Sheet 13 of 18

16 of 245

PIPING SPECIFICATION

RATING

3A1

PIPELINE FROM HANUMAN JUNCTION TO


VCL

TEMPERATURE ( 0 TO 60 C)
PRESSURE

CODE

300#
ANSI B 31.8

BASIC MATERIAL

(49 bar g)

BRANCH TABLE

1/2" 3/4"

1" 1.1/2" 2"

3"

4"

6"

8"

10"

12"

S
14"

1/2"

3/4"

1"

1.1/2"

2"

3"

4"

6"

8"

10"

12"

14"

16"

16"

LEGEND
T : TEE
S: SOCKOLET -SW
W : WELDOLET- BW

PIPING MATERIAL SPECIFICATION

Document No.

Rev.

11-0330G01-01-08-02-001

Sheet 14 of 18

17 of 245

PIPING SPECIFICATION

RATING

6A1
TEMPERATURE

ITEM

PIPELINE

PIPES

ELBOWS 90 LR

ELBOWS 45 LR

PIPELINE FROM HANUMAN JUNCTION TO VCL


(92 bar g)

SHORT

SIZE

RATING

DIMENSION

CODE

FROM-

AND/OR

STANDARD

THRU

SCHED.

PL

E45

DESCRIPTION

MATERIAL

4"

BE

6.4 mm

API 5L

API 5L Gr. X42

6"

BE

6.4 mm

API 5L

API 5L Gr. X52

8"

BE

6.4 mm

API 5L

API 5L Gr. X56

0.50" - 1.5"

PE, SEAMLESS

XXS

ASME B36-10

ASTM A 106 Gr.B

2"-10"

BE, SEAMLESS

XS

ASME B36-10

ASTM A 106 Gr.B

12" - 16"

BE, SEAMLESS

S60

ASME B36-10

ASTM A 106 Gr.B

0.50" - 1.50"

SW

6000#

ASME B16.11

ASTM A105

2" - 16"

BW, 1.5D, 3D

ASME B16.9

ASTM A 234 Gr WPB

0.50" - 1.50"

SW

6000#

ASME B16.11

ASTM A105

2" - 16"

BW, 1.5D, 3D

ASME B16.9

ASTM A 234 Gr WPB

LR Bends 90

LR B

4-16"

BW, 3D

ASME B16.9

ASTM A 234 Gr WPB

LR Bends 45

LR B 45

4-16"

BW, 3D

ASME B16.9

ASTM A 234 Gr WPB

RC

2" - 16"

BW - ASME B16-25

MXM

ASME B16-9

ASTM A 234 Gr WPB

RE

2" - 16"

BW - ASME B16-25

MXM

ASME B16-9

ASTM A 234 Gr WPB

0.50" - 1.50"

SW

6000#

ASME B16.11

ASTM A105

2" - 16"

BW

MXM

ASME B16.9

ASTM A 234 Gr WPB

0.50" - 1.50"

SW

6000#

ASME B16.11

ASTM A105

2" - 16"

BW

MXM

ASME B16.9

ASTM A 234 Gr WPB

SW

6000#

MSS-SP 97

ASTM A105

REDUCERS

ANSI B 31.8

BASIC MATERIAL

( 0 TO 60 C)

PRESSURE

600#

CODE

REMARKS

CONCENTRIC

REDUCERS
ECCENTRIC

TEES EQUAL

TEES RED

TR

SOCKOLET

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

FC

0.50" - 1.50"

SW

6000#

ASME B16-11

ASTM A105

HC

0.50" - 1.50"

SW

6000#

ASME B16-11

ASTM A105

0.50" - 1.50"

COUPLINGS
HALF
COUPLINGS

NOTE:1. M=THICKNESS TO MATCH PIPE WALL THICKNESS

PIPING MATERIAL SPECIFICATION

Document No.

Rev.

11-0330G01-01-08-02-001

Sheet 15 of 18

18 of 245

PIPING SPECIFICATION

RATING

6A1

PIPELINE FROM HANUMAN JUNCTION TO VCL

TEMPERATURE

( 0 TO 60 C)

PRESSURE

(92 bar g)

ITEM

SHORT

SIZE

CODE

FROM-

DESCRIPTION

THRU

RATING

DIMENSION

AND/OR

STANDARD

600#

CODE

ANSI B 31.8

BASIC MATERIAL

MATERIAL

REMARKS

SCHED.

WN FLANGES

FW

2"-16"

RF, 125 AARH

600#

ASME B16-5

FLG SW

FS

0.50 - 1.50

RF, 125 AARH

600#

ASME B16-5

BLIND

FB

0.50"-16"

RF, 125 AARH

600#

ASME B16-5

FF

0.5" - 16"

FF, 125 AARH

600#

ASME B16-48

FSB

16"

FF, 125 AARH

600#

ASMEB16-48

0.50" - 16''

ASTM A105

ASTM A105

ASTM A105

FLANGE

FLANGES

ASTM A105

FIG 8

SPCR &

ASTM A105

BLND

STUD BOLTS

ASME B18-2

Bolt: A193 B7
Nut: A194 Gr.2H

GASKETS

0.5" - 16"

SPIRAL, 600#

SPIRAL

B-16.20 ASME B16.5

WOUND

GATE

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

VG

0.50 - 1.50

SW

VALVE

800#

API 602

ASTM A105

600#

API 600

ASTM A 216 Gr WCB

B16.11
2" - 16"

FLGD, B-16.5,
RF/125 AARH

PLUG
VALVE

VP

0.50" - 1.50"

SW, BS -5353

800#

ASME B16-10

ASTM A105

2" - 16"

FLG/ BW, API 6D

600#

ASME B16-10

ASTM A 216 Gr WCB

NOTE: M=THICKNESS TO MATCH PIPE WALL THICKNESS

PIPING MATERIAL SPECIFICATION

Document No.

Rev.

11-0330G01-01-08-02-001

Sheet 16 of 18

19 of 245

PIPING SPECIFICATION

6A1

RATING

PIPELINE FROM HANUMAN JUNCTION TO VCL

TEMPERATURE ( 0 TO 60 C)
PRESSURE
ITEM

CODE

ANSI B 31.8

BASIC MATERIAL

(92 bar g)
SHORT

SIZE

CODE

FROM-

VBA

0.50 - 1.50

DESCRIPTION

THRU
BALL

600#

RATING

DIMENSION

AND/OR

STANDARD

MATERIAL

REMARKS

SCHED.
SW, ASME B16-11

600#

VALVES

ASME B16-10

BODY:

FULL BORE

BS 5351

ASTM A105

FIRE SAFE

BALL:SS 316

WRENCH OPERATED.

BODY SEAT: RPTFE


2"

FLGD RF:ASME B16-5

600#

or BW :ASME B16-5

ASME B16-10

BODY:

BS 5351

ASTM A216 Gr. WCB

FULL BORE, FIRE SAFE, WRENCH OPERATED

BALL:
(A 216 Gr. WCB)
+ 0.003" ENP
BODY SEAT: RPTFE
3" - 4"

FLGD RF:ASME B16-5

600#

or BW :ASME B16-5

ASME B16-10

BODY:

BS 5351

ASTM A216 Gr. WCB


(A 216 Gr. WCB)
+ 0.003" ENP
BODY SEAT: RPTFE

6"-16''

FLGD RF:ASME B16-5

600#

or BW :ASME B16-5

VGL

0.50 - 1.50

SW, ASME B16-11

600#

VALVES

FULL BORE
FIRE SAFE
WRENCH OPERATED.

ASME B16-10

BODY:

BS 5351

ASTM A216 Gr. WCB

FULL BORE

(A 216 Gr. WCB)


+ 0.003" ENP

FIRE SAFE

BODY SEAT: RPTFE


GLOBE

DOUBLE BLOCK AND BLEED

ASME B16-10

BODY:

BS 5352

ASTM A 216 Gr. WCB

DOUBLE BLOCK AND BLEED

GEAR OPERATED.
HANDWHEEL
FIRE SAFE

TRIM:
ASTM A182 F6
2" - 4"

FLGD RF:ASME B16-5

600#

ASMEB16-10

BODY:

BS 1873

ASTM A 216 Gr. WCB

HANDWHEEL
FIRE SAFE

TRIM:
ASTM A182 F6
6" - 16"

FLGD RF:ASME B16-5

600#

ASME B16-10

BODY:

BS 1873

ASTM A 216 Gr. WCB

GEAR OPERATED
FIRE SAFE

TRIM:
ASTM A182 F6
LIFT CHECK

0.50 - 1.50

SW, ASME B16-11

600#

VALVES

ASME B16-10

BODY:

BS 5352

ASTM A 105

HORIZONTAL INSTALLATION

TRIM:
ASTM A182 F6
VCH

2"-16''

FLGD RF:ASME B16-5

600#

ASME B16-10

BODY:

BS 1868

ASTM A 216 Gr. WCB

SWING
CHECK
VALVE

HORIZONTAL INSTALLATION
VERTICAL INSTALLATION FLOW UPWARDS

TRIM:
ASTM A182 F6

NOTE: M=THICKNESS TO MATCH PIPE WALL THICKNESS

PIPING MATERIAL SPECIFICATION

Document No.

Rev.

11-0330G01-01-08-02-001

Sheet 17 of 18

20 of 245

PIPING SPECIFICATION

RATING

6A1

PIPELINE FROM HANUMAN JUNCTION TO


VCL

TEMPERATURE ( 0 TO 60 C)
PRESSURE

600#

CODE

ANSI B 31.8

BASIC MATERIAL

(92 bar g)

BRANCH TABLE

1/2" 3/4"

1" 1.1/2" 2"

3"

4"

6"

8"

10"

12"

S
14"

1/2"

3/4"

1"

1.1/2"

2"

3"

4"

6"

8"

10"

12"

14"

16"

16"

LEGEND
T : TEE
S: SOCKOLET -SW
W : WELDOLET- BW

PIPING MATERIAL SPECIFICATION

Document No.

Rev.

11-0330G01-01-08-02-001

Sheet 18 of 18

21 of 245

GAIL (India) Limited


PIPELINE FROM HANUMAN JUNCTION TO VCL

CLIENT JOB NO.

MECHANICAL DESIGN BASIS


TOTAL SHEETS

DOCUMENT NO

11

0330G01

01

09

11

02

001

28.06.11

ISSUED FOR TENDER

MH

ASD

AD

24.06.11

ISSUED FOR IDC

MH

ASD

AD

REV

DATE

DESCRIPTION

PREP

CHK

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

MECHANICAL DESIGN BASIS

Document No.

Rev

11-0330G01-01-09-02-001

SHEET 2 of 11
23 of 245

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

303500SCMD at 30.79 Kg/Cm2 g (pressure at

point

Tatipaka has been considered 42 Kg/Cm2g)

MECHANICAL DESIGN BASIS

Document No.

Rev

11-0330G01-01-09-02-001

SHEET 3 of 11
24 of 245

Details

of

PRS,CMS

(near

existing VCL Terminal)

Pressure

26-27 Kg/cm2g to 6 Kg/cm2g

Temperature

18 C

Design Pressure
Section: Hanuman Junction to

72 Kg/cm2 g

PRS CMS
Delivery Pressure at customer

1-4 Kg/cm2 g

end
4

Operating Pressure

Considering a pressure of 42.5Kg/Sq.cm(g) at


Tatipaka

Pressure at Hanuman Junction

31 Kg/Sq.cm(g)

Ist Stage pressure reduction


at CMS
U/S of PRMS

25-72 Kg/Sq.cm(g)

D/S of PRMS

14-19 Kg/Sq.cm(g)

nd

Stage pressure reduction

at CMS

2.

U/S of PRMS

14-19 Kg/Sq.cm(g)

D/S of PRMS

2 -4 Kg/Sq.cm(g)

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

CODES AND STANDARDS:

ASME Section V

ASME Section VIII, Div 1 -

Unfired Pressure Vessels.

ASME Section IX

Qualification Standard for welding and brazing procedures.

ASME B 31.3

Process Piping

ASME B 31.4

Pipe line transportation systems for liquid hydro carbons

Non-Destructive examination

and other liquids.


x

ASME B 31.8

Gas Transmission and Distribution piping Systems.

API 5L

Specificafication for line pipe.

API 1104

Specification for welding pipeline and related facilities.

MSS-SP-53

Quality Standard for steel casting and forging for valves,

MECHANICAL DESIGN BASIS

Document No.

Rev

11-0330G01-01-09-02-001

SHEET 4 of 11
25 of 245

flanges and fittings and other piping components magnetic particle Examination method.
x

MSS-SP-75

Specification for High test Wrought butt welding Fittings.

NACE RP 0286

The Electrical Isolation of Cathodically Protected


Pipelines.

SSPC-VIS-I

Steel Structures Painting Council-Visual Standard.

OISD-STD-18

Layouts for Oil & Gas Installation

In case of contradiction, the most stringent shall apply.

3.2

MATERIALS:

ASTM A 105

Forgings, Carbon Steel for piping Components

ASTM A 106

Seamless Carbon Steel pipe for High Temperature


Service.

ASTM A 153

Zinc coating (hot dip) on iron and steel hardware.

ASTM A 181

Forging, Carbon steel for general purpose piping.

ASTM A 182

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

Piping Fittings of wrought carbon Steel and Alloy.

ASTM A 312

Seamless and welded austenitic stainless steel pipe.

ASTM A 320

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.

MECHANICAL DESIGN BASIS

Document No.

Rev

11-0330G01-01-09-02-001

SHEET 5 of 11
26 of 245

ASTM A-370

Standard Test Methods and Definitions for Mechanical


Testing of Steel products.

ASTM A 403

Wrought austenitic Stainless Steel piping fittings.

ASTM A 420

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

DIMENSIONAL / DESIGN STANDARDS

ASME B 1.20.1

Pipe threads, general purpose (inch).

ASME B 16.5

Pipe Flanges and flanged fittings (NPS1/2 through NPS


24").

ASME B 16.9

Factory made wrought steel butt welding fittings.

ASME B 16.10

Face to face and end to end dimensions of valves.

ASME B 16.11

Forged fittings, socket-welding and threaded.

ASME B 16.20

Metallic gasket for pipe flanges - ring joint, spiral wound


and jacketed.

ASME B 16.21

Non-metallic gasket for pipe flanges.

ASME B 16.25

Butt welding ends.

ASME B 16.34

Valves-flanges, threaded and welding ends.

ASME B 16.36

Orifice flanges.

ASME B 16.38

Large metallic valves for gas distribution) manually


operated, NPS 2 1/2 to 1212,125 psig maximum).

ASME B 16.47

Large diameter steel flanges (NPS 26 through NPS 60).

ASME B 36.10

Welded seamless wrought steel pipe.

ASME B 36.19

Stainless steel pipe.

API 6D

Pipeline valves

API 6FA/API 607

Fire Safe Design Valve

API 590

Steel line blank

API 600

Steel gate valves flanges and buttwelding ends.

API 602

Compact steel gate valves.

MSS SP 97

Integrally reinforced forged branch outlet fitting - socket


welding, threaded and buttwelding ends.

3.4

ORDER OF PRECEDENCE

MECHANICAL DESIGN BASIS

Document No.

Rev

11-0330G01-01-09-02-001

SHEET 6 of 11
27 of 245

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.

DESIGN BASIS

4.1

The equipment proposed to meet the specification shall be designed and manufactured to achieve the
highest possible reliability for design life of 30 years.

4.2

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.

4.3

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.

4.4

Scrapper Launcher/Receiver interface shall be designed as a minimum of ASME B31.4/ASME B31.8 as


applicable.

4.5

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.

4.6

4.7

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.

4.8

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.

4.9

The design pressure and temperature for all parts shall be 98 barg and 0 to 65 deg.C respectively.

4.10

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.

4.11

Material of construction of all piping except Trunk line shall be SA 106 Gr B.

4.12

The basic material of construction for Launchers and Receivers shall be API 5L Gr. X 70/equivalent.

4.13

The basic material of construction for hinged closure shall be ASTM A694 Gr. F65.

4.14

Spectacle blind at the flanged end of Launcher/Receiver to be provided along with other spectacle on
kicker line and by-pass line.

4.15

The venting arrangement in station should have ball and plug valve combination.

4.16

ASME B31.8 and ASME B16.9 shall be followed for designing of flow tee.

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4.17

The size of the flow tee shall be such that it will not restrict the path of pig.

4.18

The jib crane shall have antifriction bearing.

4.19

Jib crane shall be self balancing type during operation.

4.20

Jib crane must be spark proof.

4.21

Cantilever of Jib crane shall not bend during operation.

4.22

Insulating joint shall not restrict the pipeline bore and shall allow free passage of instrumented pigs.

4.23

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.

4.24

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.

4.25

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.

4.26

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.

4.27

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.

4.28

All the first isolation valves connected to the mainline shall be welded types.

4.29

All vent isolation valves shall be equipped with spectacle blind at downstream of the valve.

4.30

All valves on mainline shall be Top Entry type only. Other Valves shall be either Top entry or Side entry.

4.31

All valves to be full bore type only, irrespective of their location.

4.32

All Ball valves 6 - 12 shall be Gear operated and above 12 shall be hand Operated & Hydraulically
Actuated Manual Valves.

5.

COLOUR CODING:

5.1
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6

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

5.2

All under ground valves shall have epoxy base coating after surface finish of SA 2.5.

5.3

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

MECHANICAL DESIGN BASIS

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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.

ENVIRONMENTAL DESIGN CRITERIA AND UTILITIES

7.1

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.

DESIGN REQUIREMENTS

8.1

All materials shall conform to project Specification and the identified API, ASME, ASTM, BS and NACE
codes and Standards.

8.2

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.

8.3

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.

8.4

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.

8.5

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.

8.5.2

Reducing the corrosion allowance for Terminal piping but not less than the internal corrosion
allowance in corresponding pipeline.

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.

8.7

Wherever dissimilar metals are in contact, insulating gasket or sacrificial spool piece of 600 mm shall be
provided to avoid galvanic corrosion.

8.8

Piping general arrangement drawings/isometrics/support drawings etc. shall be prepared using good
engineering practices and as per guidelines furnished in project Specifications.

8.9

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

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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.

8.11

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.

8.12

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.

8.13

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

To provide means of escape & access for fire fighting.

8.15

To satisfy all requirements indicated in process documents.

8.16

To minimize shutdown duration.

8.17

To provide neat and economical layout, allowing for easy supporting and adequate flexibility to meet
equipment allowable nozzle load.

8.18

To comply with the requirements of Area classification.

8.19

To comply with statutory guidelines.

9.

FLEXIBILITY ANALYSIS CRITERIA & GENERAL GUIDELINES

9.1

Flexibility analysis shall be carried out as per requirements of ASME B 31.3.

10.

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.

9.1.2

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.

Other Technical Requirements

MECHANICAL DESIGN BASIS

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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

10.3

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.

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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GAIL (India) Limited


PIPELINE FROM HANUMAN JUNCTION TO VCL

CLIENT JOB NO.

TECHNICAL SPECIFICATION FOR ASSORTED VALVES


TOTAL SHEETS

DOCUMENT NO

11

0330G01

01

08

36

02

008

28.06.11

ISSUED FOR TENDER

MH

ASD

AD

24.06.11

ISSUED FOR IDC

MH

ASD

AD

REV

DATE

DESCRIPTION

PREP

CHK

APPR

33 of 245

TABLE OF CONTENT

BALL VALVE
CONTENTS

PAGE NO.

1.0

SCOPE

2.0

REFERENCEE DOCUMENTS

3.0

DEFINITIONS

4.0

INSPECTION

5.0

MATERIALS

6.0

DESIGN AND CONSTRUCTION

7.0

INSPECTION AND TESTS

12

8.0

TEST CERTIFICATES

14

9.0

PAINTING, MARKING & SHIPMENT

14

10.0

SPARES AND ACCESSORIES

15

10.0

DOCUMENTATION

15

11.0

REFERENCE DRAWINGS

17

PLUG VALVE

CONTENTS

PAGE NO.

1.0

SCOPE

20

2.0

REFERENCEE DOCUMENTS

20

3.0

DEFINITIONS

21

4.0

MATERIALS

21

5.0

DESIGN AND CONSTRUCTION

22

6.0

INSPECTION AND TESTS

24

7.0

TEST CERTIFICATES

26

8.0

PAINTING, MARKING & EQUIPMENT

27

9.0

SPARES AND ACCESSORIES

27

TECHNICAL SPECIFICATION
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SHEET 2 of 36
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10.0

DOCUMENTATION

28

11.0

REFERENCE DRAWINGS

30

CHECK VALVES
CONTENTS

PAGE NO.

1.0

SCOPE

32

2.0

REFERENCEE DOCUMENTS

32

3.0

MATERIALS

32

4.0

DESIGN AND CONSTRUCTION

32

5.0

INSPECTION AND TESTS

33

6.0

TEST CERTIFICATES

34

7.0

PAINTING, MARKING & SHIPMENT

34

8.0

SPARES AND ACCESSORIES

35

9.0

DOCUMENTATION

35

10.0

GUARANTEE

36

TECHNICAL SPECIFICATION
FOR ASSORTED VALVES

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SHEET 3 of 36
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BALL VALVE

TECHNICAL SPECIFICATION
FOR ASSORTED VALVES

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SHEET 4 of 36
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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

Specification for Pipeline Valves.

API 605

Large Diameter Carbon steel Flanges.

API 6FA

Specification for Fire Test for Valves.

API 5L

Specification for Line Pipe.

API 1104

Specification for Welding Pipelines and related facilities.

ASME 16.10

Face to Face and End to End Dimensions of Valves

ASME 16.20

Metallic gasket for pipe flanges Ring joint or spiral wounds and
jacketed.

ASME 16.21

Non Metallic Gaskets for pipe flanges.

ASME B 16.5

Steel Pipe Flanges and Flanged Fittings.

ASME B 16.34

Valves - Flanged, Threaded and Welding Ends.

ASME B 16.5

Steel Pipe Flanges and Flanged Fittings.

ASME B 31.3

Process Piping.

ASME B 31.8

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 A370

Standard Test Methods and Definitions for Mechanical Testing of Steel


Products.

ASTM B 733

Auto catalytic Nickel Phosphorous Coating on Metals.

BS 6755-1

Testing of Valves. Specification for production pressure testing


requirements.

TECHNICAL SPECIFICATION
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EN 1004511

Metallic products: Charpy Impact test test methods (U & V Notches)

BS 6755-2

Testing of Valves. Specification for fire type-testing requirement.

EN 10204

Metallic Materials Types of Inspection documents.

MSS-SP-6

Standard Finishes for Contact Faces of Pipe Flanges and Connecting end Flanges of Valves and Fittings.

MSS-SP-25

Standard marking system for Valves, Fittings, Flanges and Union.

MSS-SP-44

Steel Pipeline Flanges.

MSS-SP-53

Quality Standard for Steel Casting and Forgings for Valves, Flanges and
Fittings and Other Piping Components Magnetic Particle Examination
Method.

MSS-SP-55

Quality Standard for Steel casting of valves, Flanges, Fittings & other
Piping components (Visual Method)

MSS-SP-72

Ball Valves with Flanged or Buttwelding ends for General Service.

ISO 5208

Industrial Valves Pressure Testing of Valves

ISO 10497

Testing of Valves fire type testing requirements.

ISO 13623

Petroleum & Natural Gas Industry pipeline transportation system.

ISO 14313

Petroleum & Natural Gas Industry. Pipeline transportation system


pipeline Valves

SSPC-VIS-1

Steel Structures Painting Council Visual Standard.

In case of contradiction the most stringent shall apply.

3.0 DEFINITIONS
Purchaser

: The Company which makes purchase order.

Manufacturer

: Manufacturer who receive the purchase order.

Shall

: This verbal form indicates requirements strictly to be followed in order


to confirm to the standards and from which no deviation is permitted.

Should

: 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.

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May

: This verbal form indicates a course of action permissible within the limits
of this standard.

Can

: This verbal form used for statements of possibility & capability, whether
material, physical or casual.

4.0

INSTRUCTIONS

4.1

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.

4.2

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.

4.3

The manufacturer shall provide a technical description of the manufacturing method that might influence
the quality of material.

4.4

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.

4.5

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.

4.6

A copy of ISO 9001 Certificate shall be included in the offer.

4.7

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.

4.8

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.

5.0

MATERIALS

5.1

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 (suitable for service conditions as indicated in valve data sheet), which shall
be subjected to approval by Purchaser.

5.2

Carbon steel used for the manufacture of valves shall be fully killed.

