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Tender146vol II PDF
Tender146vol II PDF
PIPELINE ENGINEERING
0 10.11.2008
DESIGN BASIS/JOB
SPECIFICATION/ STANDARD
SPECIFICATION/STANDARDS/
DRAWINGS/DATASHEET
REV. DATE
INDEX
Volume – II
PIPELINE ENGINEERING
Page 1 of 7
Specification for flanges &
11 Welded Fittings (Size DN 450 0 S-04-02-014 07
mm (18") and above
Specification for Long Radius
12 0 S-04-02-015 10
Bends for Onshore Pipelines
Specification for Flow Tee (Bar
13 0 S-04-02-016 12
Tees) for Onshore Pipeline
Specification for Scraper Traps
14 0 S-04-02-017 17
for Onshore Pipelines
Specification for Pig Signaler for
15 0 S-04-02-018 6
Onshore Pipelines
Specification for Insulating
16 0 S-04-02-019 9
Joints for Onshore Pipelines
Specification for Casing
17 0 S-04-02-020 08
Insulator and End Seals
Specification for Field Joint
18 0 S-04-02-021 15
Coating (Onshore Pipeline)
Specification for Concrete
19 Weight Coating of Onshore 0 S-04-02-022 15
Pipelines
Specification for Repair of
20 0 S-04-02-023 06
Polyethylene Coating
Specification for Quick Opening
21 0 S-04-02-024 08
End Closure
Specification for Pipeline River
22 0