5.3

The carbon equivalent (CE) of valve end connections which are subject to further field welding by
Purchaser shall not exceed 0.45 on check analysis for each heat of steel used, shall be calculated by the
following formula:
CE = C + Mn +
6

Cr + Mo + V + Ni + Cu
5
15

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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.

5.5

When the ball of valve is manufactured out of C.S, it shall be subjected to 75m/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.

5.6

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

DESIGN AND CONSTRUCTION

6.1

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.

TECHNICAL SPECIFICATION
FOR ASSORTED VALVES

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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.

6.5

Reduced bore valves shall be provided if specifically mentioned in data sheet. Valve body shall be
manufactured by casting or forging.

6.6

All valves 4NB and above shall be trunion mounting type. Valves below 4 shall be floating type unless
specifically mentioned in data sheet otherwise.

6.7

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.

6.8

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).

6.9

Valves shall be designed to withstand a sustained internal vacuum of at least 1 (one) milli-bar in both
open and closed positions.

6.10

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.

6.11

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.

6.12

Valve design shall ensure repair of stem seals/packing under full line pressure.

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.

6.17

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.

6.18

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.

6.19

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.

6.20

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.

6.21

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.

6.22

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.
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6.23

The valve stem shall have anti-blowout feature with antistatic device conforming to BS 5351

6.24

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.

6.27

The welders involved in welding shall be qualified in accordance with ASME Section IX.

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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.

6.29

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.

6.30

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.

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.

7.3

Dimensional check on all valves shall be carried out as per the Purchaser approved drawings.

7.4

Chemical composition and mechanical properties shall be checked as per relevant material standards
and this specification, for each heat of steel used.

7.5

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.

7.6

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.

7.7

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.

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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.

7.11

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.

7.12

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.

7.13

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.

7.14

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.

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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

PAINTING, MARKING AND SHIPMENT

9.1

Valve surface shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of
corrosion resistant paint. Surface preparation shall be carried out by shot blasting to SP-6 in accordance
with Steel Structures Painting Council - Visual Standard SSPC-VIS-1. For the valves to be installed
underground, when indicated in Valve Data Sheet, the external surfaces of buried portion of the valve
shall be painted with three coats of suitable coal tar epoxy resin with a minimum dry film thickness of 300
microns.

9.2

All valves shall be marked as per API 6D. The units of marking shall be metric except nominal diameter,
which shall be in inches.

9.3

Valve ends shall be suitably protected to avoid any damage during transit. All threaded and machined
surfaces subject to corrosion shall be well protected by a coat of grease or other suitable material. All
valves shall be provided with suitable protectors for flange faces, securely attached to the valves. Bevel
ends shall be protected with metallic or high impact plastic bevel protectors.

9.4

All sealant lines and other cavities of the valve shall be filled with sealant before shipment.
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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.

9.6

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

10.0

SPARES AND ACCESSORIES

10.1

Manufacturer shall furnish list of recommended spares and accessories for valves required during startup and commissioning.

10.2

Manufacturer shall furnish list of recommended spares and accessories required for two years of normal
operation and maintenance of valves.

10.3

Manufacturer shall quote for spares and accessories as per Material Requisition.

11.0

DOCUMENTATION

11.1

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.

11.2

i)

Copy of valid API 6D Certificate.

j)

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:

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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

: Specification for Welding Pipelines and related facilities.

ASME 16.10

: Face to Face and End to End Dimensions of Valves

ASME 16.20

: Metallic gasket for pipe flanges Ring joint or spiral wounds and jacketed.

ASME 16.21

: Non Metallic Gaskets for pipe flanges.

ASME B 16.5

: Steel Pipe Flanges and Flanged Fittings.

ASME B 16.34

: Valves - Flanged, Threaded and Welding Ends.

ASME B 16.5

: Steel Pipe Flanges and Flanged Fittings.

ASME B 31.3

: Process Piping.

ASME B 31.8

: 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.

ASTM B 733

: Auto catalytic Nickel Phosphorous Coating on Metals.

BS 6755-1

: Testing of Valves. Specification for production pressure testing requirements.

BS 6755-2

: Testing of Valves. Specification for fire type-testing requirement.

EN 10204

: Metallic Materials Types of Inspection documents.

MSS-SP-6

: Standard Finishes for Contact Faces of Pipe Flanges and Connecting - end
Flanges of Valves and Fittings.

MSS-SP-25

: Standard marking system for Valves, Fittings, Flanges and Union.

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MSS-SP-44

: Steel Pipeline Flanges.

MSS-SP-53

: Quality Standard for Steel Casting and Forgings for Valves, Flanges and
Fittings and Other Piping Components Magnetic Particle Examination
Method.

ISO 5208

: Industrial Valves Pressure Testing of Valves

ISO 10497

: Testing of Valves fire type testing requirements.

ISO 13623

: Petroleum & Natural Gas Industry pipeline transportation system.

ISO 14313

: Petroleum & Natural Gas Industry. Pipeline transportation system Valves.

SSPC-VIS-1

: Steel Structures Painting Council Visual Standard.

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.

Should

: 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.

May

: This verbal form indicates a course of action permissible within the limits
of this standard.

Can

: This verbal form used for statements of possibility & capability, whether
material, physical or casual.

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.

4.2

Carbon steel used for the manufacture of valves shall be-fully killed.

4.3

The Carbon Equivalent (CE) of valve end connections which are subject to further field welding by
Purchaser shall not exceed 0.45 in check analysis for each heat of steel used, as calculated by
the following formula:
CE

4.4

C + Mn + Cr +
6

Mo + V +
5

Ni + Cu
15

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 75m/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.

4.6

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.

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

150

300

600

900

Size Range, DN mm ( inch )

Pattern

50-100 (2-4)

Short

150-300 (6-12)

Regular

350 (14) & above

Venturi

50-100 (2-4)

Short

150-250 (6-10)

Regular

300 (12) & above

Venturi

50-250 (2-10)

Regular

300 (12) & above

Venturi

50-250 (2-10)

Regular

300 (12) & above

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.

5.4

Cover shall be bolted to the body and screwed connections are not acceptable.

5.5

Soft seats to achieve a seal between plug and body are not permitted.

5.6

All valves shall have the provision for secondary sealant injection under full line pressure for seat
and stem seals. All sealant injection connections shall be provided with an internal non-return
valve. Valve design shall have a provision (e.g. Ball Type Check Valve/Needle Valve) to replace
the sealant injector fitting under full line pressure. Location and arrangement of sealant injection
points shall be as per Figure-4.6.

5.7

When specified in the Vale Data Sheet, valves shall be designed to withstand a sustained internal
vacuum of at least 1 (one) milli-bar in both open and closed position.

5.8

Valve design shall ensure repair of gland packing under full line pressure.

5.9

a) Valve ends shall be either flanged or butt-welded or one end flanged and one end butt-welded
as indicated in the Valve Data Sheet. Flanges of the flanged end cast body valves shall be
integrally cast with the body of the valve. Face to face/end to end dimensions shall conform to
API 6D.
b) Flanged end shall have dimensions as per 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.

5.10

Valves shall be provided with plug position indicator and stops of rugged construction at the fully
open and fully closed positions.

5.11

When indicated in Material Requisition, valves shall have locking devices to lock the valve either
in full open (LO) or full close (LC) position. Locking devices shall be permanently attached to the
valve operator and shall not interfere with operation of the valve.

5.12

Valves shall be suitable for either buried or aboveground installation as indicated in Valve Data
Sheet.

5.13

When stem extension requirement is indicated in Valve Data Sheet, the valves shall have the
following provisions: a) Valves provided with stem extension shall have waterproof outer casing. Length of stem
extension shall be as indicated in Valve Data Sheet. The length indicated corresponds to the
distance between 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.

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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.

5.16

The tolerance on internal diameter and out of roundness at the ends for welded ends valves shall
be as per connected pipe specification as indicated in the Valve Data Sheet.

5.17

Valve stem shall be capable of withstanding the maximum operating torque required to operate
the valve against the maximum differential pressure corresponding to applicable class rating. The
combined stress shall not exceed the maximum allowable stresses specified in ASME section
VIII, Division 1.
For Power Actuated Valves, the valve stem shall be designed for maximum output torque of the
selected power actuator (including gear box, if any) at the valve stem..

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:

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6.1

All valves shall be visually inspected.

6.2

Dimensional check on all valves shall be carried out as per the Purchaser approved drawings.

6.3

Chemical composition and mechanical properties shall be checked as per relevant material
standards and this specification, for each heat of steel used.

6.4

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.

6.5

All Valves shall be impact tested at -20qC. The average energy absorbed shall be 35J and min.
28J.

6.6

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.

6.7

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.

6.10

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

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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.

6.12

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

PAINTING, MARKING AND SHIPMENT

8.1

Valve surface shall be thoroughly cleaned, freed from rust and grease and applied with
sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot
blasting to SP-6 in accordance with Steel Structures Painting Council - Visual Standard
SSPC-VIS-1. For the valves to be installed underground, when indicated in Valve Data Sheet,
the external surfaces of buried portion of the valve shall be painted with three coats of suitable
coal tar epoxy resin with a minimum dry film thickness of 300 microns.

8.2

All valves shall be marked as per API 6D. The units of marking shall be metric except nominal
diameter, which shall be in inches.

8.3

Valve ends shall be suitably protected to avoid any damage during transit. All threaded and
machined surfaces subject to corrosion shall be well protected by a coat of grease or other
suitable material. All valves shall be provided with suitable protectors for flange faces, securely
attached to the valves. Bevel ends shall be protected with metallic or high impact plastic bevel
protectors.

8.4

All sealant lines and other cavities of the valve shall be filled with sealant before shipment.

8.5

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.

8.6

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

SPARES AND ACCESSORIES

9.1

Manufacturer shall furnish list of recommended spares and accessories for valves required
during start-up and commissioning.

9.2

Manufacturer shall furnish list of recommended spares and accessories required for two years
of normal operation and maintenance of valves.

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9.3

Manufacturer shall quote for spares and accessories as per Material Requisition.

10.0

DOCUMENTATION

10.1

At the time of bidding, Manufacturer shall submit the following documents:

10.2

a)

Filled 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.

b)

Sectional drawing showing major parts with reference numbers and material
specification. In particular a blow up drawing of ball-seat assembly shall be furnished
complying with the requirement of clause 4.6 of this specification.

c)

Reference list of similar ball valves manufactured and supplied in last five years
indicating all relevant details including project, year, client, location, size, rating, service
etc.

d)

Torque curves for the power actuated valves along with the break torque and maximum
allowable stem torque. In addition, sizing criteria and torque calculations shall also be
submitted for power actuated valves.

e)

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

f)

Descriptive technical catalogues of the manufacturer.

g)

Installation, Operational and Maintenance Manual.

h)

Copy of valid API 6D Certificate.

i)

Details of support foot including dimensions and distance from valve centerline to bottom
of support foot.

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.

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.

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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.

10.4

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.

10.5

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

REFERENCE DOCUMENTS

2.1

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

MATERIALS

3.1

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.

3.2

Carbon steel used for the manufacture of valves shall be fully killed.

3.3

The Carbon Equivalent (CE) of valve end connections which are subject to further field welding by
Purchaser, shall not exceed 0.45% (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

3.4

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.

4.0

DESIGN AND CONSTRUCTION

4.1

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

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.

4.4

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.

4.5

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.

4.6

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.

4.7

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.

4.8

An arrow indicating the direction of flow shall be embossed or cast on the body of all valves.

4.9

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.

4.10

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.

5.0

INSPECTION AND TESTS

5.1

The Manufacturer shall perform all inspection and tests as per the requirements of this specification and
the relevant codes, prior to shipment at his works. Inspection certification shall be confirmed to EN10204-3.1b. Such inspection and tests shall be, but not limited to, the following:

5.1.1

All valves shall be visually inspected.

5.1.2

Dimensional check on all valves shall be carried out as per the Purchaser approved drawings.

5.1.3

Chemical compositions and mechanical properties shall be checked as per relevant material standards
and this specification, for each heat of steel used.

5.1.4

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.

b)

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.

c)

The extent of radiography/ultrasonic examination shall be as follows :


ANSI Class 150

All sizes

Nil

ANSI Class 300

< DN 400mm (16)


> DN 450mm (18)

100%
100%

ANSI Class 600

100%

All sizes

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5.1.5

All valves shall be tested in compliance with the requirements of applicable standard (refer clause 2.0).

5.2

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.

b)

Hydrostatic test certificates complete with records of timing and pressure of each test.

c)

Test reports of radiograph and ultrasonic inspection, as applicable.

d)

All other tests reports and certificates as required by applicable standard and this specification.

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

PAINTING, MARKING AND SHIPMENT

7.1

Valve surface shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of
corrosion resistant paint. Surface preparation shall be carried out by shot blasting to SP-6 in accordance
with Steel Structures Painting Council Visual Standard SSPC-VIS-1.

7.2

All valves shall be marked as per applicable standard. The units of marking shall be metric except
nominal diameter, which shall be in inches.

7.3

Valve ends shall be suitably protected to avoid any damage during transit. All threaded and machined
surfaces subject to corrosion shall be well protected by a coat of grease or other suitable material. All
valves shall be provided with suitable protectors for flange faces, securely attached to the valves.

7.4

Packaging and shipping instructions shall be as per applicable standard.

7.5

On packages, the following shall be marked legibly with suitable marking ink :
a)

Order Number

b)

Manufacturers Name and trade mark.

c)

Valve Size and Rating

d)

Tag Number.

e)

Minimum & maximum operating temperature.

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f)

Body material designation.

g)

Maximum operating pressure.

8.0

SPARES AND ACCESSORIES

8.1

Manufacturer shall recommend and quote separately the spares for valves required for commissioning
and two years of normal operation.

9.0

DOCUMENTATION

9.1

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.

b)

Sectional drawing showing major parts with reference numbers and material specification and
Quality assurance plan (QAP).

c)

Details of corrosion resistant paint proposed to be applied.

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)

Detailed sectional drawings showing all parts with reference numbers and material specification.

b)

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.

9.4

Prior to shipment, Manufacturer shall submit to Purchaser one reproducible and six copies of the
following:
a)

Test certificates as listed in clause 6.0 of this specification.

b)

Manual for installation, erection, maintenance and operation instructions, including a list of
recommended spares for the valves.

9.5

All documents shall be in English language.

10.0

GUARANTEE

10.1

Manufacturer shall guarantee that the materials and machining of valves and fittings comply with the
requirements in this specification and in the Purchase Order.

10.2

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.

10.3

If valve defect or malfunctioning cannot be eliminated, Manufacturer shall replace the valve without delay.

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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.

10.5

All expenses shall be to Manufacturers account.

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GAIL (India) LIMITED

CLIENT
SIZE/QUANTITY

PROJECT:PIPELINE FROM HANUMAN JUNCTION TO VCL

**
GENERAL SPECIFICATION
NG

Process Fluid

( 0 to 65 deg C)

Design Temperature

Size, mm (inch)
Body Type

49 barg

Design Pressure

API 6D

Design Standard

300#

ANSI Rating

3A1

Piping Class

2" to 12"
Full Bore

**

End Connection Type

ASME B16.25/ASME B16.5

Standard

RF 125AARH

Flange Face Finish

Special Requirement

Vent, drain & Sealant connection


Anti Blow out system

As per Technical Spec.

Locking Device Reqd

VALVE DESIGN CONDITIONS


0

Corrosion Allowance
Installation

0.5

Design Factor

Underground/Aboveground Stem Ext Length, mm

2 meter (Approx for U/G installation)

CONNECTING PIPE DETAILS


Diameter, mm (inch)

10"/8"/6"/4"

Diameter, mm (inch)

2"

MATERIAL

Refer P&Id

MATERIAL

Refer P&Id

VALVE OPERATION
As per Technical Spec.

Actuation Type

Not Applicable

Type of Actuator

VALVE MATERIAL SPECIFICATION


SPECIFIED

PART DISCRIPTION
Body

A 216 Gr. WCB / A234GrWPB

Ball

(A 216 Gr. WCB / A234GrWPB) + 0.003" ENP

Seat Rings

AISI 4140 + 75 micrometer (0.003") ENP/ AISI 410

Seat Seal

VITON

Stem

AISI 4140 + 75 micrometer (0.003") ENP/ AISI 410

Stem Seal

PTFE/ VITON

Stud Bolts

ASTM A 193 Gr. B7

Nuts

A194 Gr. 2H
TESTING REQUIREMENT

Hydrostatic Test Pressure

Body: 74 barg

Air Test Pressure

Seat: 54 barg
7barg

Anti-Static Testing Requirement

As per API 6D Latest Edition

Hardness Test

248 HV10

Charpy Impact Test/ Temperature

Yes (at 0 deg C)

DATA SHEET FOR BALL VALVES


(2"-12," 300#)

Document No.

Rev.

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

As per API 6FA

Valve Painting Specification

Suitable for Corrosive Industrial Environment


*

Manufacturer's Painting Specification Number

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#)

70 of 245

Document No.
11-0330G01-01-08-03-002
SHEET 2 of 2

Rev.
0

GAIL (India) LIMITED

CLIENT
SIZE/QUANTITY

PROJECT: PIPELINE FROM HANUMAN JUNCTION TO VCL

**
GENERAL SPECIFICATION
NG

Process Fluid

( 0 to 65 deg C)

Design Temperature

6A1

Piping Class

2" to 12"

Size, mm (inch)
Body Type

92 Kg/cm2 g

Design Pressure

API 6D

Design Standard

600#

ANSI Rating

Full Bore

**

End Connection Type

ASME B16.25/ASME B16.5

Standard

Vent, drain & Sealant connection


Anti Blow out system

RF 125AARH

Flange Face Finish

Special Requirement
As per Technical Spec.

Locking Device Reqd

VALVE DESIGN CONDITIONS


0

Corrosion Allowance
Installation

0.5

Design Factor

2 meter (Approx for U/G installation)

Underground/Aboveground Stem Ext Length, mm


CONNECTING PIPE DETAILS

Diameter, mm (inch)

10"/8"/6"/4"

MATERIAL

Refer P&Id

Diameter, mm (inch)

2"

MATERIAL

Refer P&Id

VALVE OPERATION
Actuation Type
Type of Actuator

As per Technical Spec.


Not Applicable
VALVE MATERIAL SPECIFICATION
SPECIFIED

PART DISCRIPTION
Body
Ball
Seat Rings

A 216 Gr. WCB / A234GrWPB


(A 216 Gr. WCB / A234GrWPB) + 0.003" ENP
AISI 4140 + 75 micrometer (0.003") ENP/ AISI 410
VITON

Seat Seal
Stem

AISI 4140 + 75 micrometer (0.003") ENP/ AISI 410

Stem Seal

PTFE/ VITON

Stud Bolts

ASTM A 193 Gr. B7


A194 Gr. 2H

Nuts

TESTING REQUIREMENT
Hydrostatic Test Pressure

Body:147 Kg/cm2 g

Air Test Pressure

Seat:107.8 Kg/cm2 g
7barg

Anti-Static Testing Requirement

As per API 6D Latest Edition

Hardness Test

248 HV10

Charpy Impact Test/ Temperature

Yes (at 0 deg C)

DATA SHEET FOR BALL VALVES


(2"-12," 600#)

Document No.

Rev.

11-0330G01-01-08-03-002

SHEET 1 of 2

71 of 245

CLIENT

GAIL (India) LIMITED

SIZE/QUANTITY

PROJECT:PIPELINE FROM HANUMAN JUNCTION TO VCL

**

Fire Safe Test

As per API 6FA

Valve Painting Specification

Suitable for Corrosive Industrial Environment


*

Manufacturer's Painting Specification Number

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", 600#)

72 of 245

Document No.
11-0330G01-01-08-03-002
SHEET 2 of 2

Rev.
0

GAIL (India) LIMITED

CLIENT
SIZE/QUANTITY

PROJECT:PIPELINE FROM HANUMAN JUNCTION TO VCL

**
GENERAL SPECIFICATION
NG

Process Fluid

( 0 to 65 deg C)

Design Temperature

1A1

Piping Class

2" to 12"

Size, mm (inch)
Body Type

19 barg

Design Pressure

API 6D

Design Standard

150#

ANSI Rating

Full Bore
**

End Connection Type


Flange Face Finish
Locking Device Reqd

ASME B16.25/ASME B16.5

Standard

Vent, drain & Sealant connection


Anti Blow out system

RF 125AARH
Special Requirement
As per Technical Spec.
VALVE DESIGN CONDITIONS

0.5

Corrosion Allowance

Design Factor

Installation

**

Stem Ext Length, mm

Not Applicable

CONNECTING PIPE DETAILS


Diameter, mm (inch)

10"/8"/6"/4"

MATERIAL

Refer P&Id

Diameter, mm (inch)

2"

MATERIAL

Refer P&Id

VALVE OPERATION
Actuation Type
Type of Actuator

As per Technical Spec.


Not Applicable
VALVE MATERIAL SPECIFICATION
SPECIFIED

PART DISCRIPTION
Body
Ball
Seat Rings

A 216 Gr. WCB / A234GrWPB


(A 216 Gr. WCB / A234GrWPB) + 0.003" ENP
AISI 4140 + 75 micrometer (0.003") ENP/ AISI 410
VITON

Seat Seal
Stem

AISI 4140 + 75 micrometer (0.003") ENP/ AISI 410

Stem Seal

PTFE/ VITON

Stud Bolts

ASTM A 193 Gr. B7


A194 Gr. 2H

Nuts

TESTING REQUIREMENT
Hydrostatic Test Pressure

Body: 29 barg

Air Test Pressure

Seat: 21 barg
7 barg

Anti-Static Testing Requirement

As per API 6D Latest Edition

Hardness Test

248 HV10

Charpy Impact Test/ Temperature

Yes (at 0 deg C)

DATA SHEET FOR BALL VALVES


(2"-12",150#)

Document No.

Rev.

11-0330G01-01-08-03-002

SHEET 1 of 2

73 of 245

CLIENT

GAIL GAS LIMITED

SIZE/QUANTITY

PROJECT: PIPELINE FROM HANUMAN JUNCTION TO VCL

**

Fire Safe Test

As per API 6FA

Valve Painting Specification

Suitable for Corrosive Industrial Environment

Manufacturer's Painting Specification Number

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

DATA SHEET FOR BALL VALVES


(2"-12",150#)

74 of 245

Document No.
11-0330G01-01-08-03-002
SHEET 2 of 2

Rev.
0

3. SPINDLE

2. DISC & SEAT RING

1. BODY & BONET


( REFER NOTE-1)

RAW MATERIAL

MOC

MOC

PER HEAT

PER HEAT

CHEM. TEST

PHY. TEST

PER HEAT

PER HEAT

CHEM. TEST

PHY. TEST

PER HEAT

IMPACT TEST
( 0 DEG C )

MOC

MOC

MOC

MOC

35J AVERAGE VALUE /


28J (ONE SPECIMEN)

MOC

MOC

ASTM A 16.34

ASTM A 16.34

35J AVERAGE VALUE /


28J (ONE SPECIMEN)

MOC

MOC

ACCEPTANCE NORMS

75 of 245

ASTM A 370

ASTM A 16.34

100%

MPT

10% WITNESS &


100% REVIEW

ASTM A 16.34

100%

RADIOGRAPHY

VISUAL

ASTM A 370

MSS-SP-75

MOC

MOC

REFERENCE
DOCUMENT

PER HEAT

IMPACT TEST
0 DEG C )

100%

PER HEAT

PHY. TEST

VISUAL

PER HEAT

CHEM. TEST

QUANTAM OF
CHECK

GAIL (India) LIMITED


WGI

CLIENT:
CONSULTANT:
VENDOR:

SR. NO. COMPONENTS & OPERATIONS TYPES OF CHECK

PIPELINE FROM HANUMAN JUNCTION TO VCL

PROJECT:

P/W

INSPECTION
REPORT

LAB T.C.

LAB T.C.

INSPECTION
REPORT

SUPPLIER T.C.

P/W

P/R

P/W

P/W

P/W

P/W

P/W

INSPECTION
REPORT/RT
FILMS

SUPPLIER T.C.

P/W

T.C.

P/W

P/W

3.2 Certificate

INTERNAL Q.C

P/R

SUBVENDOR/
VENDOR

3.2 Certificate

FORMAT OF
RECORD

TPI

INSPECTION

QAP NO: 11-0330G01-02-08-10-002


REV NO: 0
ITEM DESCRIPTION/ QUANTITY: BALL VALVE
JOB NO.: 110330G01
PAGE NO: 1 of 3

RW

WGI/GAIL

SR. NO.

100%

HARDNESS & D.P.

4. HARD FACING

1. FASTNERS

BROUGHTOUT ITEM

-DO-

100%

DIMENSIONS

3. SPINDLE

INSPECTION
REPORT

ASTM B 16.34 350 to


450 BHN

10%

PER LOT

IMPACT TEST
( 0 DEG C )

76 of 245

ASTM A 370

35J AVERAGE
VALUE / 28J (ONE
SPECIMEN)


3.2 Certificate

ASTM A 193 Gr. B7 & ASTM A 193 Gr. B7 &


A 194 Gr. 2H
A 194 Gr. 2H

PER LOT

PHYSICAL

DIMENSIONS

ASTM A 193 Gr. B7 & ASTM A 193 Gr. B7 &


A 194 Gr. 2H
A 194 Gr. 2H

P/W

P/W

P/W

P/W

P/W

SUBVENDOR
/VENDOR

PER LOT

INSPECTION
REPORT

-DO-

-DO-

INSPECTION
REPORT

INSPECTION
REPORT

FORMAT OF
RECORD

-DO-

-DO-

APPVD.DRG

ACCEPTANCE
NORMS

TPI

INSPECTION

REV NO: 0
ITEM DESCRIPTION/ QUANTITY: BALL VALVE
JOB NO.:110330G01
PAGE NO: 2 of 3

QAP NO: 11-0330G01-02-08-10-002

CHEMICAL

ASTM B 16.34

-DO-

100%

DIMENSIONS

2. DISC & SEAT RING

APPVD.DRG

100%

100%

TRANSFER OF
HEAT NO.

REFERENCE
DOCUMENT

DIMENSIONS

1. BODY & BONET

INPROCESS INP

QUANTAM OF
CHECK

GAIL (India) LTD.


WGI

CLIENT:
CONSULTANT:
VENDOR:

COMPONENTS & OPERATIONS TYPES OF CHECK

PIPELINE FROM HANUMAN JUNCTION TO VCL

PROJECT:

RW

WGI/GAIL

FINAL DOCUMENTS

10% WITNESS &


100% REVIEW

100%

REVIEW

100%

100%

PRIMER & FINISH COAT


(EACH TWO COAT)

MARKING/TAG DETAILS

100%

SURFACE PREPARATION
SA 2/

VISUAL

API 598

100%

HIGH PRESSURE
PNEUMATIC SHELL TEST

AS PER
SPEC./APPD.DRG.

AS PER
SPEC./APPD.DRG.

Final dossier - IRN,


3.2 Certificate, Insp &
AS PER SPEC./MSS AS PER SPEC./MSS test report, Drawing
etc
SP25
SP 25

PAINT.INSP.
REPORT

SPEC 60-80 EACH


COAT & TOTAL
WITHIN 300

SPEC

-DO-

-DO-

-DO-

INSPECTION
REPORT

API 598

APPVD.DRG &
API 598

APPVD.DRG &
API 598

-DO-

INSPECTION
REPORT

FORMAT OF
RECORD

SPEC 60-80
ROUGH

SPEC

APPVD.DRG &
API 598

100%

APPVD.DRG &
API 598

APPVD.DRG &
API 598

APPVD.DRG &
API 598

LOW PRESSURE CLOSER


(SEAT) TEST

100%

HYD. BODY TEST

APPVD.DRG &
API 598

APPVD.DRG &
API 598

100%

100%

DIMENSIONS

ACCEPTANCE
NORMS

REFERENCE
DOCUMENT

HIGH PRESSURE CLOSER


( SEAT) TEST

100%

QUANTAM OF
CHECK

VISUAL

TYPES OF CHECK

GAIL (INDIA) LIMITED.


WGI

CLIENT:
CONSULTANT:
VENDOR:

77 of 245

P/W

P/W

P/W

P/W

P/W

SUBVENDOR/
VENDOR

TPI

INSPECTION

QAP NO: 11-0330G01-01-08-10-002


REV NO: 0
ITEM DESCRIPTION/ QUANTITY: BALL VALVE
JOB NO.: 110330G01
PAGE NO: 3 of 3

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.

PAINTING

ASPER API 598

FINAL INSPECTION

COMPONENTS &
OPERATIONS

NO.

SR.

PIPELINE FROM HANUMAN JUNCTION TO VCL

PROJECT:

RW

RW

RW

RW

WGI/GAIL

CLIENT

GAIL (India) LIMITED

SIZE/QUANTITY

PROJECT:PIPELINE FROM HANUMAN JUNCTION TO VCL

**
GENERAL SPECIFICATION
NG/ R-LNG

Process Fluid

( 0 to 65 deg C)

Design Temperature

Size, mm (inch)

2" & above

Valve Pattern

Regular

End Connection

49 barg

Design Pressure

API6D / BS 5353

Design Standard

300#

ANSI Rating

**

3A1

Piping Class

Standard

Flange Face Finish

RF 125AARH

Locking Device Reqd

NA

ASME B16.25/ASME B16.5

Special Requirement
VALVE DESIGN CONDITIONS
0 mm

Corrosion Allowance
Installation

0.5

Design Factor

NA/ ~2 meter for Underground Valves

Aboveground/Underground Stem Ext Length, mm


NA

Opening/Closing time

CONNECTING PIPE DETAILS


***

Diameter, mm (inch)

ASTM A 106 Gr.B (Schedule 80)

Material

Not Applicable

Out of roundness

VALVE OPERATION
Actuation Reqd

As per tech. spec.

Type of Actuator

Manual
VALVE MATERIAL SPECIFICATION
SPECIFIED

PART DISCRIPTION

A 216 Gr. WCB / A234GrWPB

Body

ASTM A 216 Gr WCB + 0.003ENP

Plug (Lubricated)
Cover

ASTM A 216 Gr WCB

Stem

AISI 4140 + 0.03" ENP/ AISI 410


PTFE/ Graphite

Stem Seal
Lubricant Screw

Manufacturer's Standard

TESTING REQUIREMENT
Body: 74 barg

Hydrostatic Test Pressure


Air Test Pressure

Seat: 54 barg
7 bar

Anti-Static Testing Requirement

As per API 6D Latest Edition

Hardness Test

248 HV10

Charpy Impact Test/ Temperature

Yes (at 0 deg C)

DATA SHEET FOR


PLUG VALVES
300#

Document No.

Rev.

11-0330G01-01-08-03-008

SHEET 1 of 2

78 of 245

CLIENT

GAIL (India) LIMITED

SIZE/QUANTITY

PROJECT: PIPELINE FROM HANUMAN JUNCTION TO VCL

**

Fire Safe Test

As per API 6FA

Valve Painting Specification

Suitable for Corrosive Industrial Environment

Manufacturer's Painting Specification Number

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

Document No.

Rev.

11-0330G01-01-08-03-008

SHEET 2 of 2

79 of 245

CLIENT
GAIL (India) LIMITED
SIZE/QUANTITY

PROJECT:PIPELINE FROM HANUMAN JUNCTION TO VCL

**
GENERAL SPECIFICATION
NG/ R-LNG

Process Fluid

Size, mm (inch)

2" & above

Valve Pattern

Regular

End Connection

19 barg

Design Pressure

API6D / BS 5353

Design Standard

150#

ANSI Rating

( 0 to 65 deg C)

Design Temperature

1A1

Piping Class

**

ASME B16.25/ASME B16.5

Standard

Flange Face Finish

RF 125AARH

Locking Device Reqd

NA

Special Requirement
VALVE DESIGN CONDITIONS

0.0 mm

Corrosion Allowance
Installation

0.5

Design Factor

NA/ ~2 meter for Underground Valves

Aboveground/Underground Stem Ext Length, mm


NA

Opening/Closing time

CONNECTING PIPE DETAILS


Diameter, mm (inch)

Refer P&Id

Material

Refer P&Id
Not Applicable

Out of roundness

VALVE OPERATION
As per tech. spec.

Actuation Reqd

Manual

Type of Actuator

VALVE MATERIAL SPECIFICATION


SPECIFIED

PART DISCRIPTION
Body

ASTM A 216 Gr WCB / A234Gr.WPB

Plug (Lubricated)

ASTM A 216 Gr WCB + 0.003ENP

Cover

ASTM A 216 Gr WCB

Stem

AISI 4140 + 0.03" ENP/ AISI 410


PTFE/ Graphite

Stem Seal
Lubricant Screw

Manufacturer's Standard

TESTING REQUIREMENT
Body: 29 barg

Hydrostatic Test Pressure


Air Test Pressure

Seat: 21 barg
7 bar

Anti-Static Testing Requirement

As per API 6D Latest Edition

Hardness Test

248 HV10

Charpy Impact Test/ Temperature

Yes (at 0 deg C)

DATA SHEET FOR


PLUG VALVES
150#

Document No.

Rev.

11-0330G01-01-08-03-008

SHEET 1 of 2

80 of 245

CLIENT

GAIL (India) LIMITED

SIZE/QUANTITY

PROJECT: PIPELINE FROM HANUMAN JUNCTION TO VCL

**

Fire Safe Test

As per API 6FA

Valve Painting Specification

Suitable for Corrosive Industrial Environment

Manufacturer's Painting Specification Number

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

Document No.

Rev.

11-00330G01-01-08-03-008

SHEET 2 of 2

81 of 245

CLIENT

GAIL (India) Limited

PROJECT:PIPELINE FROM HANUMAN JUNCTION TO VCL

SIZE/QUANTITY
GENERAL SPECIFICATION
Process Fluid

NG/ R-LNG

Design Temperature

( 0 to 65 deg C)

Design Standard

6A1

Piping Class

Size, mm (inch)

2" & above

Valve Pattern

Regular
B.W./ FLG

Pup piece/ Flange Face


Finish

92 Kg/cm2 g

Design Pressure

API 6D

Connection Type

600#

ANSI Rating

Standard

ASME B16.25/ ASME B16.5, B16.47

N.A./ RF 125AARH

Vent, drain & Sealant connection


Anti Blow out system

Special Requirement

Locking Device Reqd

Corrosion Allowance

0 mm

VALVE DESIGN CONDITIONS

Installation

0.5

Design Factor

N.A./2.0 m approx. for underground Valves

Aboveground/Underground Stem Ext Length, mm

Opening/Closing time

*
CONNECTING PIPE DETAILS

Diameter, mm (inch)

Wall Thck, mm/Sch

*
*

Out of roundness

VALVE OPERATION
*

Actuation Requirement

Type of Actuator

VALVE MATERIAL SPECIFICATION


SPECIFIED

MATERIAL OFFERED

Body

A 216 Gr.WCB / A234Gr.WPB

Plug

A 216 Gr.WCB + 0.003" ENP

Cover

A 216 Gr.WCB

Stem

AISI 4140 + 0.03" ENP/ AISI 410

PTFE/ Graphite

Graphoil

ASTM A 193 Gr.B7

A194 Gr. 2H

PART DISCRIPTION

Stem Seal
Gasket
Stud Bolts
Nuts

TESTING REQUIREMENT
Hydrostatic Test Pressure

Body: 147 Kg/cm2 g

Air Test Pressure

Seat: 107.8 Kg/cm2 g


7 bar

Anti-Static Testing Requirement

As per API 6D Latest Edition

Hardness Test

248 HV10
Yes (at 0 deg C)

Charpy Impact Test/ Temperature

DATA SHEET FOR


PLUG VALVES
600#

Document No.

Rev.

11-0330G01-01-08-03-008

SHEET 1 of 2

82 of 245

CLIENT

GAIL (India) Limited

PROJECT:PIPELINE FROM HANUMAN JUNCTION TO VCL

SIZE/QUANTITY

Fire Safe Test

As per API 6FA

Valve Painting Specification

Suitable for Corrosive Industrial Environment

Manufacturer's Painting Specification Number

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

DATA SHEET FOR


PLUG VALVES

Document No.

Rev.

11- 0330G01-01-08-03-008

SHEET 2 of 2

83 of 245

CLIENT

GAIL (India) Limited

PROJECT:PIPELINE FROM HANUMAN JUNCTION TO VCL

SIZE/QUANTITY
GENERAL SPECIFICATION
Process Fluid

NG/ R-LNG

Design Temperature

( 0 to 65 deg C)

Design Standard

6A1

Piping Class

Size, mm (inch)

15(1/2") to 40(1.1/2")

Valve Pattern

Regular

Pup piece/ Flange Face


Finish

92 Kg/cm2 g

Design Pressure

BS 5353

End Connection

600#

ANSI Rating

S.W, 800#

ASME B16.11

Standard

Not Required
Special Requirement

Locking Device Reqd

*
VALVE DESIGN CONDITIONS

Corrosion Allowance
Installation

0
Aboveground

Opening/Closing time

Design Factor

0.5

Stem Ext Length, mm

N.A.

N.A.
CONNECTING PIPE DETAILS

Diameter, mm (inch)

Wall Thck, mm/Sch

Out of roundness

*
VALVE OPERATION

Actuation Reqd

Yes

Type of Actuator

Manual
VALVE MATERIAL SPECIFICATION

PART DISCRIPTION

SPECIFIED

MATERIAL OFFERED

ASTM A 105

ASTM A 105 + 0.003ENP

Cover

ASTM A 105

Stem

AISI 4140 + 0.03" ENP/ AISI 410

PTFE/ Graphite

Manufacturer's Standard

Body
Plug (Lubricated)

Stem Seal
Lubricant Screw

TESTING REQUIREMENT
Hydrostatic Test Pressure

Body: 147 Kg/cm2 g

Air Test Pressure

Seat: 107.8 Kg/cm2 g


7 bar

Anti-Static Testing Requirement

As per API 6D Latest Edition

Hardness Test

248 HV10

Charpy Impact Test/ Temperature

Yes (at 0 deg C)

DATA SHEET FOR


PLUG VALVES
800#

Document No.

Rev.

11-0330G01-01-08-03-008

SHEET 1 of 2

84 of 245

CLIENT

GAIL (India) Limited

PROJECT:PIPELINE FROM HANUMAN JUNCTION TO VCL

SIZE/QUANTITY

Fire Safe Test

As per API 6FA

Valve Painting Specification

Suitable for Corrosive Industrial Environment

Manufacturer's Painting Specification Number

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

DATA SHEET FOR


PLUG VALVES

TAG NUMBERS

QTY

Document No.

Rev.

11-0330G01-01-08-03-008

SHEET 2 of 2

85 of 245

3. SPINDLE

2. PLUG & SEAT RING

1. BODY & BONET


REFER NOTE-1)

RAW MATERIAL

SR. NO. COMPONENTS & OPERATIONS

MSS-SP-75

100%

PER HEAT

PER HEAT

CHEM. TEST

PHY. TEST

PER HEAT

10% WITNESS &


100% REVIEW

IMPACT TEST
( 0 DEG C )

VISUAL

PER HEAT

PHY. TEST

100%

MPT
PER HEAT

100%

RADIOGRAPHY

CHEM. TEST

PER HEAT

IMPACT TEST
( 0 DEG C )

86 of 245

AISI 4140/AISI 410

AISI 4140/AISI 410

ASTM A 370

ASTM A 216 Gr WCB

ASTM A 216 Gr WCB

ASTM A 16.34

ASTM A 16.34

ASTM A 370

ASTM A 216 Gr WCB

PER HEAT

PHY. TEST

VISUAL

ASTM A 216 Gr WCB

REFERENCE
DOCUMENT

PER HEAT

QUANTAM OF
CHECK

CHEM. TEST

TYPES OF
CHECK

CLIENT: GAIL (India) LIMITED


CONSULTANT: WGI
VENDOR:

SUPPLIER T.C.
SUPPLIER T.C.

ASTM A 216 Gr
WCB
ASTM A 216 Gr
WCB

35J AVERAGE
VALUE / 28J
(ONE
SPECIMEN)
AISI 4140/AISI
410
AISI 4140/AISI
410

LAB T.C.

LAB T.C.

INSPECTION
REPORT

P/W

INSPECTION
REPORT

ASTM A 16.34

P/W

P/R

P/W

P/W

P/W

P/W

P/W

ASTM A 16.34

INSPECTION
REPORT/RT
FILMS

P/W

P/W

P/R

SUBVENDOR/
VENDOR

P/W

INTERNAL Q.C

3.2 Certificate

3.2 Certificate

FORMAT OF
RECORD

PAGE NO: 1 of 3

TPI

INSPECTION

QAP NO: 11-0330G01-01-08-10-004


REV NO: 0
ITEM DESCRIPTION/ QUANTITY: PLUG VALVE
JOB NO.: 110330G01

T.C.

35J AVERAGE
VALUE / 28J
(ONE
SPECIMEN)

ASTM A 216 Gr
WCB
EN 10204/3.1B
ASTM A 216 Gr
WCB
EN 10204/3.1B

ACCEPTANCE
NORMS

PROJECT: PIPELINE FROM HANUMAN JUNCTION TO VCL

RW

WGI/GAIL

SR. NO.

HARDNESS & D.P.

4. HARD FACING

1. FASTNERS

IMPACT TEST
( 0 DEG C )

DIMENSIONS

PHYSICAL

CHEMICAL

DIMENSIONS

3. SPINDLE

BROUGHTOUT ITEM

DIMENSIONS

DIMENSIONS

TRANSFER OF
HEAT NO.

TYPES OF CHECK

2. PLUG & SEAT RING

1. BODY & BONET

INPROCESS INP

COMPONENTS &
OPERATIONS

PER LOT

10%

PER LOT

35J AVERAGE
VALUE / 28J (ONE
SPECIMEN)

A193 B7
&
A194 Gr.2H
A193 B7
&
A194 Gr.2H

3.2 Certificate

INSPECTION
REPORT

INSPECTION
REPORT

ASTM B 16.34 350 to


450 BHN

-DO-

INSPECTION
REPORT

INSPECTION
REPORT

FORMAT OF
RECORD

PAGE NO: 2 of 3

-DO-

-DO-

APPVD.DRG

ACCEPTANCE
NORMS

QAP NO: 11-0330G01-01-08-10-004

P/W

P/W

P/W

P/W

P/W

SUBVENDOR
/VENDOR

RW

RW

TPI

INSPECTION

RW

WGI/GAIL

REV NO: 0
ITEM DESCRIPTION/ QUANTITY: PLUG VALVE
JOB NO.: 110330G01

-DO-

87 of 245

ASTM A 370

A193 B7
&
A194 Gr.2H
A193 B7
&
A194 Gr.2H

ASTM B 16.34

100%

PER LOT

-DO-

-DO-

APPVD.DRG

REFERENCE
DOCUMENT

100%

100%

100%

100%

QUANTAM OF
CHECK

PROJECT: PIPELINE FROM HANUMAN JUNCTION TO VCL


CLIENT: GAIL (India) LIMITED
CONSULTANT:WGI
VENDOR:

PAINTING

ASPER API 598


( REF.ANNEXURE-1 )

FINAL INSPECTION

COMPONENTS &
OPERATIONS

PRIMER & FINISH COAT


(EACH TWO COAT)

SURFACE PREPARATION
SA 2/

100%

100%

10% WITNESS &


100% REVIEW

VISUAL

API 598

100%

HIGH PRESSURE
PNEUMATIC SHELL TEST

SPEC

SPEC

API 598

INSPECTION
REPORT

PAINT.INSP.
REPORT

SPEC 60-80 EACH


COAT & TOTAL
WITHIN 300

-DO-

-DO-

-DO-

-DO-

-DO-

-DO-

INSPECTION
REPORT

FORMAT OF
RECORD

SPEC 60-80
ROUGH

API 598

API 598

APPVD.DRG &
API 598

APPVD.DRG &
API 598

100%

APPVD.DRG &
API 598

APPVD.DRG &
API 598

APPVD.DRG &
API 598

PERFORMANCE TEST

APPVD.DRG &
API 598

100%

100%

HIGH PRESSURE
CLOSER ( SEAT) TEST

APPVD.DRG &
API 598

APPVD.DRG &
API 598

BACKSEAT TEST

100%

HYD. BODY TEST

APPVD.DRG &
API 598

APPVD.DRG &
API 598

100%

100%

DIMENSIONS

ACCEPTANCE
NORMS

REFERENCE
DOCUMENT

LOW PRESSURE CLOSER


(SEAT) TEST

100%

QUANTAM OF
CHECK

VISUAL

TYPES OF CHECK

PAGE NO: 3 of 3

REVIEW

100%

88 of 245

R
R

TPI

INSPECTION

P/W

P/W

P/W

P/W

P/W

P/W

P/W

SUBVENDOR/
VENDOR

QAP NO: 11-0330G01-01-08-10-004


REV NO: 0
ITEM DESCRIPTION/ QUANTITY: PLUG VALVE
JOB NO.: 110330G01

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.

NO.

SR.

PROJECT:PIPELINE FROM HANUMAN JUNCTION TO VCL


CLIENT: GAIL GAS LIMITED
CONSULTANT: WGI
VENDOR:

RW

RW

RW

RW

RW

WGI/GAIL

CLIENT

GAIL (India) LIMITED

SIZE/QUANTITY

PROJECT: PIPELINE FROM HANUMAN JUNCTION TO VCL

**
GENERAL SPECIFICATION
NG/ R-LNG

Process Fluid

( 0 to 65 deg C)

Design Temperature

19 barg

Design Pressure

API 6D

Design Standard

150#

ANSI Rating

1A1

Piping Class
2" & above

Size, mm (inch)

Swing check

Type
FLG

End Connection Type


Flange Face Finish

ASME B16.5, B16.47

Standard

RF 125AARH

Special Requirement
VALVE DESIGN CONDITIONS

0 mm

Corrosion Allowance

Aboveground

Installation

Design Factor

0.5

Stem Ext Length, mm

N.A.

Opening/Closing time

VALVE OPERATION
Actuation Requirement

Not Applicable

Type of Actuator

Not Applicable
VALVE MATERIAL SPECIFICATION
MATERIAL OFFERED

SPECIFIED

PART DISCRIPTION
Body

ASTM A216 Gr.WCB /A234GrWPB

Wedge

ASTM A216 Gr.WCB

Disc

ASTM A216 Gr.WCB

Hinge Pin

ASTM A 182 F6

Gasket

Grafoil

Stud Bolts

A193 B7

Nuts

A194 Gr.2H

TESTING REQUIREMENT
Body: 29 barg

Hydrostatic Test Pressure


Air Test Pressure

Seat: 21 barg
7 barg

High Pressure Closure Test

API 598

Low Pressure Closure Test

API 598

Leak Test

API 598

DATA SHEET FOR


CHECK VALVES

Document No.

Rev.

11-0330G01-01-08-03-005

SHEET 1 of 2

89 of 245

CLIENT

GAIL (India) LIMITED

SIZE/QUANTITY

PROJECT: PIPELINE FROM HANUMAN JUNCTION TO VCL

**

Fire Safe Test

As per API 6FA

Manufacturer's Painting Specification Number

PAINTING

A/G

U/G

Surface Preparation

SA 2.5

SA 2.5

Primer

30-40 micrometer

30-40 micrometer

Finish

30-40 micrometer

2 - layers polyurethane
- 1000 microns

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. 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

Document No.

DATA SHEET FOR


CHECK VALVES

11- 0330G01-01-08-03-005
SHEET 2 of 2

90 of 245

Rev.
0

CLIENT

GAIL (India) LIMITED

SIZE/QUANTITY

PROJECT: PIPELINE FROM HANUMAN JUNCTION TO VCL

**
GENERAL SPECIFICATION
NG/ R-LNG

Process Fluid

( 0 to 65 deg C)

Design Temperature

49 barg

Design Pressure

API 6D

Design Standard

300#

ANSI Rating

3A1

Piping Class
2" & above

Size, mm (inch)

Swing check

Type
FLG

End Connection Type


Flange Face Finish

ASME B16.5, B16.47

Standard

RF 125AARH

Special Requirement
VALVE DESIGN CONDITIONS

Corrosion Allowance

Aboveground

Installation

Design Factor

0.5

Stem Ext Length, mm

N.A.

Opening/Closing time

VALVE OPERATION
Actuation Requirement

Not Applicable

Type of Actuator

Not Applicable
VALVE MATERIAL SPECIFICATION
SPECIFIED

PART DISCRIPTION

MATERIAL OFFERED

Body

ASTM A216 Gr.WCB / A234GrWPB

Wedge

ASTM A216 Gr.WCB

Disc

ASTM A216 Gr.WCB

Hinge Pin

ASTM A 182 F6

Gasket

Grafoil

Stud Bolts

A193 B7

Nuts

A194 Gr.2H

TESTING REQUIREMENT
Body: 74 barg

Hydrostatic Test Pressure


Air Test Pressure

Seat: 54 barg
7 barg

High Pressure Closure Test

API 598

Low Pressure Closure Test

API 598

Leak Test

API 598

DATA SHEET FOR


CHECK VALVES

Document No.

Rev.

11-0330G01-01-08-03-005

SHEET 1 of 2

91 of 245

CLIENT

GAIL (India) LIMITED

SIZE/QUANTITY

PROJECT: PIPELINE FROM HANUMAN JUNCTION TO VCL

**

Fire Safe Test

As per API 6FA

Manufacturer's Painting Specification Number

PAINTING

A/G

U/G

Surface Preparation

SA 2.5

SA 2.5

Primer

30-40 micrometer

30-40 micrometer

Finish

30-40 micrometer

2 - layers polyurethane
- 1000 microns

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. 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

Document No.

DATA SHEET FOR


CHECK VALVES

11-0330G01-01-08-03-005
SHEET 2 of 2

92 of 245

Rev.
0

CLIENT

GAIL (India) LIMITED

SIZE/QUANTITY

PROJECT: PIPELINE FROM HANUMAN JUNCTION TO VCL

**
GENERAL SPECIFICATION
NG/ R-LNG

Process Fluid

( 0 to 65 deg C)

Design Temperature

92 Kg/cm2 g

Design Pressure

API 6D

Design Standard

600#

ANSI Rating

6A1

Piping Class
2" & above

Size, mm (inch)

Swing check

Type
BW / FLG

End Connection Type


Flange Face Finish

ASME B16.5, B16.47

Standard

NA / RF 125AARH

Special Requirement

VALVE DESIGN CONDITIONS


0

Corrosion Allowance

Aboveground

Installation

Design Factor

0.5

Stem Ext Length, mm

N.A.

Opening/Closing time

VALVE OPERATION
Actuation Requirement

Not Applicable

Type of Actuator

Not Applicable
VALVE MATERIAL SPECIFICATION
MATERIAL OFFERED

SPECIFIED

PART DISCRIPTION
Body

ASTM A216 Gr.WCB /A234GrWPB

Wedge

ASTM A216 Gr.WCB

Disc

ASTM A216 Gr.WCB

Hinge Pin

ASTM A 182 F6

Gasket

Grafoil

Stud Bolts

A193 B7

Nuts

A194 Gr.2H

TESTING REQUIREMENT
Body:147 Kg/cm2 g

Hydrostatic Test Pressure


Air Test Pressure

Seat: 107.8 Kg/cm2 g


7 barg

High Pressure Closure Test

API 598

Low Pressure Closure Test

API 598

Leak Test

API 598

DATA SHEET FOR


CHECK VALVES

Document No.

Rev.

11- 0330G01-01-08-03-005

SHEET 1 of 2

93 of 245

CLIENT

GAIL (India) LIMITED

SIZE/QUANTITY

PROJECT: PIPELINE FROM HANUMAN JUNCTION TO VCL

**

Fire Safe Test

As per API 6FA

Manufacturer's Painting Specification Number

PAINTING

A/G

U/G

Surface Preparation

SA 2.5

SA 2.5

Primer

30-40 micrometer

30-40 micrometer

Finish

30-40 micrometer

2 - layers polyurethane
- 1000 microns

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. 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

Document No.

DATA SHEET FOR


CHECK VALVES

11- 0330G01-01-08-03-005
SHEET 2 of 2

94 of 245

Rev.
0

SR.
NO.

2. DISC & SEAT RING

1. BODY & BONET


( REFER NOTE-1)

RAW MATERIAL

COMPONENTS &
OPERATIONS

ASTM A 216 Gr. WCB


ASTM A 216 Gr. WCB


PER HEAT
PER HEAT
10% WITNESS
& 100% REVIEW

CHEM. TEST

PHY. TEST

P/W

P/W

P/W

INSPECTION
REPORT

ASTM A 216 Gr.


SUPPLIER T.C.
WCB

P/W

INSPECTION
REPORT/RT
FILMS

P/W

P/W

P/W

3.2 Certificate

INTERNAL Q.C

P/R

SUBVENDOR/
VENDOR

3.2 Certificate

FORMAT OF
RECORD

PAGE NO: 1 of 3

TPI

INSPECTION

QAP NO: 11-0330G01-01-08-10-005


REV NO: 0
ITEM DESCRIPTION/ QUANTITY: CHECK VALVE
JOB NO.: 110330G01

ASTM A 216 Gr.


SUPPLIER T.C.
WCB

ASTM A 16.34

ASTM A 16.34

95 of 245

ASTM A 16.34

100%

MPT

VISUAL

ASTM A 16.34

100%

RADIOGRAPHY

MSS-SP-75

100%

PER HEAT

PHY. TEST

ACCEPTANCE
NORMS

ASTM A 216 Gr.


WCB
EN 10204/3.1B
ASTM A 216 Gr.
ASTM A 216 Gr. WCB
WCB
EN 10204/3.1B
ASTM A 216 Gr. WCB

REFERENCE
DOCUMENT

VISUAL

PER HEAT

QUANTAM OF
CHECK

CHEM. TEST

TYPES OF
CHECK

CLIENT: GAIL (India) LIMITED


CONSULTANT: WGI
VENDOR:

PROJECT:PIPELINE FROM HANUMAN JUNCTION TO VCL

WGI

SR.
NO.

1. FASTNERS

DIMENSIONS

PHYSICAL
10%

PER LOT

PER LOT

INSPECTION
REPORT

ASTM B 16.34
350 to 450 BHN

96 of 245

A 193 Gr.B7 & A A 193 Gr.B7 & A


194 GR 2H
194 GR 2H

3.2 Certificate

INSPECTION
REPORT

-DO-

-DO-

INSPECTION
REPORT

INSPECTION
REPORT

FORMAT OF
RECORD

-DO-

-DO-

APPVD.DRG

ACCEPTANCE
NORMS

A 193 Gr.B7 & A A 193 Gr.B7 & A


194 GR 2H
194 GR 2H

ASTM B 16.34

100%

HARDNESS & D.P.

4. HARD FACING

CHEMICAL

-DO-

100%

DIMENSIONS

3. SPINDLE

BROUGHTOUT ITEM

-DO-

100%

DIMENSIONS

2. DISC & SEAT RING

APPVD.DRG

100%

REFERENCE
DOCUMENT

100%

TRANSFER OF
HEAT NO.

TYPES OF CHECK

QUANTAM OF
CHECK

DIMENSIONS

1. BODY & BONET

INPROCESS INP

COMPONENTS &
OPERATIONS

P/W

P/W

P/W

P/W

P/W

SUBVENDOR
/VENDOR

TPI

INSPECTION

RW

WGI

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:

FINAL DOCUMENTS

APPVD.DRG &
API 598

APPVD.DRG &
API 598

100%

100%

HYD. BODY TEST

HIGH PRESSURE CLOSER


( SEAT) TEST

100%

100%

REVIEW

MARKING/TAG DETAILS

100%

PRIMER & FINISH COAT


(EACH TWO COAT)

SURFACE PREPARATION
SA 2/
100%

10% WITNESS &


100% REVIEW

VISUAL

API 598

100%

HIGH PRESSURE
PNEUMATIC SHELL TEST

INSPECTION
REPORT
PAINT.INSP.
REPORT

SPEC 60-80
ROUGH
SPEC 60-80 EACH
COAT & TOTAL
WITHIN 300

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

SPEC

SPEC

-DO-

API 598

100%

PERFORMANCE TEST
API 598

-DO-

APPVD.DRG &
API 598

APPVD.DRG &
API 598

100%

BACKSEAT TEST
API 598

-DO-

APPVD.DRG &
API 598

APPVD.DRG &
API 598

100%

-DO-

-DO-

-DO-

INSPECTION
REPORT

FORMAT OF
RECORD

LOW PRESSURE CLOSER


(SEAT) TEST

APPVD.DRG &
API 598

APPVD.DRG &
API 598

APPVD.DRG &
API 598

100%

DIMENSIONS

APPVD.DRG &
API 598

ACCEPTANCE
NORMS

REFERENCE
DOCUMENT

100%

QUANTAM OF
CHECK

VISUAL

TYPES OF CHECK

PAGE NO: 3 of 3

97 of 245

P/W

P/W

P/W

P/W

P/W

P/W

P/W

SUBVENDOR/
VENDOR

TPI

INSPECTION

ITEM DESCRIPTION/ QUANTITY: CHECK VALVE


JOB NO.: 110330G01

CONSULTANT: WGI
VENDOR:

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.

PAINTING

ASPER API 598


( REF.ANNEXURE-1 )

FINAL INSPECTION

COMPONENTS &
OPERATIONS

NO.

SR.

QAP NO:11-0330G01-01-08-10-005
REV NO: 0

PROJECT: PIPELINE FROM HANUMAN JUNCTION TO VCL

CLIENT: GAIL (India) LIMITED

RW

RW

RW

RW

RW

WGI

GAIL (India) Limited


PIPELINE FROM HANUMAN JUNCTION TO
VCL
CLIENT JOB NO.

STANDARD SPECIFICATION FOR ASSORTED PIPES


TOTAL SHEETS

DOCUMENT NO

11

0330G01

01

08

02

011

28.06.11

ISSUED FOR TENDER

MH

ASD

AD

24.06.11

ISSUED FOR IDC

MH

ASD

AD

REV

DATE

DESCRIPTION

PREP

CHK

APPR

98 of 245

TABLE OF CONTENT

1.0

GENERAL .............................................................................................................................. 3

2.0

IBR PIPES.............................................................................................................................. 4

3.0

HYDROSTATIC TEST............................................................................................................ 5

4.0

MARKING AND DISPATCH................................................................................................... 5

SPECIFICATION FOR
ASSORTED PIPES

Document No.

Rev

11-0330G01-01-08-02-011

SHEET 2 of 8
99 of 245

1.0

GENERAL

1.1

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.

1.2

Testing

1.2.1

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.

1.2.2

Material test certificates (physical property, chemical Composition & treatment report) shall also be
furnished for the pipes supplied.

1.3

Manufacturing Processes

1.3.1

Steel made by Acid Bessemer Process shall not be acceptable.

1.3.2

All longitudinally welded pipes other than IS:3589 should employ automatic welding.

1.4

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.

1.5
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.

1.7

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 4

Figure 5 Type A
Figure 6 Type A

1.8

Galvanized pipes shall be coated with zinc by hot dip process conforming to IS: 4736/ ASTM A 153.

1.9

All austenitic stainless steel pipes shall be supplied in solution annealed condition.

1.10

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.)

SPECIFICATION FOR
ASSORTED PIPES

Document No.

Rev

11-0330G01-01-08-02-011

SHEET 3 of 8
100 of 245

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.

1.12

Pipes under NACE category shall meet the requirements given in MR-01-75.

1.13

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.

1.14

For black or galvanised pipes to IS: 1239, the minimum percentage of elongation shall be 20%.

2.0

IBR PIPES

2.1

IBR Documentation

2.1.1

Pipes under purview of IBR shall be accompanied with IBR certificate original in Form 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.

2.1.2

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

: Allowable stress at the working metal temperature.

Et

: Yield point (0.2% proof stress at the working metal temperature.

Sc

: The average stress to produce elongation of 1% (creep) in 1, 00,000 hrs at the working
metal temperature.

Sr

: 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.

SPECIFICATION FOR
ASSORTED PIPES

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SHEET 4 of 8
101 of 245

SA (psi)

Temperature (F)

Material
A335 Gr. P11
A 691 Gr. 1
Cr
A335 Gr. P2/
A691 Gr. 2
1/4 Cr

500

600

650

700

17200

16700

16200

15600

18900

18300

18000

17900

17900

17900

750

800

850

900

950

1000

1050

1100

15200 15000 14500 12800

9300

6300

4200

2800

17600

17300 16800 16300 15000

9900

6300

4200

2800

17900

17900 17800 14500 12800 10800

7800

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

MARKING AND DESPATCH

4.1

All pipes shall be marked in accordance with the applicable codes, standards and specifications. In
addition, the purchase order number, the item code & special conditions like IBR, CRYO, NACE,
etc., shall also be marked.

4.2

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.

4.3

Paint or ink for marking shall not contain any harmful metal or metallic salts such as zinc, lead or copper
which cause corrosive attack on heating.

4.4

Pipes shall be dry, clean and free from from moisture, dirt and loose foreign materials of any kind.

4.5

Pipes shall be protected from rust, corrosion and mechanical damage during transportation, shipment
and storage.

4.6

Rust preventive used on machined surfaces to be welded shall be easily removable with petroleum
solvent and the same shall not be harmful to welding.

4.7

Both ends of the pipe shall be protected with the following material:
Plain end
:
Bevel end
:
Threaded end :

Plastic cap
Wood, Metal or Plastic cover
Metal or Plastic threaded cap

4.8

End protectors to be used on bevelled ends shall be securely and tightly attached with belt or wire.

4.9

Steel end protectors to be used on galvanised pipes shall be galvanized.

SPECIFICATION FOR
ASSORTED PIPES

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102 of 245

ANNEXURE I
3.0

HYDROSTATIC TEST

3.1

All pipes shall be hydrostatically tested.

3.2

The mill test pressure shall be as follows:

3.2.1

Seamless, E.R.W. & Spiral Welded


a)

Carbon Steel
Material 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)

c)

Test Pressure Standard


ASTM A 530
API 5L
API 5L
API 5L
ASTM A 530
ASTM A 530

Seamless Alloy Steel


Material Standard

Test Pressure Standard

ASTM A335 GR.P1, P12, P11, P22, P5 P9

ASTM A 530

ASTM A268 TP 405, TP41O

ASTM A 530

Seamless Stainless Steel


Material Standard

Test Pressure Standard

ASTM A312 GR.TP304,304L,304H,


ASTM A 530
316,316L, 316H, 321,347

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

e)

Test Pressure Standard


ASTM B161
ASTM B165
ASTM B167
ASTM B407

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

SPECIFICATION FOR
ASSORTED PIPES

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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

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

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)

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

Pipe Schedule: S 40

Pipe Schedule: S 80

Material
Gr.1

Material
Gr.2

Material
Gr.1.

Material
Gr.2

Material
Gr.1

Material
Gr.2

100

80

155

130

230

190

80

60

155

130

230

190

80

50

155

130

230

190

65

35

90

75

155

130

Size

c)

Stainless Steel E.FS.W. ( 8 and above)


Material Standard

Test Pressure standard

ASTM A358 TP
304L,304,304H,316L,316,316H,321,347
(Classes 1, 3 & 4)

P=2ST/D
S=85% of SMSYS
T=Nominal wall thickness
D=O.D. of pipe

ASTM A358 TP 304L, 304, 304H, 316L,


316
316H, 321, 347 (Classes 2 & 5)

P=2ST/D
S=72% of SMYS
T=Nominal Wall thickness
D=O.D. of pipe

SPECIFICATION FOR
ASSORTED PIPES

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SHEET 7 of 8
104 of 245

3.2.3

Carbon Steel Pipes to IS Standards

Material Standard

Test Pressure Standard

IS : 1239

IS : 1239

IS : 3589

IS : 3589

SPECIFICATION FOR
ASSORTED PIPES

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SHEET 8 of 8
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GAIL (India) Limited


PIPELINE FROM HANUMAN JUNCTION TO VCL

CLIENT JOB NO.

TOTAL SHEETS

11

TECHNICAL NOTES FOR VALVES

DOCUMENT NO

11

0330G01

01

08

02

016

28.06.11

ISSUED FOR TENDER

MH

ASD

AD

24.06.11

ISSUED FOR IDC

MH

ASD

AD

REV

DATE

DESCRIPTION

PREP

CHK

APPR

106 of 245

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

10

9. DESPATCH

10

TECHNICAL NOTES
FOR VALVES

Document No.

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11-0330G01-01-08-02-016

SHEET 2 of 11
107 of 245

TECHNICAL NOTES FOR VALVES


1.0

GENERAL

1.1

Vendor shall supply valves in accordance with the valve specification sheets along with auxiliaries, if any,
such as gear operator, bypasses, drains etc. wherever specified in the specification sheets, subject notes
and other enclosures to the material requisition (MR).

1.2

Vendor shall quote in strict accordance with the valve data / specification sheets, subject technical notes
and all other enclosures to the MR. Deviations to the specification / data sheets, subject technical notes
and other enclosures of the MR, if any, shall be asked as explained in clause 2.0.

1 .3

All codes and standards for manufacture, testing, inspection etc. shall be of latest editions.

2.0

DOCUMENTATION

2.1

Vendor shall submit the following with the offer:

2.1.1

Manufacturers complete descriptive and illustrative catalogue I literature.

2.1.2

Detailed dimensioned cross section drawing with parts/material lists, weight etc. for the ball valves, plug
valves, butterfly valves, diaphragm valves and valves to manufacturers standard.

2.1.3

Drawings for valves with accessories like gear operator, hydraulic / pneumatic operator, motor, extension
bonnet, extended stems with stands, bypass etc. giving major salient dimensions.

2.1 .4

One copy of the valve specification sheets signed as Accepted by the manufacturer with all deviations
marked clearly.

2.1.5

If the valve is regretted or has no deviation, the manufacturer shall write clearly on valve specification
sheets as Regret or No Deviation.

2.1.6

For subject notes, if there is any deviation, the same shall be listed clausewise.
Even clauses which are acceptable shall be categorically confirmed as Accepted.

2.1.7

On failure to submit documents as specified in clauses 2.1.1 to 2.1 .6 above, the offer is likely to he
rejected.

2.2

The following documents shall be submitted after placement of the order

2.2.1

Vendor shall submit for approval drawings mentioned in clauses 2.1.2 & 2.1.3 before start of
manufacture. No other drawing shall be submitted for approval.

2.2.2

Test report shall 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.

2.2.3

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.

3.0

DESIGN AND CONSTRUCTION

3.1

Valve shall be designed, manufactured, tested, inspected and marked as per the manufacturing
standards; design codes and standards (latest editions) indicated in the respective valve specification
sheets.Any conflict between the requisition, enclosures, specification sheets and referred standard codes
shall be brought to the notice of the purchaser for clarifications. But generally, specification sheets and
enclosures of the requisition including subject notes shall govern. After issue of the Purchase Requisition
(PR). no deviation to specification/standards shall be permitted through vendor drawing approval.
Approval of drawings shall be valid only for design / constructional features.
TECHNICAL NOTES
FOR VALVES

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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

1000 u in AARH max

serrations with 125 to 250 u m in AARH

Serrated finish / smooth


Finish / 125 AARH

Extra Smooth Finish / 63 AARH :


3.3

32 to 63 u in AARH

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)

Alloy Steel. Stainless Steel &


Low temp. Carbon Steel

3.4

Wall Thickness

Weld Contour

Upto 22 mm

Figure 2 Type A

> 22 mm

Figure 3 Type A

Upto 10 mm

Figure 4

> 10mm & Upto


25 mm

Figure 5 Type A

> 25 mm

Figure 6 Type A

For flanged valves with ring joint flanges, the hardness shall be as follows
Flange Material

Mm. Hardness of Groove (BHN)

Carbon Steed

140

1% Cr to 5 Cr

150

Type 304, 316, 321, 347

160

Type 304L, 316L.

140

3.5

Following requirements for check valves shall be met over and above the valve spec sheet requirements:

3.5.1

Unless specified otherwise in the data sheet all check valves 3 & above (except in 900#, 1500# & 2500#
rating) shall have a drain boss at location G (Refer Fig. No. 1 of ASME B16.34). A tapped drain hole
with plug shall be provided as per ASME B16.34. Threads shall be as per ASME B1.20.l (Taper) NPT.

3.5.2

Wherever check valve disc assembly is supported from the cover of the check valves the following shall
be ascertained.
i)
Positive location / positioning of cover must he provided to ensure correct alignment of the valve
disc.
ii)

3.5.3

Hinge pin design must permit accurate alignment of the disc and valve seat.

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

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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.

3.7

Following valve bypass requirements shall be met

3.7. 1

By-pass requirement for (Gate valves is indicated in the respective data sheets. As a rule, the following
shall be followed
ANSI 150 Class
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

3.7.2

The by-pass piping arrangement shall be such that clearance between main valve body and by-pass
assembly shall be the minimum possible for layout reasons.

3.7.3

By-pass valve shall be a globe valve. The sizes shall be as under


On main valve 4
On main valve > 4 but  10
On main valve > 10

:
:
:

1/2 or more
3/4 or more
1 or more

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.

3.8

Valve body / bonnet shall be forged / cast as specified. Forgings are acceptable in place of casting but
not vice-versa.

3.9

Material of construction of yoke shall be minimum equivalent to body / bonnet material.

3.10

Stem shall be forged or machined from forged / rolled bar. No casting is permitted. However, integral
stem of cast stainless steel ball valve is acceptable.

3.11

Stelliting / hardfacing by deposition shall be minimum 1.6 mm. Renewable seat rings shall be seal
welded.

3.12

Valves under NACE category shall meet the requirements specified in MR-0l-75 unless otherwise
specified.

3.13

For all austenitic stainless steel valves Inter Granular Corrosion (IGC) test shall be conducted as per the
following

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.

TECHNICAL NOTES
FOR VALVES

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SHEET 5 of 11
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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.

3.16

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.

3.17

Ball / Plug / Butterfly Valves

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

Floating ball

150#
10 & above

Trunnion mounted

4 & below

Floating ball

300#
6 & above
1.5 & below
600#
& above
2 & above

Trunnion mounted
Floating ball
Trunnion mounted

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.

TECHNICAL NOTES
FOR VALVES

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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.

4.0

OPERATION

4.1

Generally the valves are hand wheel or lever operated. Gear operation shall be provided as under

Valve Type

Class

Size Requiring GearOperator

150 Class

14 and larger

300 Class

14 and larger

600 Class

12 and larger

900 Class

6 and larger

1500 Class

3 and larger

2500 Class

3 and larger

300 & 600


Class

6 and larger

900 Class

6 and larger

1500 Class

3 and larger

2500 Class

3 and larger

150 Class

6 and larger

300 Class

6 and larger

600 Class

4 and larger

900 Class

3 and larger

1500 Class

3 and larger

150, 300
Class

6 and larger

Gate Valve & Diaphragm Valve

Globe Valve

Ball Valve/Plug Valve (Other than pressure


balance plug valves)

Butterfly Valve

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.

TECHNICAL NOTES
FOR VALVES

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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

Totally enclosed bevel gear in grease case with


grease nipples / plugs.

For Ball/ Plug I


Butterfly Valves

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).

4.4

Gear operator shall be so designed as to operate effectively with the differential pressure across the
closed valve equal to the cold non-shock pressure rating.

4.5

Ball, plug and butterfly valves, even with wrench or lever operators shall have Open position indicators
with limit stops.

4.6

Hand wheel diameter shall not exceed 750mm and lever length shall not exceed 500mm on either side.
Effort to operate shall not exceed 35 Kg at handwheel periphery. However, failing to meet the above
requirements, vendor shall offer gear operated valve and quote as per clause 4.3.

5.0

INSPECTION AND TESTING

5.1

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.

5.2

Every valve, its components and auxiliaries must be subjected to all the mandatory tests and checks
called for in the respective codes, data sheets etc. by the manufacturer.

5.3

Though the extent of inspection shall be as under, exact extent with hold points shall he decided by
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.

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.

TECHNICAL NOTES
FOR VALVES

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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.

5.5

Positive Material Identification (PMI) shall be performed as per the scope and procedures as defined in
the Specification for Positive Material Identification (PMI) at Vendors Works

6.0

RADIOGRAPHY OF CAST VALVES

6.1

Valve castings shall undergo radiographic examination as specified below. However, for sizes 24 &
below in 150# and 16 & below in 300#, radiography percentage specifically mentioned in individual valve
material spec sheet shall govern.

Material

Rating
150#

Size Range

Radiography

24 and below

NIL

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.
All

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.

6.3

For random radiography wherever specified in individual data sheets, the sampling shall he per size of
the quantity ordered for each foundry.

6.4

Radiography wherever specified in the data sheets or as per clause 6.1 shall be done by X-ray/gammaray to get the required sensitivity.

7.0

IBR CERTIFICATION

7.1

For valves described IBR, valves shall be in accordance with the latest IBR (Indian Boiler Regulation)
including the requirements specified in the specification.

7.2

For SW / BW end carbon steel valves under IBR, the chemical composition shall conform to the following
Carbon (Max)
0.25%
others (S. P, Mn):
As per IBR regulations
The above composition is not valid for non-IBR valves.

7.3

Valves coming under the purview of IBR (Indian Boiler Regulations) shall each be individually
accompanied by IBR certificate original in Form Ill-C duly approved by IBR authority / local authority
empowered by the Central Boiler Board of India. Photocopy of original certificate duly attested by the
local boiler inspector where the supplier is located is the minimum requirement for acceptance.

7.4

All IBR valves shall be painted red in body-bonnet / body-cover joint.

TECHNICAL NOTES
FOR VALVES

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8.0

MARKING

8.1

Valve markings, symbols, abbreviations etc. shall be in accordance with MSS-SP-25 or the standard
referred in specification sheet as applicable. Vendors name, valve rating, material designation, nominal
size, direction of flow (if any) etc. shall be integral on the body.

8.2

Each valve shall have a corrosion resistant tag giving size, valve tag / code no., securely attached to the
valve body.

8.3

Paint or ink for marking shall not contain any harmful metal or metal salts such as zinc, lead or copper
which cause corrosive attack on heating.

8.4

Carbon Steel I Alloy Steel valves shall he painted with one coat of inorganic zinc silicate
(minimum DFT 65 to 75 microns).

9.0

DESPATCH

9.1

Valve shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind.

9.2

Valves shall be protected from rust, corrosion and any mechanical damage during transportation,
shipment and storage.

9.3

Rust preventive on machined surfaces to be welded shall be easily removable with a petroleum solvent
or shall not be harmful to welding.

9.4

Each end of valve shall be protected with the following materials


Flange Face
:
Wood or Plastic Cover
Beveled End
:
Wood or Plastic Cover
SW & SCRD
:
End Plastic Cap

9.5

End protectors of wood/plastic to be used on flange faces shall be attached by at least three bolts and
shall not be smaller than the outside diameter of the flange. However plastic caps for SW & SCRD, end
valves shall be press fit type.

9.6

End protectors to be used on beveled end shall be securely and tightly attached.

9.7

For special service valves additional requirement of dispatch shall be prescribed in data sheet.

TECHNICAL NOTES
FOR VALVES

Document No.

Rev

11-0330G01-01-08-02-016

SHEET 10 of 11
115 of 245

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.

TECHNICAL NOTES
FOR VALVES

Document No.

Rev

11-0330G01-01-08-02-016

SHEET 11 of 11
116 of 245

GAIL (India) Limited


PIPELINE FROM HANUMAN JUNCTION TO VCL

TECHNICAL NOTES FOR BUTT WELDED,


SOCKET WELDED AND SCREWED FITTINGS

DOCUMENT NO

11

0330G01

01

CLIENT JOB NO.

TOTAL SHEETS

08

02

017

28.06.11

ISSUED FOR TENDER

MH

ASD

AD

24.06.11

ISSUED FOR IDC

MH

ASD

AD

REV

DATE

DESCRIPTION

PREP

CHK

APPR

117 of 245

TECHNICAL NOTES FOR BUTT WELDED, SOCKET WELDED AND SCREWED FITTINGS
1.0

GENERAL

1.1

Chemical composition, physical properties, tests, dimensions and tolerances, heat treatment and marking
shall conform to the applicable latest codes/standards/specifications as specified in the material requisition
(MR). Any deviation shall be highlighted on a separate sheet by the vendor in the quotation itself.

1.2

Test reports shall be supplied for all mandatory tests as per the material specifications Test reports shall
also be furnished for any supplementary tests as specified in the MR, Clauses 1.7.8, 1.9, 1.10 & 1.11.
Material test certificates (physical properties, chemical composition & heat treatment report) shall also be
furnished for fittings supplied.

1.3

All fittings shall be seamless in construction unless otherwise specified. If fittings are specified as welded,
the same shall conform to Clause 1.7. Seamless fittings can be supplied in place of welded fitting but with
maximum negative tolerance of 0.3mm (max.) on wall thickness. Welded fittings shall not be acceptable in
place of seamless fittings.

1.4

Outside diameters and wall thickness (unless otherwise mentioned) of butt welded fittings shall be in
accordance with ASME B36.10 and ASME B36.19 as applicable.

1.5

For reducing butt weld fittings having different wall thicknesses at each end, the greater wall thickness of
the fitting shall be employed and inside bore at each end shall be matched with the specified inside
diameter.

1.6

Bevelled ends for all fittings shall conform to ASME B16.25. Contour of bevel shall be as follows:
Material
Carbon Steel (Except Low Temp. Carbon Steel)
Alloy Steel,
Stainless Steel & Low Temp. Carbon Steel

1.7

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

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.

TECHNICAL NOTES FOR


BUTT WELDED, SOCKET WELDED
AND SCREWED FITTINGS
118 of 245

Document No.
11-0330G01-01-08-02-017
SHEET 2 of 5

Rev
0

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

Fittings under NACE category shall meet the requirements of MR-01-75.

1.10

Thickness/schedule lower or higher than specified shall not be accepted.

1.11

The gasket contact surfaces of stub ends shall be flat with face finish 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

Seamless stub ends shall not have any welds on the body.

1.13

Galvanised fittings shall be coated with zinc by hot dip process conforming to IS 4736/ ASTM A 153.

1.14

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.

1.15

Unless and otherwise specified in the MR, all socket welded and screwed fittings shall be in accordance
with ASME B16. 11 to the extent covered in the specification except for unions which shall be in
accordance with MSS-SP-83.

1.16

Special fittings like weld-o-let, sock-o-let, sweep-o-let etc. which are not covered in ASME, MSS-SP &
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.

1.17

Length of all long half couplings shall be 100 mm unless otherwise specified.

1.18

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:

TECHNICAL NOTES FOR


BUTT WELDED, SOCKET WELDED
AND SCREWED FITTINGS
119 of 245

Document No.
11-0330G01-01-08-02-017
SHEET 3 of 5

Rev
0

Welded Pipe Employed For Manufacture Of Welded Fittings.

Test Criteria

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)

P = 2ST/D
S = 90% of SMYS.
T = Nom. Wall Thickness
D = O.D. of Pipe.

API5L
ASTM A358 TP 304, 304L, 304H,318, 318L, 318H,321,347
(Cl.1, 3, 4)

P = 2ST/D
S = 85% of SMYS.
T = Nom. Wall Thickness
D = O.D. of Pipe.

ASTM B725

ASTM B725

ASTM B517

ASTM B517

ASTM B514

ASTM B514

1.19

The bevel ends of all butt weld fittings shall undergo 100% MP/DP test.

1.20

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.

1.21

Abbreviations for ends of swages and nipples shall be as follows:


PBE
: Plain Both Ends
TBE
: Threaded Both Ends

2.0

IBR REQUIREMENTS

2.1

IBR Documentation Required:

2.1.1 Fittings under the purview of IBR (Indian Boiler Regulations) shall be accompanied with original IBR
certificate in Form Ill-C duly approved and countersigned by IBR authority / local authority empowered by
Central Boiler Board of India. Photocopy of the original certificate duly attested by the local boiler inspector
where the supplier is located is the minimum requirement for acceptance.
2.1.2

For materials 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

: Allowable stress at the working metal temperature.

Et

: Yield point (0.2% proof stress at the working metal temperature)

Sc

: The average stress to produce elongation of 1 % (creep) in 100000 hrs at the working metal
temperature.

Sr

: The average stress to produce rupture in 100000 hrs at the working metal temperature and in
no case more than 1.33 times the lowest stress to produce rupture at this temperture.

TECHNICAL NOTES FOR


BUTT WELDED, SOCKET WELDED
AND SCREWED FITTINGS
120 of 245

Document No.
11-0330G01-01-08-02-017
SHEET 4 of 5

Rev
0

SA (psi)
Temp(F)
Material

500

600

650

700

750

800

850

900

950

1000

1050

1100

A 234
Gr.WP11 /
A234
Gr.WPI1W

21700

20900

20500

20100

19700

19200

18700

13700

9300

6300

4200

2800

A 234
Gr.WP22 /
A234
Gr.WP22W

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

MARKING AND DISPATCH

3.1

Each fitting shall be legibly and conspicuously stamped in accordance with the requirements of
applicable standards along with special condition like IBR, Cryo, NACE etc.

3.2

Steel die marking with round bottom punch may be permitted on body of butt weld CS & lower alloy steel
fittings, but for SS & higher alloy steel fittings, the same should be marked by electro-etching only.

3.3

Paint or ink for marking shall not contain any harmful metals or metal salts such as Zinc, Lead or Copper
which causes corrosive attack on heating.

3.4

Fittings shall be dry, clean and free of moisture, dirt and loose foreign materials of any kind.

3.5

Fittings shall be protected from rust, corrosion and mechanical damage during transportation, shipment
and storage.

3.6

Rust preventive used on machined surfaces to be welded shall be easily removable with a petroleum
solvent and the same shall not be harmful to welding.

3.7

Fittings under IBR, Cryo, NACE shall be painted in red, light purple and canary yellow stripes
respectively for easy identification. Width of the stripe shall be 25 mm.

3.8

Each end of fitting shall be protected with a wood, metal or plastic cover.

3.9

Each size of fitting shall be supplied in separate packaging marked with the purchase order number, item
code number, material specification, size and schedule I thickness / rating.

TECHNICAL NOTES FOR


BUTT WELDED, SOCKET WELDED
AND SCREWED FITTINGS
121 of 245

Document No.
11-0330G01-01-08-02-017
SHEET 5 of 5

Rev
0

GAIL (India) Limited


PIPELINE FROM HANUMAN JUNCTION TO VCL

CLIENT JOB NO.

TECHNICAL NOTES FOR BOLTS & NUTS


TOTAL SHEETS

DOCUMENT NO

11

0330G01

01

09

02

010

28.06.11

ISSUED FOR TENDER

MH

ASD

AD

24.06.11

ISSUED FOR IDC

MH

ASD

AD

REV

DATE

DESCRIPTION

PREP

CHK

APPR

122 of 245

TABLE OF CONTENT

1.0

GENERAL ....................................................................................................................................... 3

2.0

ACCEPTABLE DEVIATIONS ......................................................................................................... 4

TECHNICAL NOTES
FOR BOLTS & NUTS

Document No.

Rev

11-0330G01-01-09-02-010

SHEET 2 of 4
123 of 245

TECHNICAL NOTES FOR BOLTS AND NUTS


1.0

GENERAL

1.1

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.

1.2

Testing
1.2.1

Test reports shall be supplied for all mandatory tests as per the relevant material specifications.

1.2.2

Material test certificate shall also be furnished. (Heat Analysis, Product Analysis and Mechanical
Requirement)

1.2.3

PMI shall be performed as per the scope and procedures defined in the Specification for PMI at
Vendors Works.

1.2.4

Stress Rupture Test as detailed in ASTM A453 shall be carried out for all ASTM A453 bolting
material irrespective of the temperature.

1.3

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.

1.4

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.

1.5

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.

1.6

The nuts shall be double chamfered, semi-finished, heavy hexagonal type and shall be made by the hot
forged process and stamped as per respective material specification.

1.7

Heads of jackscrews and m/c bolts shall be heavy hexagonal type. Jackscrew end shall be rounded.

1.8

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.

1.9

All items shall be inspected and approved (stagewise) by Wood Group Kenny.

1.10

The heat treatment for stud bolts & nuts shall be as per code unless mentioned otherwise.

1.11

All austenitic stainless steel bolts, nuts, screws shall be supplied in solution annealed condition unless
specified otherwise in the material specification.

1.12

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.

1.13

Bolts/nuts of material of construction B7M/ 2HM shall be 100% Hardness tested as per supplementary
requirement S3 of ASTM A 193.

1.14

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.

TECHNICAL NOTES
FOR BOLTS & NUTS

Document No.

Rev

11-0330G01-01-09-02-010

SHEET 3 of 4
124 of 245

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.

2.0

ACCEPTABLE DEVIATIONS

2.1

Nuts to ASTM A194Gr.7 are acceptable in place of ASTM A194Gr.4.

TECHNICAL NOTES
FOR BOLTS & NUTS

Document No.

Rev

11-0330G01-01-09-02-010

SHEET 4 of 4
125 of 245

GAIL (India) Limited


PIPELINE FROM HANUMAN JUNCTION TO VCL

TECHNICAL NOTES FOR FLANGES,


SPECTACLE BLIND AND DRIP RINGS

DOCUMENT NO

11

0330G01

01

CLIENT JOB NO.

TOTAL SHEETS

09

03

009

28.06.11

ISSUED FOR TENDER

MH

ASD

AD

24.06.11

ISSUED FOR IDC

MH

ASD

AD

REV

DATE

DESCRIPTION

PREP

CHK

APPR

126 of 245

TECHNICAL NOTES FOR FLANGES, SPECTACLE BLINDS AND DRIP RINGS


1.0

GENERAL

1.1

All items, their dimensions, tolerances, chemical composition, physical properties, heat treatment and
testing etc. shall conform to the latest codes and standards specified in the requisition. Deviations, if any,
shall be clearly highlighted on a separate sheet by the vendor in the quotation itself.

1 .2

Testing

1.2.1 Test reports shall 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

1.4

Bevel end details for welding neck flanges shall be as per ASME B16,25. Contour of bevel end shall be as
follows
Material

Wall Thickness

Weld Contour

Carbon Steel (Except Low Temp.


Carbon Steel)

Upto 22 mm

Figure 2 Type A

> 22 mm

Figure 3 Type A

Upto 10 mm

Figure 4

> 10 mm upto 25 mmm

Figure 5 Type A

> 25 mm

Figure 6 Type A

Alloy steel, stainless steel and low


temp carbon steel

1.5

Bore of socket weld flanges & reducing blind flanges shall suit the outside diameter and schedule /
thickness of matching pipe.

1.6

Bore of slip on flanges shall suit the outside diameter of matching pipe.

1.7

Flange face finish shall 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

1.8

Galvanised flanges shall be coated with zinc by hot dip process conforming to IS 4736 / ASTM A 153.

1.9

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).

1.10

For ring joint flanges, blinds and spacers the hardness shall be as follows:

TECHNICAL NOTES FOR


FLANGES, SPECTACLE BLIND AND
DRIP RINGS
127 of 245

Document No.
11-0330G01-01-09-02-009
SHEET 2 of 4

Rev
0

Flange Material

Mm. Hardness of
Groove (BHN)

Carbon Steel

140

1 %Cr to 5% Cr

150

Type 304, 316, 321, 347

160

Type 304L, 316L

140

1.11

For ring joint flanges, blinds and spacers, the hardness shall be recorded in the test report.

1.12

Flanges, blinds, drip rings under NACE category shall meet the requirements given in MR-01-75 unless
otherwise specified.

1.13

All austenitic stainless steel flanges shall be supplied in solution annealed condition.

1.14

I.G.C. Test for Stainless Steels:

1.14.1 For all austenitic stainless steel flanges, blinds, drip rings & Fig.8 flanges 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.

1.16

AWWA C207 flanges shall be hub type.

2.0

IBR REQUIREMENTS

2.1

IBR Documentation:

2.1.1 Flanges coming under the purview of IBR (Indian Boiler Regulations) shall be accompanied with 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.

TECHNICAL NOTES FOR


FLANGES, SPECTACLE BLIND AND
DRIP RINGS
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3.0

SPECIAL REQUIREMENTS FOR HYDROGEN SERVICE

3.1

Method of Manufacture

3.1.1 All carbon steel flanges having wall thickness 9.53 mm and above shall be 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

MARKING AND DESPATCH

4.1

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.

4.2

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.

4.3

Paint or ink for marking shall not contain any harmful metal or metal salts such as zinc, lead or copper
which cause corrosive attack on heating.

4.4

All items shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind.

4.5

All items shall he protected from rust, corrosion and mechanical damage during transportation, shipment
and storage.

4.6

Rust preventive on machined surfaces to be welded shall be easily removable with a petroleum solvent
and the same shall not be harmful to welding.

4.7

Each end of flange shall he protected with the following materials:


Flange face
Bevelled end
Threaded end
Socket welding end

4.8

: Wood, metal or plastic cover


: Wood, metal or plastic cover
: Plastic plug
: Plastic cover or plug

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.

TECHNICAL NOTES FOR


FLANGES, SPECTACLE BLIND AND
DRIP RINGS
129 of 245

Document No.
11-0330G01-01-09-02-009
SHEET 4 of 4

Rev
0

GAIL (India) Limited


PIPELINE FROM HANUMAN JUNCTION TO VCL

CLIENT JOB NO.

TECHNICAL NOTES FOR GASKETS


TOTAL SHEETS

DOCUMENT NO

11

0330G01

01

08

02

018

28.06.11

ISSUED FOR TENDER

MH

ASD

AD

24.06.11

ISSUED FOR IDC

MH

ASD

AD

REV

DATE

DESCRIPTION

PREP

CHK

APPR

130 of 245

TABLE OF CONTENT
1. GENERAL

TECHNICAL NOTES
FOR GASKETS

Document No.

Rev

11-0330G01-01-08-02-018

SHEET 2 of 4
131 of 245

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

GENERAL

1.1

All gaskets shall conform to the codes/standards and specifications given in the requisition. Vendor shall
strictly comply with MR/PR stipulations and no deviations shall be permitted.

1.2

Process of manufacture, dimensions and tolerances not specified in requisition shall be in accordance
with the requirements of the manufacturers standards.

1.3

Testing

1.3.1

Test reports shall be supplied for all mandatory tests for gaskets as per the standards specified in the
requisition.

1.3.2

Chemical composition and hardness of RTJ gaskets shall also be furnished in the form of test reports on
samples.

1.3.3

For Spiral wound material following shall be furnished:


a)

Manufacturers test certificate for filler material and spiral material as per the relevant material
specifications.

b)

Manufacturers test certificate for raw materials and tests for compressibility/ seal-ability & recovery
as per the relevant material specifications.

1.4

Full face gaskets shall have bolt holes punched out.

1.5

Filler material for spiral wound gaskets shall not have any colour or dye.

1.6

All spiral wound gaskets shall be supplied with Outer ring. Material of the outer ring shall be CS unless
otherwise specified in the MR.

1.7

For spiral wound gaskets, material of Inner Compression ring shall be same as Spiral Strip material. In
addition to the requirements as per code and as specified in the MR. inner rings shall be provided for the
following:

1.8

a)

Sizes 26 and above.

b)

Class 900 and above.

Hardness of metallic RTJ gaskets shall not exceed the values specified below unless otherwise specified
in MR:

TECHNICAL NOTES
FOR GASKETS

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SHEET 3 of 4
132 of 245

Ring Gasket
Soft Iron
Carbon steel
5Cr.1/2Mo

Material Maximum Hardness (BHN)


90
120
130

1.9

Face finish of metallic RTJ gaskets shall be 32 to 63 AARH.

1.10

Gaskets of different types and sizes shall be placed in separate shipping containers and each container
clearly marked with the size, rating, material specification and item code.

1.11

All items shall be inspected and approved by Wood Group Kenny / owner / TPI

1.12

Any additional requirements specified in the requisition, shall be fully complied with.

1.13

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.

1.14

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.

1.15

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

TECHNICAL NOTES
FOR GASKETS

Document No.

Rev

11-0330G01-01-08-02-018

SHEET 4 of 4
133 of 245

GAIL (India) Limited


PIPELINE FROM HANUMAN JUNCTION TO VCL

TECHNICAL SPECIFICATION
FOR
INSULATING JOINTS

DOCUMENT NO

0
A

REV

28.06.11
24.06.11

DATE

11

0330G01

CLIENT JOB NO.


TOTAL SHEETS

01

09

02

08
003

ISSUED FOR TENDER

MH

ASD

AD

ISSUED FOR IDC

MH

ASD

AD

DESCRIPTION

PREP

CHK

APPR

134 of 245

TABLE OF CONTENTS

Sl.No.

DESCRIPTION

PAGE NO.

1.0

SCOPE ------------------------------------------------------------------------------------ 3

2.0

REFERENCE DOCUMENTS-------------------------------------------------------- 3

3.0

DEFINITIONS---------------------------------------------------------------------------- 4

4.0

MATERIALS------------------------------------------------------------------------------ 4

5.0

DESIGN & CONSTRUCTION REQUIREMENTS------------------------------ 5

6.0

INSPECTION AND TESTS---------------------------------------------------------- 6

7.0

TEST CERTIFICATES----------------------------------------------------------------- 7

8.0

PAINTING, MARKING AND SHIPMENT----------------------------------------- 7

9.0

SPARES AND ACCESSORIES----------------------------------------------------- 8

10.0

DOCUMENTATION-------------------------------------------------------------------- 8

TECHNICAL SPECIFICATION
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SHEET 2 of 8

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

REFERENCE DOCUMENTS

2.1

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.

ASME B 31.8

: Gas Transmission and Distribution piping systems.

ASME Section VIII


ASME Section IX

: Boiler & pressure Vessel Code.

ASTM A 370

: Standard Test Methods and Definitions for Mechanical Testing


of steel Products.

ASTM B 733

: Auto catalytic Nickel Phosphorous coating on metals.

ANSI B 16.25

: Butt Welding Ends

EN 1024

: Metallic Materials-Types of inspection documents.

MSS-SP-25

: Standard marking systems for valves, Fittings, Flanges and


union.

MSS-SP-53

: Quality standard for steel casting and forging for valves,


flanges, fittings and other piping components Magnetic particle
Examination method.

MSS-SP-75

: Specification for High Test Wrought welding fittings.

NACE RP o286

: The electrical isolation of catholically protected pipelines.

ISO 13623

: Petroleum & Natural Gas industry Pipeline transportation


system.

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.

TECHNICAL SPECIFICATION
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SHEET 3 of 8

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.

Should

: 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.

May

: This verbal form indicates a course of action permissible


within the limits of this standard.

Can

: This verbal form used for statements of possibility &


capability , whether material, physical or casual.

4.0

MATERIALS

4.1

Material for the pressure containing parts of the insulating joints shall be as indicated in the data
sheets. Material for pups shall be equivalent or superior to the material of connecting pipeline, which
is indicated in the data sheets. 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.

4.2

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

4.3

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.

4.4

Carbon steel used for the manufacture shall be fully killed.

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.

4.6

Insulation material shall be minimum 20 mm thick and shall comply section 5, NACE RP 0286.

TECHNICAL SPECIFICATION
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SHEET 4 of 8

5.0

DESIGN & CONSTRUCTION REQUIREMENTS

5.1

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.

5.1.2

All materials used for the manufacture of the insulating joint shall be in accordance with clause 4.0 of
this Specification.

5.1.3
5.1.4

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.

5.1.5

The joint between pipe pup pieces and main forging shall be full penetration butt weld type. Weld
design shall be such as resulting in a weld joint factor of 1.0.

5.1.6

Butt weld ends shall have ends as per ASME B16.25. However, end preparation for butt welding
ends having unequal thickness with respect to connecting pipe, shall be as per ASME B31.4/ B31.8
as applicable.

5.1.7

The reinforcement of inside weld seam, in case pups fabricated from LSAW pipes, shall be removed
for a distance of at least 50mm from each end to facilitate welding.

5.1.8

Insulating joints shall allow free passage of scraper/ instrumented pigs. The internal bore shall be
same as that of connecting pipe including its tolerances.

5.1.9

The insulating joint shall be formed by sandwiching and locking in positions the insulating material in
a bell and spigot type of joint. The joint shall be assembled in such a way that its various
components are firmly locked in position and the completed joint is capable of withstanding stresses
due to designed operating conditions and field hydrostatic testing.

5.1.10

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.

5.1.11

5.1.12

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.

5.1.13

Internal diameter at the welding end shall not vary more than + 1, -3 mm from the nominal internal
diameter.

5.1.14
5.2

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

5.2.1

The average dielectric strength of the insulating joint shall be minimum 15 kilo Volts.

5.2.2

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.

TECHNICAL SPECIFICATION
FOR
MONOLITHIC INSULATING JOINTS
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SHEET 5 of 8

6.0

INSPECTION &TESTING

6.1

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:

6.1.1

All insulating joints shall be visually inspected.

6.1.2

Dimensional checks shall be carried out as per the purchaser approved drawings.

6.1.3

Chemical composition and mechanical properties including hardness shall be checked as per
relevant material standards and this specification, for each heat of steel used.

6.1.4

Non-destructive inspection of insulating joints shall be carried out as given below:


a) 100% radiography shall be carried out on all butt & repair welds of pressure containing parts.
Acceptance limits shall be as per API 1104.

Welds, which in purchaser's 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.

6.1.6

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.

6.1.7

DIELECTRIC TEST
a)

Insulation resistance of each insulating joint shall be at least 50 mega-ohms when checked
with1000 V DC.

b)

Insulating joint before and after the hydrostatic test, shall be tested for dielectric integrity for
one minute at 5000 V A.C., 50 cycles and the leakage current before and after hydrostatic
test shall be equal. Testing time voltage and leakage shall be recorded and certified. No
repair shall be permitted to the insulating joints failed in the above mentioned tests.

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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SHEET 6 of 8

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

TEST CERTIFICATES

7.1

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.

b)

Test reports on non-destructive testing.

c)

Test certificates for hydrostatic and air tests.

d)

Test certificate for electrical resistance test.

e)

Test report for dielectric strength test.

8.0

PAINTING, MARKING AND SHIPMENT.

8.1

Insulating joint surface shall be thoroughly cleaned, freed from rust and grease and applied with
sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot blasting
to SP-6 in accordance with "steel structures painting council - Visual standard SSPC-VIS-l.".
External surfaces of buried insulating joints shall be painted with three coats of suitable coal tar
epoxy resin with a minimum dry film thickness of 300 microns.
Manufacturer shall indicate the type of corrosion resistant paint used, in the drawings submitted for
approval.

8.2

8.3

Insulating joints shall be marked with indelible paint with the following data:a.

Manufacturer's name

b.

Suitable for- inch nominal diameter pipeline

c.

End thickness in mm

d.

Material

e.

Design Pressure/ Hydrostatic Test Pressure

f.

ANSI Class Rating

g.

Tag No.

h.

Year of Manufacture

Insulating joints shall be suitably protected to avoid any damage during transit. Metallic bevel
protectors shall be provided to weld ends.

TECHNICAL SPECIFICATION
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SHEET 7 of 8

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

DOCUMENTATION

10.1

All documents shall be in English Language.

10.2

At the time of bidding, Bidder shall submit the following documents:a)

10.3

b)

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.

c)

Clause wise list of deviation from this specification, if any.

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)

Fabrication drawings and relevant calculations for pressure containing parts.

b)

Welding procedure and method of manufacture for all phases of manufacture.

c)

Quality Assurance Plan (QAP)

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.

10.5

Prior to shipment, the manufacturer shall submit one reproducible and six copies of the test
certificates as listed in Clause 6.0 of this specification.

TECHNICAL SPECIFICATION
FOR
MONOLITHIC INSULATING JOINTS
141 of 245

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SHEET 8 of 8

GAIL (India) Limited


PIPELINE FROM HANUMAN JUNCTION TO VCL

WELDING SPECIFICATION FOR


FABRICATION OF PIPING

DOCUMENT NO

11

0330G01

01

CLIENT JOB NO.

TOTAL SHEETS

26

09

02

011

28.06.11

ISSUED FOR TENDER

MH

ASD

AD

24.06.11

ISSUED FOR IDC

MH

ASD

AD

REV

DATE

DESCRIPTION

PREP

CHK

APPR

142 of 245

Abbreviations:
ASME

American Society of Mechanical Engineers

ASNT

American Society for Nondestructive Testing

AWS

American Welding Society

BPVC

Boiler & Pressure Vessel Code

CFH

Cubic Feet per Hour

DWDI

Double Wall Double Image

DWSI

Double Wall Single Image

SWSI

Single Wall Single Image

GTA

Gas Tungsten Arc

GTAW

Gas Tungsten Arc Welding

IBR

Indian Boiler Regulations

IQI

Image Quality Indicator

NDT

Non Destructive Testing

PQR

Procedure Qualification Record

RT

Radiographic Testing

SMAW

Shielded Metal Arc Welding

UTS

Ultimate Tensile Strength

WELDING SPECIFICATION FOR


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SHEET 2 of 26
143 of 245

TABLE OF CONTENT

1.0

GENERAL

2.0

APPLICABLE CODES & STANDARDS

3.0

BASE MATERIALS

4.0

WELDING CONSUMABLES

5.0

SHIELDING & PURGING GAS

6.0

EQUIPMENTS & ACCESSORIES

7.0

WELDING PROCESSES

8.0

EDGE PREPARATION

9.0

ALIGNMENT & SPACING

10.0

WEATHER CONDITIONS

11.0

WELDING TECHNIQUE

12.0

HEAT TREATMENT

13.0

CLEANING OF THE WELD JOINT

14.0

INSPECTION & TESTING

15.0

REPAIRS OF WELDS

12

16.0

DOCUMENTS TO BE SUBMITTED BY CONTRACTOR

12

17.0

ATTACHMENT 1

27

WELDING SPECIFICATION FOR


FABRICATION OF PIPING

Document No.

Rev

11-0330G01-01-09-02-011

SHEET 3 of 26
144 of 245

(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

BASE METAL

3.1

In general, use of carbon steel, alloy steel and stainless steel is envisaged. The details of the material
specifications are given in the Welding Specification Chart.

3.2

The Contractor shall provide the manufacturers test certificates for every heat of the materials supplied by
him.

4.0

WELDING CONSUMABLES

4.1

The Contractor shall provide, at his own expense, all the welding consumables necessary for the
execution of the job such as electrodes, filler wires, argon etc. and these should bear the approval of the
Engineer-in-Charge.

4.2

The welding electrodes and filler wires supplied by the Contractor shall conform to the class specified in
the Welding Specification Chart. The materials shall be of the make approved by the Engineer-in-Charge.

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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.

4.4

The Contractor shall submit batch test certificates, from the electrode manufacturers, giving details of
physical and chemical tests carried out by them, for each batch of electrodes to be used.

4.5

All electrodes shall be purchased in sealed containers and stored properly to prevent deterioration. The
electrodes removed from the containers shall be kept in holding ovens at temperatures recommended by
the electrode manufacturer. Out of the oven time or electrodes, before they are consumed, shall not
exceed the limits recommended by the electrode manufacturer. The electrodes shall be handled with care
to avoid any damage to the flux covering.

4.6

All low hydrogen type of electrodes shall be rebaked at 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.

4.7

The electrodes, filler wires and flux used shall be free from rust, oil, grease, earth and other foreign matter
which affect the quality of welding.

4.8

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.

5.0

SHIELDING & PURGING GAS

5.1

Argon gas used in GTA welding for shielding purposes shall be 99.995% pure. The purity of the gas shall
be certified by the manufacturer. The rate of flow for shielding purposes shall be established through
3
procedure qualification tests. Normally this rate may be 0.34 0.57 M per hour.

5.2

Argon gas with a purity level of 99.995% shall be used for purging.

5.3

When GTAW process alone or a combination of GTAW and SMAW processes is recommended for the
production of a particular joint, the purging shall be maintained during the root pass and for the first filling
pass to minimize oxidation on the inner side of the pipe, unless otherwise specified in Welding
Specification Chart.

5.4

Initial purging shall be maintained for sufficient period of time so that at least 4-5 times the volume
between the dams is displaced, in order to completely remove the entrapped air. In no case should the
initial purging period be less than 10 minutes. High gas pressure should be avoided.

5.5

After initial purging, the flow of the backing gas should be reduced to a point where only a slight positive
pressure prevails. For systems, which have a small volume (up to 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.

5.6

Gas backing (purging) is not required for socket type of welded joints.

5.7

Dams, used for conserving inert gas during purging, shall be removed after completion of the welding, and
shall be accounted for. Wherever, removal of dams is not possible after welding, use of water-soluble
dams should be made.

6.0

EQUIPMENTS & ACCESSORIES

6.1

The Contractor should have the arrangement of sufficient number of welding and cutting equipments,
auxiliaries, and accessories of sufficient capacities so as to meet the target/schedule.

6.2

All the equipments for performing the heat treatment, including transformers, thermocouples, pyro-meters,
automatic temperature recorders (with suitable calibration arrangement etc.) shall be provided by the
Contractor at his own expenses and these should bear the approval of the Engineer-in-Charge.
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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.

6.4

Redoing of any work, necessitated by faulty equipments or operation used by the Contractor will be done
at his own expense.

7.0

WELDING PROCESS

7.1

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)

7.2

The welding processes to be employed are given in the Welding Specification Chart. Any deviation desired
by the Contractor shall be obtained through the express consent of the Engineer-in-Charge.

7.3

Automatic and semi-automatic welding processes shall be employed only with the express approval of the
Engineer-in-Charge. The welding procedure adopted and consumables used shall be specifically
approved.

7.4

A combination of different welding processes could be employed for a particular joint only after duly
qualifying the welding procedure to be adopted and obtaining the approval of Engineer-in-Charge.

8.0

EDGE PREPARATION

8.1

General
The edges to be welded shall be prepared to meet the joint design requirements by any of the following
methods recommended:
(a) Carbon Steel
Gas cutting, machining or grinding methods shall be used. After gas cutting, oxides shall be removed
by chipping or grinding.
(b) Low Alloy Steels (containing up to 5% Chromium).
Gas cutting, machining or grinding methods shall be used. After gas cutting, machining or grinding
shall be carried out on the cut surface.
(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.

8.2

Cleaning
(a) The ends to be welded shall be properly cleaned to remove paint, oil, grease, rust, oxides, sand, earth
and other foreign matter. The ends shall be completely dry before the welding commences.
(b) On completion of each run, craters, welding irregularities, slag etc., shall be removed by grinding and
chiseling. Wire brushes used for cleaning stainless steel joints shall have stainless steel wires and the
grinding wheels used for grinding stainless steel shall be of a suitable type. Separate grinding wheels
and wire brushes should be used for carbon steels and stainless steels.

9.0

ALIGNMENT & SPACING

9.1

Components to be welded shall be aligned and spaced as per the requirements laid down in applicable
code. Special care must be taken to ensure proper fitting and alignment when the welding is performed by
GTAW process. Flame heating for adjustment and correction of ends is not permitted unless specifically
approved by the Engineer-in-Charge.

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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.

9.3

For pipes of wall thickness 5 mm and above, the ends to be welded shall be secured in position with the
aid of couplers, yokes and C clamps, to maintain perfect alignment. Yokes shall be detached after the
completion of weld, without causing any surface irregularity. Any irregularity caused on the pipe surface
must be suitably repaired to the satisfaction of the Engineer-in-Charge.

9.4

Tack welds, for maintaining the alignment, of pipe joints shall be made only by qualified welders using
approved 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.

9.5

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.

9.6

Welding shall commence only after approval of fit-up by the Engineer-In-Charge.

10.0

WEATHER CONDITIONS

10.1

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.

10.2

During field welding using GTAW process, particular care shall be exercised to prevent any air current
affecting the welding process.

11.0

WELDING TECHNIQUE

11.1

Root Pass
(a) Root pass shall be made with electrodes/filler wires recommended in the welding specification chart.
For fillet welding, root welding shall be done with consumables recommended for filler passes. The
preferred size of the electrodes is 2.5 mm diameter (12 SWG) but in any case not greater than 3.25
mm (10 SWG).
(b) Upward technique shall be adopted for welding pipe held fixed with its axis horizontal.
(c) The root pass of butt joints should be executed so as to achieve full penetration with complete fusion
of the root edges. Weld projection inside the pipe shall be as per applicable code. It shall be limited
3mm map. When the applicable code does not place any restriction.
(d) Any deviation desired from the recommended welding technique and electrodes indicated in the
welding specification chart should be adopted only after obtaining express approval of the Engineer-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.

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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

HEAT TREATMENT

12.1

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

INSPECTION AND TESTING

14.1

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- in- charge 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.

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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:

B:

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.

U.T.S.

Date:

Yield Point

Elongation

Remarks

1.
2.
C:

Impact Test Results


Test Temperature

Notch in

Type of Specimens (Charpy)

Size of Specimens

Specimen No.

Impact Value

Average

2
3
4
5
D:

Chemical Analysis Results


Electrode Size Result

Batch No.

%C

%S

%P

%Si

%Mn

%Cr

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%Ni

%Mo

Other

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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)

F:

2.

Macro Test Results

Fracture Test Results

Remarks

Other Test Results

1. Transverse tensile test

In combination with

Base material used

Position of welding

Preheat temperature

Post weld heat treatment

Radiography

Identification No.

U.T.S.

Guided Bend Test

Position

Fracture in

Identification No.

Remarks

Root, Face or Side Bend

Remarks

1
2

3
4
5
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

: _____________________________

Specification
Reference No.

1.

Other Details

General Details
Name of the

Type of Heating: Elec. Res/ Induction

Equipment: ________________________
(Tick mark applicable method)
Maximum Permissible Temp at
Uncovered Parent Metal
Width of heated band _________
Width of Insulation __________
Material: __________________________

No. of Themo couples (dia wise)

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

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:

POSTWELDED HEAT TREATMENT

Position (s) of Groove


Welding Progression : UP

Temperature Range

Down

Time Range

Position (s) of Fillet


PREHEAT

GAS

Preheat Temp. Min.

Shielding Gas (es)


Percent Composition (mixtures)

Interpass Temp. Max.


Flow Rate
Gas Backing

Preheat Maintenance

Trailing Shielding Gas Composition


ELECTRICAL CHARACTERISTICS
Current AC or DC

Polarity

Amps (Range)

Volts (Range)

(Amps and volts range should be recorded for each electrode size,
position, and thickness, etc. This information may be listed in a
tabular form similar to that shown below).
Tungsten Electrode Size and Type
(Pure Tungsten, 2% 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

Weld
Layer(s)

Process

Filler Metal

Current

Class

Type
Polarity

Dia.

Volt
Range

Travel
Speed
Range

Others

Amp.
Range
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
Date

Procedure Qualification Record No.


WPS No.
Welding Process (es)
Types (Manual, Automatic, Semi-Auto)

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.

POST WELD HEAT TREAT MENT

Type of Grade

Temperature

P.No.

Time

to P.No.

Other

Thickness of Test Coupon


Diameter of Test Coupon
Other
FILLER METALS
Weld Metal Analysis A No.

GAS

Size of Filler Metal

Type of Gas on Gases

Filler Metal E.No.

Composition of Gas Mixture

SFA Specification

Other

AWS Classification
Other
ELECTRICAL CHARACTERISTICS
POSITION

Current

Position of Groove

Polarity

Weld Progression (Uphill, Downhill)

Amps.

Other

Tungsten Electrode Size


Other

WELDING SPECIFICATION FOR


FABRICATION OF PIPING

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SHEET 20 of 26
161 of 245

EXHIBIT-D
Sheet 2 of 2
TECHNIQUE
Travel Speed

PREHEAT

String or Weave Bead

Preheat Temp.

Oscillation

Interpass Temp.

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

Test
temperature

type

Impact

Lateral exp.

Drop weight

value
%
shear

Mils

Break

No
Break

FILLET WELD TEST


Result - Satisfactory: Yes ____ No

Penetration into Parent Metal: Yes

No

Marco Results
OTHER TESTS
Type of Test
Deposit Analysis
Other
Welders Name
Test Conducted by

Clock No.

Stamp No
Laboratory Test 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).

WELDING SPECIFICATION FOR


FABRICATION OF PIPING

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SHEET 21 of 26
162 of 245

EXHIBIT - E
Sheet 1 of 2
FORMAT FOR MANUFACTURER S RECORD FOR WELDER OR WELDING OPERATOR QUALIFICATION
TESTS
Welder Name

Check No.

Using WPS No.

Rev.

Stamp. No.

The above welder is qualified for the following ranges


Variable

Record Actual Values


Used in qualification

Qualification Range

Process
Process Type
Backing (metal,
Weld metal, flux, etc)
Material Spec.

to

to

Thickness
Groove
Filler
Diameter
Groove
Filler
Filler Metal
Spec. No.
Class
F.No.
Position
Weld Progression
Gas Type
Electrical Characteristics
Current
Polarity

WELDING SPECIFICATION FOR


FABRICATION OF PIPING

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SHEET 22 of 26
163 of 245

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
inches

Length and Per Cent of Defects

Macro Test Fusion


Appearance - Fillet Size (ing)

Convexity or Concavity

Test Conducted by _________________________ Laboratory - Test No. _________________


We certify that the statements in this record are correct and that the test welds were prepared. Welded and
tested in accordance with the requirements of Section IX of the ASME Code.
Date

Organization
By

(Details of record tests are illustrative only and may be modified to conformation to the type & number of tests
required by the Code).
Note: Any essential variables in addition to those above shall be recorded.

WELDING SPECIFICATION FOR


FABRICATION OF PIPING

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SHEET 23 of 26
164 of 245

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

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.

WELDING SPECIFICATION FOR


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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

WELDING SPECIFICATION FOR


FABRICATION OF PIPING

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SHEET 25 of 26
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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

8 <T < 19

<8

IN-SITU WELDS

SOURCE

FILM : CEN
Class

SOURCE

FILM : CEN Class

All Materials

Gamma
Ray

C5

Gamma Ray

C5

Carbon
Steel

Gamma
Ray

C4

Gamma Ray

C4

All other
materials

Gamma
Ray

C3

Gamma Ray

C3

Carbon
Steel
Other than
Inspection
Class IV

Gamma
Ray

C3

Gamma Ray

C3/C 1

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.

All other
materials
and Carbon
Steel of
Inspection
Class IV

X-Ray

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

KODAK

AGFA

FUJI

---

CX

D8

---

C5

AA400

D7

1X100

C4

T200

D5

1X80

C3

MX125

D4

1X50

C2

M100

D3

---

C1

DR5O

---

SR**

D2
---

1X25
---

* * Special films, extremely fine grain & very high resolution

WELDING SPECIFICATION FOR


FABRICATION OF PIPING

Document No.

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SHEET 26 of 26
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GAIL (India) Limited


PIPELINE FROM HANUMAN JUNCTION TO VCL

STANDARD SPECIFICATIONS FOR NON DESTRUCTIVE


REQUIREMENTS OF PIPING

DOCUMENT NO

11

0330G01

01

CLIENT JOB NO.

TOTAL SHEETS

08

02

019

28.06.11

ISSUED FOR TENDER

MH

ASD

AD

24.06.11

ISSUED FOR IDC

MH

ASD

AD

REV

DATE

DESCRIPTION

PREP

CHK

APPR

168 of 245

TABLE OF CONTENT
1. GENERAL

2. VISUAL EXAMINATION

3. NON DESTRUCTIVE EXAMINATION

4. TABLE-I (with applicable Notes to Table-I)

NON DESTRUCTIVE EXAMINATION


REQUIREMENT OF PIPING

Document No.

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SHEET 2 of 8
169 of 245

Abbreviations:
DP/LP

Dye/Liquid Penetrant

MP

Magnetic Particle

CS

Carbon Steel

AS

Alloy Steel

SS

Stainless Steel

ASTM

American Society for Testing & Materials

ASME

American Society of Mechanical Engineers

IBR

Indian Boiler Regulations

PMS

Piping Material Specification

NON DESTRUCTIVE EXAMINATION


REQUIREMENT OF PIPING

Document No.

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SHEET 3 of 8
170 of 245

1.0

GENERAL

1.1

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)

ASME Boiler & Pressure Vessel Codes, Section V & VIII (Div. 1) including addenda.

b)

ASME B31.3

c)

ASME B16.5

d)

ASME B16.34

e)

Standard Piping Material Specification, 11-0330G01-01-08-02-001

f)

Welding Specification Charts for Piping Classes

g)

Standard Specification for Fabrication & Erection of Piping

h)

ASTM E1O

i)

Welding Specification for Fabrication of Piping, 11-0330G01-01-09-02-011

2.0

VISUAL EXAMINATION

2.1

Weld shall be visually inspected wherever accessible in accordance with the following
requirements:

a)

Internal misalignment

1.5 mm or less

b)

Cracks or lack of fusion

not permitted

c)

Incomplete penetration
(For other than 100%
radiography butt-weld)

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

d)

Surface porosity and


exposed slag inclusions
(For nom. wall thickness
4.7 mm and less)

not permitted

e)

Concave root surface (Suck up)

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.

f)

Weld ripples irregularities

2.5 mm or less.

NON DESTRUCTIVE EXAMINATION


REQUIREMENT OF PIPING

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g)

Lack of uniformity in bead


width

2.5 mm or less.

h)

Lack of uniformity of leg


length

2.5 mm or less.

i)

Unevenness of bead

2.0 mm or less.

j)

Weld undercutting

0.8 mm or 1/4 thickness of thinner components


joined by butt weld, whichever is less. (shall be
smooth finished)

k)

Overlap

1.5 mm or less

l)

Bead deflection

2.5 mm or less

m)

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)

Weld reinforcement or internal weld protrusion


(mm) max

6.4 and under


Over 6.4 -12.7
Over 12.7 -25.4
Over 25.4

1.6
3.2
4.0
4.8

n)

Throat thickness of fillet welds: Nominal thickness of the thinner component x 0.7 or more.

p)

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.

3.0

NON DESTRUCTIVE EXAMINATION

3.1

The type and extent of weld examination shall be in accordance with Table-1. All visual and
supplementary methods of girth weld examination shall be in accordance with ASME B31.3 & the
requirements of this standard specification.

3.2

Welds between dissimilar materials shall be examined by method & to the extent required for the material
having the more stringent examination.

NON DESTRUCTIVE EXAMINATION


REQUIREMENT OF PIPING

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SHEET 5 of 8
172 of 245

4.0

TABLE-I (with applicable notes)


TABLE 1: CLASS, TYPE & EXTENT OF WELD EXAMINATION
INSPECTION CLASS: I
TYPE OF WELD EXAMINED

PRESS.

INSPN.

SERVICE

MATERIAL
(NOTE 3)

P.NO.

TEMP.

CLASS

DEG.C

B16.5/
B16.34

CLASS

APPLICABLE
PIPING
CLASS

TYPE OF
EXAMINATION

GIRTH

SOCKET

BUTT

WELD

WELD

(NOTE
2)

FAB.
ATTACH

BRANC

- MENT

H WELD

WELD

(NOTE
1)

10

11

100%

100%

100%

RADIOGRAPHY

20%

c) LP, MP
(NOTE4, 6, 9)

d) HARDNESS

NOTE-7

a) VISUAL

FAB.
WELDS
OF
MITRES
/
REDUC.

12

13

100%

100%

100%

20%

20%

NOTE 7

NOTE-7

NOTE -7

NOTE-7

1A1, 3A1,
150#
CARBON
HYDROCARBON
I

STEEL

-29
1

TO
186

VAPOURS &

6A1
b)

IJPTO
10.55
KG/CM2

GAS SERVICES

CURPO
NICKEL

-29 TO

34

60

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.

2.

Seal welds of threaded joints shall be given the same examination as socket welds.

3.

Unless specifically stated, all materials shall be for Non-IBR service.

4.

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.

NON DESTRUCTIVE EXAMINATION


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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

No. of times repair welding is allowed


3 or less
2 or less
2 or less

b.6

Welds not found acceptable for allowed number of times of repair as per b.5 above shall
be replaced and reexamined.

b.7

If any of the items examined as required by b.4 above reveals a defect requiring repair,
all items represented by these 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

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7.

8.

Hardness Test:
a)

Hardness test shall be in accordance with ASTM specification E10. Hardness tests of the heat
affected zone shall be made at a point as near as practicable to the edge of the weld. One test
per weld shall be performed.

b)

Hardness test where specifically called out in Table-I of this specification or in PMS, shall be
carried out irrespective of thickness and to the extent (%age) as mentioned therein.

c)

All welds which are given heat treatment shall be hardness tested. Hardness test shall be
performed after final heat treatment.

d)

A minimum of 10% of welds of hot formed and hot bent materials in each heat treatment batch
which are furnace heat treated and 100% of those which are locally heat treated, shall be
hardness tested.

e)

For C-0.5 Mo steels, a minimum of 10% of welds shall be hardness tested.

f)

Hardness test requirement not covered in b) & e) above shall be as per ASME B3l .3.

g)

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

For IBR service lines, following IBR requirements shall apply in addition to the notes 4, 5, 6,
7, 12 and Table I. In case of conflict between above notes and these requirements, the more stringent
ones shall apply. IBR piping shall be erected of IBR inspector approved material and construction
procedure. Erected piping shall be hydrotested, inspected and approved by IBR inspector.
a)

Piping over 102 mm (4) bore:


10% of welds made by each welder on a pipeline with a minimum of two welds per welder,
selected at random, shall be subjected to radiography.

b)

Piping 102 mm (4) 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.

c)

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.

d)

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.

9.

For fabricated fittings LP test shall be done on the final pass of welding only, in addition to visual
examination.

10.

For mitres and fabricated reducers, LP / MP test shall be done on root pass in addition to radiography
applicable to circumferential joint of respective piping class.

11.

For branch connections, LP/MP test shall be done on root pass and final pass.

12.

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.

NON DESTRUCTIVE EXAMINATION


REQUIREMENT OF PIPING

Document No.

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SHEET 8 of 8
175 of 245

GAIL (India) Limited


PIPELINE FROM HANUMAN JUNCTION TO VCL

CLIENT JOB NO.

TECHNICAL SPECIFICATION FOR PAINTING


TOTAL SHEETS

DOCUMENT NO

11

0330G01

01

09

27

02

007

28.06.11

ISSUED FOR TENDER

MH

ASD

AD

24.06.11

ISSUED FOR IDC

MH

ASD

AD

REV

DATE

DESCRIPTION

PREP

CHK

APPR

176 of 245

TABLE OF CONTENT

1.0

GENERAL .............................................................................................................................. 3

2.0

CODES & STANDARDS ........................................................................................................ 3

3.0

CONDITIONS OF DELIVERY ................................................................................................ 4

4.0

COMPOSITION OF THE PAINT PRODUCTS USED............................................................. 4

5.0

IDENTIFICATION ................................................................................................................... 5

6.0

SURFACE PREPARATION STANDARDS ............................................................................ 6

7.0

PREPARATION OF THE SURFACES ................................................................................... 6

8.0

METALLISATION................................................................................................................. 10

9.0

CARRYING OUT THE PAINTWORK ................................................................................... 10

TECHNICAL SPECIFICATION
FOR PAINTING

Document No.

Rev

11-0330G01-01-09-02-007

SHEET 2 of 27
177 of 245

1.0

GENERAL

1.1

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

SCOPE

1.2.1

Scope of work covered in the specification shall include, without being limited to the following.

1.2.2

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.

1.2.3

Extent of Work

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)

j.

Over insulation surface of equipments and pipes wherever required.

k.

Painting under insulation for carbon steel, alloy steel and stainless steel as specified.

l.

Painting of pre-erection/fabrication and Shop primer.

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.

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SHEET 3 of 27
178 of 245

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.

1.2.6

Changes and deviations required for any specific job due to clients requirement or otherwise shall be
referred to Wood Group Kenny for deviation permit.

2.0

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.

3.0

IS: 5

Colors for ready mixed paints and enamels.

IS: 101

Methods of test for ready mixed paints and enamels,

IS: 161

Heat resistant paints.

IS: 2074

Specifications for ready mixed paint, red oxide zinc chrome priming.

IS: 2339

Aluminum paint for general purposes in dual container.

IS: 2379

Color code for identification of pipelines.

IS: 2932

Specification for enamel, synthetic, exterior (a) undercoating. (b) Finishing.

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
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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

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

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

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).

5.

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.

b).

The paint manufacturer's instruction shall be followed as far as practicable at all times.
Particular attention shall be paid to the following:
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.

7.0

PREPARATION OF THE SURFACES

7.1

General Specifications
The cases that occur in practice on building sites, with regard to painted surfaces, can be broken down
as follows:
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
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x
x
x

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

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

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.
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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)

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

7.10

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.

8.0

METALLISATION

8.1

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

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.

9.0

CARRYING OUT THE PAINTWORK

9.1

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:
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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

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.

Volume solids

30 - 35%

DFT

25 microns/coat (min)

Covering capacity

12-13 M/Lit/coat
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b)

Primer (P-2)
High build chlorinated rubber zinc phosphate primer

c)

Type and Composition

Single pack, Chlorinated rubber medium Plasticised with


unsaponifiable plasticiser pigmented with zinc phosphate

Volume solids

35- 40%

DFT

50 MICRONS/COAT (MIT)

Covering capacity

7-8 M/Lit/Coat

Primer (P-3)
High build zinc phosphate primer

d)

Type and Composition

Single Pack, Synthetic medium, pigmented with zinc


phosphate.

Volume solids

40-45%

DFT

35-50 microns/coat

Covering capacity

10-12 M/Lit/coat

Heat resistance

Upto 100 C (dry)

Primer (P-4)
Etch Primer / Wash Primer

e)

Type and Composition

Two pack Poly vinyl butyral resin medium cured with


phosphoric acid solution pigmented with zinc tetroxy
chromate.

Volume solids

7-8%

DFT

8-10 microns/coat

Covering capacity

7-8 M/lit/coat

Primer (P-5)
Epoxy Zinc Chromate Primer

f)

Type and Composition

Two pack, Polyamide cured epoxy resin medium pigmented


with zinc chromate.

Volume solids

40%(min)

DFT

35 microns/coat (min)

Covering capacity

11-12 M2/lit/Coat

Primer (P-6)
Epoxy Zinc Phosphate Primer
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g)

Type and Composition

Two pack, Polyamide cured Epoxy resin medium pigmented


with zinc phosphate.

Volume solids

40% 35 microns / coat (min)

Covering capacity

11-12 M/lit/coat

Primer (P-7)
Epoxy high build M10 Paint (Intermediate Coat)

h)

Type and composition

Two pack Poly Polyamide cured epoxy resin medium


pigmented with micaceous iron oxide. Volume solids 7- 8%

Volume Solids

50%

DFT

100 microns/coat (min)

Covering capacity

5.0 M/lit/coat

Primer (P-8)
Epoxy Red Oxide zinc phosphate primer

i)

Type and Composition

Two pack. Polyamine cured epoxy resin pigmented with Red


oxide and Zinc phosphate.

Volume solids

42%

DFT

30 microns/coat (min)

Covering capacity

13-14 M/lit/coat

Primer (P-9)
Epoxy based tie coat (suitable for conventional alkyd based coating prior to application of acrylic
polyurethane epoxy finishing coat)

j)

Type and Composition

Two pack, Polyamide cured epoxy resin medium


suitably pigmented.

Volume solids

50-60%

DFT

50 microns/coat (min)

Covering capacity

10-12 M/Lit/Coat

Finish Coats (F-1)


Synthetic Enamel
Type and Composition

Single pack, Alkyd medium pigmented with superior


quality water and weather resistant pigments

Volume solids

30-40%

DFT

20-25 microns/coat

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Covering capacity
k)

16-18 M/lit/Coat

Finish coat (F-2)


Acrylic Polyurethane paint

l)

Type and Composition

Two pack, Acrylic resin and iso-cyanate hardener


suitably pigmented.

Volume Solids

40% (min)

DFT

30-40 microns / coat

Covering Capacity

10-12 M/lit/ coat

Finish Coat (F-3)


Chlorinated Rubber Paint

m)

Type and Composition

Single pack, Plasticised chlorinated rubber medium with


chemical & weather resistant pigments.

Volume solids

30%

DFT

30 microns/coat (min)

Covering capacity

1 0.0 M / lit /coat

Finish Coat (F-4)


High build chlorinated rubber M10 paint.

n)

Type and Composition

Single pack Chlorinated rubber based high build pigmented with


micaceous iron oxide.

Volume solids

40-50%

DFT

65-75 microns/coat

Covering capacity

6.0-7.0 M / lit / coat

Finish coat (F-5)


Chemical Resistant Phenolic based Enamel

o)

Type and Composition

Single pack phenolic medium suitably pigmented.

Volume solids

35-40%

DFT

25 microns/ coat

Covering capacity

15.0 M /lit/ coat

Finish Coat (F-6)


Epoxy High Building Coating

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p)

Type and Composition

Two pack. Polyamide cured epoxy resin medium suitably


pigmented.

Volume solids

60-65%

DFT

100 microns/coat (min)

Covering capacity

6.0-6.5 M / lit / coat

Finish Coat (F-7)


High build Coal Tar Epoxy

q)

Type and Composition

Two pack, Polyamine cured epoxy resin blended with Coal Tar.

Volume solids

65% (min)

DFT

100-125 microns/coat

Covering capacity

6.0-6.5 M / lit / coat

Finish Coat (F-8)


Self-priming epoxy high build coating (complete rust control coating)

r)

Type and Composition

Two packs. Polyamide-amine cured epoxy resin suitably


pigmented. Capable of adhering to manually prepared surface
and old coatings.

Volume solids

65-80%

DFT

125-150 microns/coat

Covering capacity

4-5 M / lit / coat

Finish Coat (F-9)


Inorganic Zinc Silicate coating

s)

Type and Composition

Two packs, self cured Ethyl silicate solvent based Inorganic Zinc
coating.

Volume solids

60% (min)

DFT

65-75 microns/coat

Covering capacity

8-9 M / lit / coat

Finish coat (F-10)


High build Black
Type and Composition

Single pack. Reinforced bituminous composition phenol based


resin.

Volume solids

55-60%

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t)

DFT

100 microns/coat (min)

Covering capacity

5.50-6.0 M / lit / coat

Finish Coat (F-11)


Heat Resistant Aluminium Paint Suitable up to 250C.

u)

Type and Composition

Duel container (paste & medium). Heat resistant spec varnish


medium combined with aluminium flakes.

Volume solids

20-25%

DFT

20 microns/coat (min)

Covering capacity

10-12 M / lit/ coat

Finish Coat (F-12)


Heat Resistant Silicon Paint suitable up to 400 C.

v)

Type and Composition

Single pack Silicone resin based with aluminium flakes.

Volume solids

20-25%

DFT

20 microns/coat (min)

Covering capacity

10-12 M/lit/coat

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,

DFT

25 microns/coat

Covering capacity

9.5 M /lit/ coat

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.

2.

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.

3.

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.

5.

Technical data sheets for all paints shall be supplied at the time of submission of quotations.

6.

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.
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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)

V)
VI)
VII)
VIII)

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

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.

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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.

iii)

Size of arrow shall be either of the following:

a)

Color Bands
Minimum width of color band shall be as per approved procedure.

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.

2.

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.

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.

iii.

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.

iv.

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
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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

Notes 1.

Primers and finish coats for any particular paint systems shall be from same
manufacturer in order to ensure compatibility.

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Table 1

Colour Coding Scheme for Pipes and Equipment

SI. No.

Content

1
a)
b)

Plant Air
Instrument Air
GASES

a)
b)
c)
d)
e)

Charge Gas
Regeneration Gas
Residue Gas
LPG
Acetylene
ALL EQUIPMENT

Ground Color

First 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

Second Color
Band
-

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

Temp.
Range

Surface
Preparation

Primer

Finish Coat

Total
DFT

Remarks

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.

90

Two coats of
F-13, 25
microns/coat
(min)

150

Three coats
of F-11, 20
microns/ coat
(min)

60

Three coats
of F-12, 20
microns/ coat
(min)

60

Paint
application
at ambient
temp. curing
at elevated
temp. during
start-up.
-do-

External surface of equipment's and piping.

1.1

-Do-

-10 to 20

SSPC-SP-3

One coat
P-2
50
microns /
coat
(min)

1.2

-Do-

21 to 60

SSPC-SP-6

1.3

-Do-

61 to 80

SSPC-SP-6

1.4

-Do-

81 to 250

SSPC-SP-6

Two
coats P1, 25
microns/
coat
(min.)
Two
coats P3, 50
microns/
coat
(min)
Covered
in Finish
coat

1.5

-Do-

251 to 400

SSPC-SP-10

Covered
in Finish
coat.

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Table- 3
Corrosive Industrial Environment (Above Ground)
SI. Description
No.

Temp.
Range

Surface
preparation

Primer

Finish Coat

1.0

External surface of un-insulated and other equipment

I.1

- do -

-10
20

to

SSPC-SP-3

1.2

- do -

21
80

to

SSPC-SP10

I.3

- do -

81
400

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.)

TECHNICAL SPECIFICATION
FOR PAINTING

Total
DFT

Remarks

160

Primer and paint


application at
ambient temp.

270

Paint application
at ambient temp.

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

Description

Temp.
Range

Surface
Preparation

Primer

Finish Coat

Total
DFT

External surface of equipments and piping.

1.1

-do-

-10 to
60

SSPC-SP-3

Two coats
P-2, 50
micron/
coat (min)

Two coats F3, 30


Microns/coat
(min.)

160

SSPC-SP10

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

1.2

do -

61
80

1.3

- do -

81 to
400

SSPC-SP-I0

1.4 - do -

i) Upto
80

SSPC-SP10

One coat
F-9, 6.5
microns /
coat (Min)

One coat of
F-2. 30
Microns/coat
(min.)

95

ii) 8l to
400

SSPC-SP10

-do-

-do-

85

1.9.4

Remarks

to

Primer and
Finish
coat
application
at Ambient
temp.
-do-

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.

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.

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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.

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.

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1.10

GROUND-LEVEL TRANSITION POINT

1.11

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)

The primer of system 01.

2)

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.

3)

He will then apply the other coats of system 01a to the surface section and thus cover the
reinforced polyester with about 5 cm.

4)

For new constructions, the polygon primer will be applied to PE and then subsequently
processed as described under point 2.

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;

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
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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

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:

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.

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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GAIL (India) Limited


PIPELINE FROM HANUMAN JUNCTION TO VCL

CLIENT JOB NO.

SPECIFICATION FOR FITTINGS AND


FLANGES UPTO 400mm (16) NB

DOCUMENT NO

11

0330G01

TOTAL SHEETS

01

08

02

006

28.06.11

ISSUED FOR TENDER

MH

ASD

AD

24.06.11

ISSUED FOR IDC

MH

ASD

AD

REV

DATE

DESCRIPTION

PREP

CHK

APPR

203 of 245

TABLE OF CONTENT

1.0

SCOPE ........................................................................................ Error! Bookmark not defined.

2.0

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

3.0

MANUFACTURER'S QUALIFICATION ................................................................................. 3

4.0

MATERIALS.......................................................................................................................... 4

5.0

DESIGN AND MANUFACTURE ............................................................................................ 4

6.0

INSPECTION AND TESTS..................................................................................................... 5

7.0

TEST CERTIFICATES ........................................................................................................... 5

8.0

MARKING .............................................................................................................................. 5

9.0

DOCUMENTATIONS ............................................................................................................. 5

SPECIFICATION FOR FITTINGS AND


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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

Steel Pipe Flanges and flanged Fittings

ASME B 16.9

Factory-Made Wrought Steel Butt Welding Fittings

ASME B 16.11 -

Forged Steel Fittings, Socket Welding and Threaded

ASME B 31.3

Process Piping

ASME B 31.4

Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas,


Anhydrous Ammonia and Alcohols

ASME B 31.8

Gas Transmission and Distribution Piping Systems

ASTM A 370

Mechanical Testing of Steel Products

API 590

Steel Line Blanks

MSS-SP-25

Standard Marking System for Valves, Fittings, Flanges and Union

MSS-SP-44

Steel Pipeline Flanges

MSS-SP-75

Specification for High Test Wrought Welded Fittings

MSS-SP-97

Forged Carbon Steel Branch Outlet Fittings-Socket Welding, Threaded and Butt
Welding Ends

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

MATERIALS

4.1

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.

4.2

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 +

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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

In case of RTJ flanges, the groove hardness shall be minimum 140 BHN

5.0

DESIGN AND MANUFACTURE

5.1

Flanges such as welding neck flanges and blind flanges shall conform to the requirement of
ASMEB16.5.

5.2

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.

5.3

Fittings such as weldolets, sockolets, nippolets, etc., shall be manufactured in accordance with
MSS-SP-97

5.4

Type, face and face finish of flanges shall be as specified in Material Requisition / Purchase Requisition.

5.5

Flanges and fittings manufactured from bar stock are not acceptable.

5.6

All butt weld ends shall be bevelled as per ASME B 16.5/ASME B 16.9/MSS-SP-97 as applicable.

5.7

Repair by welding on flanges and fittings are not permitted.

6.0

INSPECTION AND TESTS

6.1

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:

6.1.1

Visual inspection.

6.1.2

Dimensional checks.

6.1.3

Chemical composition, mechanical properties and hardness examination.

6.1.4

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.

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6.1.5

All other tests not specially listed but are required as per applicable standard / specification.

6.2

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

PAINTING, MARKING AND SHIPMENT

8.1

After all inspection and tests required have been carried out; all external surfaces shall be thoroughly
cleaned to remove grease, dust and rust and shall be applied with standard mill coating for protection
against corrosion during transit and storage. The coating shall be easily removable in the field.

8.2

Ends of all fittings and weld neck flanges shall be suitably protected to avoid any damage during transit.
Metallic or high impact plastic bevel protectors shall be provided for fittings and flanges. Flange face shall
be suitably protected to avoid any damage during transit.

8.3

All flanges and fittings shall be marked as per applicable dimension/manufacturing standard.

9.0

DOCUMENTATION

9.1

Prior to shipment, the Manufacturer shall submit six copies of the test certificates as listed in clause 7.0 of
this specification.

9.2

All documents shall be in English Language only

SPECIFICATION FOR FITTINGS AND


FLANGES UPTO 16

Document No.

Rev

11-0330G01-01-08-02-006

SHEET 5 of 5
207 of 245

GAIL (India) Limited


PIPELINE FROM HANUMAN JUNCTION TO VCL

STANDARD SPECIFICATION FOR INSPECTION, FLUSHING


AND TESTING OF PIPING SYSTEMS

DOCUMENT NO

11

0330G01

01

CLIENT JOB NO.


TOTAL SHEETS

08

02

009

28.06.11

ISSUED FOR TENDER

MH

ASD

AD

24.06.11

ISSUED FOR IDC

MH

ASD

AD

REV

DATE

DESCRIPTION

PREP

CHK

APPR

208 of 245

ABBREVIATIONS:
PMI

Positive Material Identification

NDT

Non Destructive Testing

P&ID

Process and Instrumentation Diagram

A.S.

Alloy Steel

C.S.

Carbon Steel

C.I.

Cast Iron

S.S.

Stainless Steel

LTCS

Low Temperature Carbon Steel

NACE

National Association of Corrosion Engineers

INSPECTION, FLUSHING
AND TESTING OF PIPING SYSTEMS

Document No.

Rev

11-0330G01-01-08-02-009

SHEET 2 of 8
209 of 245

TABLE OF CONTENT

1.0

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

2.0

DEFINITION

3.0

INSPECTION.......................................................................................................................... 4

4.0

FLUSHING ............................................................................................................................. 4

5.0

TESTING ................................................................................................................................ 5

INSPECTION, FLUSHING
AND TESTING OF PIPING SYSTEMS

Document No.

Rev

11-0330G01-01-08-02-009

SHEET 3 of 8
210 of 245

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

3.0

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.

Should

: 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.

May

: This verbal form indicates a course of action permissible within the limits of this
standard.

Can

: This verbal form used for statements of possibility & capability, whether material,
physical or casual.

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

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SHEET 4 of 8
211 of 245

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

TESTING

5.1

Extent of Testing
With the exclusion of instrumentation, piping systems fabricated or assembled in the field shall be tested
irrespective of whether or not they have been pressure tested prior to site welding of fabrication.
To facilitate the testing of piping systems, vessels and other equipments may be included in the system
with the prior approval of Engineer-In-Charge if the test pressure specified is equal to or less than that for
the vessels and other equipments.
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.

Rev

11-0330G01-01-08-02-009

SHEET 5 of 8
212 of 245

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.

INSPECTION, FLUSHING
AND TESTING OF PIPING SYSTEMS

Document No.

Rev

11-0330G01-01-08-02-009

SHEET 6 of 8
213 of 245

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

Testing Media, Test Pressure and Test Pressure Gauges

5.3.1

Testing Media

In general all pressure test shall be hydrostatic using iron free water, which is clean and free of silt.
Maximum chlorine content in water for hydrostatic testing for S.S. piping shall be 15-20 ppm. Air shall be
used for testing only if water would cause corrosion of the system or overloading of supports etc. in
special cases as directed by Engineer-in-Charge.
Where air/water tests are undesirable, substitute fluids such as gas oil, kerosene, methanol etc. shall be
used as the testing medium, with due consideration to the hazards involved. These test fluids shall be
specified in the line list given to the contractor.
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

Testing Procedure

5.4.1

Hydrostatic Test
All vents and other connections used as vents shall be left open while filling the line with test fluid for
complete removal of air. In all lines for 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-in- charge.

INSPECTION, FLUSHING
AND TESTING OF PIPING SYSTEMS

Document No.

Rev

11-0330G01-01-08-02-009

SHEET 7 of 8
214 of 245

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.

INSPECTION, FLUSHING
AND TESTING OF PIPING SYSTEMS

Document No.

Rev

11-0330G01-01-08-02-009

SHEET 8 of 8
215 of 245

216 of 245

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223 of 245

GAIL (India) Limited


PIPELINE FROM HANUMAN JUNCTION TO VCL

CLIENT JOB NO.

TECHNICAL SPECIFICATION
FOR
PIG SIGNALLER
DOCUMENT NO

11

0330G01

TOTAL SHEETS

01

11

02

006

28.06.11

ISSUED FOR TENDER

MH

ASD

AD

24.06.11

ISSUED FOR IDC

MH

ASD

AD

REV

DATE

DESCRIPTION

PREP

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224 of 245

TABLE OF CONTENTS

Sl.No.

DESCRIPTION

PAGE NO.

1.0

SCOPE

2.0

CODES, STANDARDS AND DOCUMENTS

3.0

GENERAL REQUIREMENTS

4.0

BASIC DESIGN DATA

5.0

DESIGN CRITERIA

6.0

MATERIALS

7.0

FABRICATION

8.0

INSPECTION & TESTING

TECHNICAL SPECIFICATION
FOR
PIG SIGNALLER
225 of 245

Document No.
11-0330G01-01-11-02-006
SHEET 2 of 5

Rev
0

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

4.0

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

Pig Signallers shall be provided with a visual indicator to indicate the passage of pigs.

3.4

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.

INSPECTION AND TESTS


4.1
4.2
4.3
4.4

5.0

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.

TEST CERTIFICATES
Manufacturer shall submit the test certificates for material compliance as per the relevant material
standards and certificates for functional tests.

TECHNICAL SPECIFICATION
FOR
PIG SIGNALLER
226 of 245

Document No.
11-0330G01-01-11-02-006
SHEET 3 of 5

Rev
0

6.0

PAINTING, MARKING AND SHIPMENT


6.1

6.2

i)
ii)
iii)
iv)

Manufacturers name.
Suitable for installation in mm dia. Pipeline
ANSI Rating
Tag No.

6.3

Each unit shall be suitably protected to avoid any damage during transit. Care shall be
exercised during packing to prevent any damage to the welding ends. All machined surfaces
subject to corrosion shall be well protected by a coat of grease or other suitable materials.

.
7.0

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:

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

All documents shall be in English language.

8.2

At the time of bidding, Manufacturer shall submit the following documents:

i)

General arrangement drawings with overall dimensions.

ii)

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

iii)

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.

8.3

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.

i)

Fabrication drawings! sectional arrangement


reference numbers and material specification.

ii)

Assembly drawing with overall dimensions

iii)

Welding and testing procedure.

iv)

Cable connection details and cable specification.

TECHNICAL SPECIFICATION
FOR
PIG SIGNALLER
227 of 245

drawings

showing

all

parts

Document No.
11-0330G01-01-11-02-006
SHEET 4 of 5

with

Rev
0

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.

8.5

Prior to shipment, Manufacturer shall submit one reproducible and six copies of the following:

i)

Test Certificates as per clause 5.0 of this specification

ii)

Manual for installation, erection instructions, maintenance and operation instructions.

TECHNICAL SPECIFICATION
FOR
PIG SIGNALLER
228 of 245

Document No.
11-0330G01-01-11-02-006
SHEET 5 of 5

Rev
0

GAIL (India) Limited


PIPELINE FROM HANUMAN JUNCTION TO VCL

CLIENT JOB NO.

DATA SHEET
FOR
PIG SIGNALLER

DOCUMENT NO

11

0330G01

TOTAL SHEETS

01

11

03

006

28.06.11

ISSUED FOR TENDER

MH

ASD

AD

24.06.11

ISSUED FOR IDC

MH

ASD

AD

REV

DATE

DESCRIPTION

PREP

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229 of 245

CLIENT:

GAIL(India) Limited

TAG NO.:

QUANTITY:

02

SIZE:

TYPE
DESIGN CONDITIONS OF PIPELINE

NON INTRUSIVE / MAGNETICALLY COUPLED

PRESSURE

72 Kg/cm2 g

TEMPERATURE

0 to 65 C

DESIGN CODE

ASME B 31.8

ANSI RATING

600#

HYDRO TEST PRESSURE


OPERATING CONDITIONS

138 Kg/cm2 g

PRESSURE

31Bar g

TEMPERATURE

5 to 35 C

FLUID HANDELED

NATURAL GAS / R-LNG

INSTALLATION

ABOVE GROUND

ELECTRICAL AREA CLASSIFICATION

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

PIG SIGNALLER MATERIAL SPECIFICATION


PART

SPECIFIED MATERIAL

Body

MFR.STD.

internals

SS-316

MATERIAL OFFERED

MICRO SWITCH DETAILS


RATING

POTENTIAL FREE CONTACT OF RATING 24DC,5A,SPDT/


240 V A.C , 2A SPDT.

ENCLOSURE

WEATHER PROOF TO IP55 & FLAME PROOF Exd.


ENCLOSURE CERTIFIED FOR AREA CLASSIFICATION

CABLE CONNECTION

NPTF

DATA SHEET
FOR
PIG SIGNALLER

DOCUMENT NO.

REV

11-0330G01-01-11-03-006

SHEET 2 OF 2
230 of 245

GAIL (India) Limited


PIPELINE FROM HANUMAN JUNCTION TO
VCL
DATA SHEET
FOR
MONOLITHIC INSULATING JOINT
DOCUMENT NO

0
A
REV

28.06.11
24.06.11
DATE

11

0330G01

CLIENT JOB NO.


TOTAL SHEETS
01

09

03

003

ISSUED FOR TENDER

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ISSUED FOR IDC

MH

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DESCRIPTION

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231 of 245

PROCESS DATA
PIPE CLASS :
FLUID :

6A1
NATURAL GAS

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

ANSI RATING :
FLUID SYMBOL :

600#
NG

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

DOCUMENT NO.

REV

11-0330G01-01-09-03-003

SHEET 2OF 2
232 of 245

CLIENT JOB NO.

LIST OF VENDOR
TOTAL SHEETS

DOCUMENT NO

11

0330G01

01

11

06

01

28.06.11

ISSUED FOR TENDER

MH

ASD

AD

24.06.11

ISSUED FOR IDC

MH

ASD

AD

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DATE

DESCRIPTION

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APPR

LIST OF VENDERS

Document No.

Rev

11-0330G01-01-11-06-01

TOTAL SHEET 8
233 of 245

LIST OF RECOMMENDED VENDORS


S.NO

ITEM

NAME OF VENDOR

ADDRESS

Ishwardas Aggarwal & Sons (Trader)

39, Lalit House, 3rd floor, Sant


Tukaram Road,
Iron Market,
Mumbai - 400 009

M.J. Patel & company (Trader)

116, P.D. Mello Road, Near Camace


Bridge,
Mumbai - 400 009

Apex Tubes Pvt. Ltd (Manufacturer &


Trader)

Apex Tubes Pvt. Ltd.


1/6 B, Asaf Ali Road
New Delhi - 110 002

Steel Tube (India) (Trader)

526/36, Maulana Azad Road, 2nd


floor, Gulawadi Circle,
Mumbai - 400 004

Nagardas Kanji Shah (Trader)

176, Magazine street, darukhana,


Mazagaon, Mumbai 400 010

(022) 3721066)/
3724157

(022) 3781032

Jyoti Industries

P.B. No. 3081, 276/278, Samuel


street, 2nd floor, Vadgadi, Mumbai
400 003

(022) 3435091/92

(022) 3421 391

205, Magnanial Chambers, Baburao


(022)3430105,
Bobde Marg, Iron Market, Mumbai
3430107, 3434918
400 009

(022) 3414763

Station Piping
(Seamless Pipes) Trader

PHONE NO

FAX NO

QUALIFIED FOR SIZE

(+91)22-342 2566 (+91)22-342 3762

011 - 3236408

(+91)22-389 5908
(+91)22-3895906
(+91)22-381 2564

The Bengal Mill stores supply co


(Trader)

Radiant Engineering Co.

M-2, sundaram, sion college,


Mumbai 40 022

(022) 409 2016,


409 6036

(022) 409 4822

Tianjin Pipe corporation

PO box 17537, Jebel Ali Free zone,


Dubai, U.A.E

97148833799

97148833899

10

Milsubihsi

11

Trub Chomulov

12

TENARIS

13

Valcvony

14

Vallurorec Maneshman Tubes Brazil

15

Virgo Engineers Ltd, Pune

Virgo Engineers, J/517, MIDC,


Bhosari, Pune - 411026

020 - 2747 4481

020-2747 0772

Upto 24"
class 600

17

Flow Chem Industries

10, Navdurga Indl. Estate, Opp Forge


Blower, Naroda Road, Ahmedabad 25

79 - 220 4773

79 - 220 1401

upto 12" class 600

18

Micro Finish Valves

B-161-162 INDUSTRIAL
ESTATE,GOKUL ROAD ,HUBLI
,KARNATKA 580030

upto 12" class 600

L&T / Audco valves

Chennai

Upto 24" 600#

Cooper Cameron Valves


(singapore) Pte. Ltd

No.2, Gul Circle, Jurong Industrial


Estate, singapore - 629560

20

21

BALL VALVES

22

BOHMER Ball Valves

23

MSA

Gedulderweg, 95
45549 Sprockhovel
Germany
Hlucinska, 41
747 22 Doinin Benesov
Czech Republic

LIST OF VENDORS

0065 865 2887

0065 861 7109

(+49) 2324 70010 (-49) 2324 700179

Upto 48" 600#

(+420) 553 881111 (+420) 553 651236

Upto 48" 600#

Document No.

Rev.

11-0330G01-01-11-06-01

SHEET 1 of 8

234 of 245

Upto 48" 600#

LIST OF RECOMMENDED VENDORS


S.NO

ITEM

QUALIFIED FOR
SIZE

NAME OF VENDOR

ADDRESS

PHONE NO

FAX NO

24

RMA Maschinen - und Armalurenbau


Fulhaber & Truttenbach

Oststrasse, 17 77694 Kehl


Germany

(+49) 78 518680

(+49) 78 5186813

upto 30" 600#

25

SCHUCK ARMATUREN
(ex BORSIG)

Dailerstrasse 4-7 89555,


Steinheim Germany

(+49) 73 29 950 0 (+49) 73 29950161

upto 30" 600#

26

SUD ROBINETTERIE INDSUTRIE


(SRI)

279 -305, Bvd D, Casanova 13309


Marseille, France

(+33) 495 055050 (+33) 495 055070

upto 30" 600#

TORMENE GAS TECHNOLOGY


(VALVITALIA)

Via L. Campolongo, 97
35020 Due Carrare PD
ITALY

(+39) 059 919


9511

(+39) 049 9125455

upto 30" 600#

28

VIAR VALVOLE

Via L. Cadorna, 6 21041 Albizzate VA


ITALY

(+39) 0331 99
2985

(+39) 0331 992992

upto 30" 600#

29

BREDA ENERGIA SESTO


INDUSTRIA

Viale Sarca, 336 20126 Milano ITALY (+39) 0264 4771 (+39) 02 64477542

upto 30" 600#

30

FLOW CONTROL TECHNOLOGIES


(TYCO flow control)

23, Deuzieme avenue


13743 Vitrolles FRANCE

(+33) 442 103600


(+91) 11 647 1469

(+33)442103636
G39
(+91) 11 646 1550

upto 30" 600#

31

PETRO VALVES

Viale G Borri, 42 21053 Catellanza


VA ITALY

(+39) 0331 334


111

(+39) 0331 675830

upto 48" 600#

27
BALL VALVES

32

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.

33

M/s BIFI

Italy

34

M/s Rotork fluid system

Italy

35

PC Intertecnik

Germany

36

M/s Bettis

Belgium

37

Flow Chem Industries

10, Navdurga Indl. Estate, Opp Forge


Blower, Naroda Road, Ahmedabad 25

79 - 220 4773

38

Shreeraj Industries

101, Samrudhi, Sattar Taluka Society,


Opp old high court lane, Ahmedabad

79 - 2204773/
3623

39

Steel Strong Valves (P) Ltd.

Plot No. R-241, TTC Industrial area,


MIDC, Rabale, New Bombay - 400
701

Upto 12" class


600 of split
body type

40

Ornate Valves Pvt. Ltd, Mumbai

104, Eric House 16th Road Chembur,


Mumbai - 400 071

upto 12" 600#

41

Micro Finish Valves

B-161-162 INDUSTRIAL
ESTATE,GOKUL ROAD ,HUBLI
,KARNATKA 580030

upto 12" class 600

42

L&T / Audco valves

Chennai

Upto 24" 600#

44

Niton valve Industries Pvt. Ltd

SD -115/116 Ghatkopar Industrial


Estate, L.B.S. marg
Ghatkopar (West)
Mumbai 400 086

022- 500 8315

022 - 5007654

45

Econo Valves Pvt Ltd

197, SIDCO Industrial Area,


Ambatturm, Chennai 600 098

044 6251829/
6254371

044 - 6257501

46

L&T / Audco valves

Chennai

47

Steel Strong Valves (P) Ltd.

Gas Over Oil Actuators

Globe Valve

79 - 220 1401

upto 12" 600#

upto 12" 600#

43

Plot No. R-241, TTC Industrial area,


MIDC, Rabale, New Bombay - 400 022 - 27699489/90
701

022 - 27695537

Upto 24" 600#

Spring loaded type


upto 12" 600#
of split body type

Check/ Non Return Valve


48

49

Micro Finish Valves

B-161-162 INDUSTRIAL
ESTATE,GOKUL ROAD ,HUBLI
,KARNATKA 580030

50

Flow Chem Industries

10, Navdurga Indl. Estate, Opp Forge


Blower, Naroda Road, Ahmedabad 25

LIST OF VENDORS

upto 12" 600 #

79 - 220 4773

79 - 220 1401

Document No.

Rev.

11-0330G01-01-11-06-01

SHEET 2 of 8

235 of 245

upto 12" 600#


(lift type, wafer
type & Swing type)

LIST OF RECOMMENDED VENDORS


S.NO

ITEM

NAME OF VENDOR

ADDRESS

PHONE NO

FAX NO

Ornate Valves Pvt. Ltd, Mumbai

104, Eric House 16th Road


Chembur, Mumbai - 400 071

Arpita Enterprise

1201, GIDC Estate, Phase IV


Vithal Udyog Nagar
Anand 388 112

02692 - 36187

53

Niton valve Industries Pvt. Ltd

SD -115/116 Ghatkopar Industrial


Estate, L.B.S. marg
Ghatkopar (West)
Mumbai 400 086

022- 500 8315

022 - 5007654

54

FMC Sanmar Ltd

147, Karapakkam Village,


Chennai-600096

044-492-5455

044-492-6114

55

Protego Equipments Pvt. Ltd.

Navi Mumbai

Larsen & Tubro

32, Sivaji Marg,Post Box 6223,Near


Moti Nagar, New Delhi

011-25931302

011-25438624

57

SEBIM valves India Pvt. Ltd.

908, Ansal Bhawan,16 Kasturba


Gandhi Marg,New Delhi

011-23312110,23318360

011-23712155

58

RMG regal + GmbH,Germany

QUALIFIED FOR SIZE

1
51

52

56

Check/ Non Return


Valve

Pressure Relief Valve

upto 12" 600#


Lift & Swing type
upto 8" 600#
(wafer type)

Upto 24" 600#


(Lift & Swing Type)

Germany
Grobe Strabe 14, 27356 Rotenburg,
"+49 4261 4081"
Germany

Upto 30" class 600 fittings


& flow tee

59

INTERFORGE

60

KURVERS Piping

Mark S Clarkelaan 13 a, Haven No.


M 512, 4761 RK Zevenbergen, The
Netherlands

"+31 168 33 43 44"

"+31 168 33 43 49"

Upto 30" class 600 fittings


& flow tee

61

MEREK Engineering

Premier estate, Leys road,


Brockmoor Brierley Hill, DY5 3UT
West midlands, UNITED KINGDOM

"+44 121 544 9938"

"+44 121 544 9132"

Upto 30" class 600 fittings


& flow tee

62

PETROFIT

0121 544 9938

0121 544 9132

Upto 30" class 600 fittings


& flow tee

63

PHOCEENINE (Groupe Genoyer)

"+32 3 860 73 70"

"+32 3 860 73 71"

Upto 30" class 600 fittings


& flow tee

64

VAN LEEUWEN BUIZEN

"+32 2 255 40 00"

"+32 2 253 20 92"

Upto 30" class 600 fittings


& flow tee

65

MS Fittings Mfg. Co. Pvt. Ltd.,


Kolkatta

033-2362902, 2362903

033-2252103

Upto 24"class 600

66

Ferrous Alloy Forgings(P) Ltd.

67

Pipe Fit Engineers

68
69

Teekay Tube
Pipe fittings (Elbows,
Tees,Reducers)

Steward & Lloyds

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

"+49 4261 3090"

02668-62479

Upto 12"

0265-2636 547/545

0265-2636 546

Upto 24"class 600

"+91 22 342 3382-83,


91 22 343 7716
,345477, 3446975"

(022)349162

Upto 24"class 600

044 8523375

044 8522877

70

Alliance Fittings & forgings


, Navi Mumbai

Alliance fittings & forgings inc.,


A-468/469,T.T.C Industrial Area

022-2788 1333/1916

022-2788 1134/
5590 2273

Upto 12" Class 600

71

Swastik Lloyds Engineering Pvt. Ltd.,


Mumbai

Swastik Lloyds Engineering Pvt.


Ltd.,5 B Islam pura Street,
Mumbai-400004

022-3860222/23

022-7402779

Upto 12" Class 600

Tube Products Incorporate.,Baroda

748/8,GIDC,Indi.Estate
Makarpura,
Baroda-390010

0265-5545211 /214

0265-2831031

upto 36" 600#

73

Steel Tubes (India)

526/36,Maulana Azad Road,2nd


Floor, (Gulawadi Circle), mumbai400004

022-3895908/
3822821

022-3895906

Upto 24"class 600

74

Eften Engineering Pvt. Ltd.

D1,Sipcot Industrial Park,


Irungaltukottai-602105, Tamil nadu

04111-256284,
256714

04111-256714

Upto 8"class 600

75

Dylan Belgie

Lerenveld 20, 2547 Lint, Belgium

32 3 488 4880

32 3 488 4880

Upto 30" class 600


fittings & flow tee

76

FBF

Dynamicalaan 4-8,
2610 Anlwerpen, Belgium

32 3 820 5880

32 3 828 2822

Upto 30" class 600


fittings & flow tee

77

Ferrostaal(Mangroup)

Hohenzollernstrasse 24, 45128


Essen, Germany

49 201 818 01

49 201 818 2822

Upto 30" class 600


fittings & flow tee

72

LIST OF VENDORS

Document No.

Rev.

11-0330G01-01-11-06-01

SHEET 3 of 8

236 of 245

LIST OF RECOMMENDED VENDORS


S.NO

ITEM

NAME OF VENDOR

Pipe fittings (Elbows,


Tees,Reducers)

Sawan Engineers

ADDRESS

PHONE NO

FAX NO

QUALIFIED FOR
SIZE

1
78

201, Palace Plaza,lalbaug Road,


0265-243 3003/553
Near kashivishwanath Temple,Baroda8303
390001, Email :sawanengg@sify.com

Ms Fittings Mfg.Co.
Pvt.Ltd.Kolkata

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

Tube Products
Incorporate,
Baroda

748/8,GIDC,Indi.Estate
Makarpura,
Baroda-390010
P.O.Box20,Near
Hapur

Ferrous Alloy
Forging(P) Ltd.

79

80

Sanghvi Forging &


Engineering Ltd

81
Sawan Engineers
ECHJAY Forgings
Ltd.

82
Flanges
83

84

85

Choudhary Hammer Works,

86
Pipe Fit Engineers
87
Punjab Steel Works
88

Flow More pumps Pvt. Ltd.

89
90

Becon Weir ltd.


Pumps

Kirloskar Pneumatic Co. Ltd.

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

0265-258 0644
/1658

0265-2433003/
3096008

0265-2435196
upto 18" 600#

upto 30" 600#

033-2352902,
2362903

033-2252103

upto 24" 600#

0265-5545211
/214

0265-2831031

upto 36" 600#

120-4744921

120-4792897

upto 24" 600#

0265-2636547
/545

0265-2636546

upto 24" 600#

011-5130960

115137432

upto 24" 600#

011-30623710
011-4175561
2062870133

ABB

14, mathura Road, Faridabad-121003

Comproton Greaves Ltd.

Vandana Building, 11 Tolstoy Marg,


New Delhi 110001

011-23354514

Hadaspur Industrial Estate, pune,


Maharashtra

2062870133

95

upto 12" 600#

225784962

92

94

0265 258 1125

225782461
225782830

Roto pump

Motors

Bharat bijli
Kirloskar Pneumatic Co. Ltd.

FMC Sanmar Ltd

147,karapakkam Village,
Chennai-600096

044-4925455

044-4926114

Larsen & Tubro

32,Shivaji Marg,Post Box


No.6223,Near Moti Nagar
New Delhi

011-5931302

011-5438624

SEBIM Valves India


Pvt. Ltd

908,Ansari Bhawan,16,
Kasturba Gandhi Marg,
New Delhi-11000

011-3312110,
3318360

011-3712155

99

RMG Regal+
Messtech Gmbh

Germany

100

TYCO SANMAR LTD

96

97

98

Pressure Safety Relief


Valves

101

102

103

upto 24" class 600

upto 24" 600#

91

93

0265-243 5196

Yokogawa Blue star


Pressure
/Level/Temeprature
transmitters

Tata Honey well ltd.

Fisher Rosemount

LIST OF VENDORS

Document No.

Rev.

11-0330G01-01-11-06-01

SHEET 4 of 8

237 of 245

LIST OF RECOMMENDED VENDORS


S.NO

ITEM

NAME OF VENDOR

ADDRESS

PHONE NO

FAX NO

A-273 Ansal chambers-1


3,Bhikaji cama place, New Delhi

011-26715408/6180

011-2671681

QUALIFIED FOR
SIZE

1
104

Invensys India/Emerson process

105

106

H. Guru
Pressure
/Level/Temeprature
transmitters

A. N Instrument

107
General Instrumants
108
Wika
109
ICA
110
Instrumentation Panel

Rittal

111
Pyrotech Controls
112
Enclotek
113

114

115

Instrument Fittings
including manifold,
needle valve etc

Impulse tubing

116

Swagelock
Parkar

Sandvik

Daniel

117

RMG
USM Meter

118

FMC

119

Instromet

120

MTL India Pvt. Ltd


Signal Repeater

121

P&F

122

Concord
Indication Lamp

123

L&T

124

SITOP
24 V DC Power supply

125

PHEONIX

126

Pyroelectric Instruments

127

General Instruments
RTD With Thermowell

128

ALTOP

129

A.N.Instruments

130

MCT

Signet International

LIST OF VENDORS

Document No.

Rev.

11-0330G01-01-11-06-01

SHEET 5 of 8

238 of 245

LIST OF RECOMMENDED VENDORS


S.NO

ITEM

NAME OF VENDOR

MCT

NEIMEX

ADDRESS

PHONE NO

FAX NO

A-273 Ansal chambers-1


3,Bhikaji cama place, New Delhi

011-26715408/6180

011-2671681

QUALIFIED FOR
SIZE

1
131

132

IIC
Alarm Anunclator

133

Procon

134

KAYCEE
Selector Switch

135

SALZER

136

Flame Proof Control Gears Pvt. Ltd

137

Flame Proof Equiments Pvt. Ltd


Junction Box

138

Flex pro Electricals pvt. Ltd,Navsari

139

CEAG

140

PEERLESS

141

GRINELL

142
143

PECO
Quick Opening and
closing

144

SIIRTEC
HUBER YALE

145

GD ENGG

146

TUBE TURN(USA)

147

Honeywell

148

ABB
Digital Indicator

149

YOKOGAWA

150

MASIBUS

151

B.C.H.

152
153

Baliga
Switch Socket & Plugs

CGL

154

MDS

155

Delton

156
157

CORDS
Instrumentation Signal
Control Cable

KEI

158

Polycabs Associate cables

159

MTL India Pvt. Ltd


Isolating Barrier

160

P&F

LIST OF VENDORS

Document No.

Rev.

11-0330G01-01-11-06-01

SHEET 6 of 8

239 of 245

LIST OF RECOMMENDED VENDORS


S.NO

ITEM

NAME OF VENDOR

ADDRESS

PHONE NO

FAX NO

QUALIFIED FOR
SIZE

1
161

Control switch Gear

162

Electromac

163

Cable Glands

Commet

164

Baliga

165

Flameproof Control Gear

166

Lugs

Dowells

167

Instrument fitting SWAGELOK

Parker

168

IL Paighat

169

Fisher

170

Foxboro

171

Control Valve

Valtex

172

Dresser valves(India)

173

Schlumberger(Actaris)

174

Masoneilan

175

Daniel
Gas Chromatgraph

176

RMG

177

Foxbro

178

Electronic Controllers
(Flow/Level/Pressure
&Temp)

179

Honeywell

ABB

180

Elemex
Terminal Block

181

Phoenix Contact(India) Pvt.Ltd.

182

PECO

183

FILTAN

184

FACET
Filtering/ Pack Element

185

VELCON

186

ACS

187

BURGESS MANNING

LIST OF VENDORS

Document No.

Rev.

11-0330G01-01-11-06-01

SHEET 7 of 8

240 of 245

LIST OF RECOMMENDED VENDORS


S.NO
188
189
190
191
192

ITEM

Hot Shrink Sleeve

Warning Mat

NAME OF VENDOR

ADDRESS

Meteor private Limited

Street 121-122 Ansal Bhawan


K G Marg
New Delhi- 110001

194

IGP Engineers Pvt. Ltd.

Ms. Bala Srinivasan,79 Valmiki Street


Chennai,Tamil Nadu
India

195

ALFA ENGINEERING srl

Corporate Headquarter: via del Lavoro, 16,


41030 Bastiglia (Modena), Italy

ADVANCE Electronics System

878/1, GIDC Estate, Makarpura


Baroda - 390 010, Gujrat
India

197

Zunt Italina

Largo Industrie, 30/33


240/20, Torre Boldone BE
Italy

198

Shanghai Fiorentini gas equipment

SHANGHAI FIORENTINI GAS EQUIPMENT


CO.LTD 4493 LONG DONG AVENUE ,
PUDONG NEW AREA , SHANGHAI , CHINA.
ZIP - 201201

Insulation Joints

TD WILLIAMSON LTD.

199
200
201
202
203
204
205
206
207

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
Skelton Hall

V K Vikram
22,Sarvodaya
Society,Nizampura,Baroda-390002

209

Tata Projects Ltd.

210

Indian Register of Shipping

The Leela Galleria,5th floor,Andheri022-26956300


Kurla Road,Andheri(E),Mumbai-400059

212

Bureau VeritasQl

213

Germanischer Lloyd

216

0265-2392863

0265-2785952

Bax counsel Insepection Bureau Pvt. 303, Madhava,Bandra Kurla Complex, 022-26591526,022022-26591526
Ltd.
Bandra(E),Mumbai-400051
26590236

211

215

QUALIFIED
FOR SIZE

Swindon Wittshire SN3 5HF


ENGLAND
Via G. Boeri, 11 20141, Milano, ITALY

FORAIN S.r.l.

208

214

FAX NO

Raychem
Denso
SHAIC International Co.
Sparco Multiplast
Parixit Industries

193

196

PHONE NO

Third Party Inspection


Agency

Velosi Certification
Serrvices,Mumbai
ABS Industrial Verification Ltd.,
Mumbai

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

Certification Engineers International EIL Bhavan,5th floor,1,Bhikaji Camma


Ltd.
Place,New Delhi-110066

022-26956309

044-24320335

044-24328186

022-25376770

022-25426777

022-27578780 /1 /2 022-27578784 / 5
011-26167539,
26102121

011-26101419

217

Dalal Mott MacDonald

501, Sakar -II, Ellisbridge,Ahemedabad380006

079-26575550

079-6575558

218

International Certification Systems

E-7,Chand Society, Juhu Road, Juhu,


Mumbai-4000049

022-26245747

022-226248167

219

SGS

SGS India Pvt. Ltd.,SGS


House,4B,A.S.Marg,Vikhroli
(W),Mumbai-400083

LIST OF VENDORS

022-25798421 to 28 022-25798431 to 33

Document No.

Rev.

11-0330G01-01-11-06-01

SHEET 8 of 8

241 of 245

242 of 245

243 of 245

244 of 245

245 of 245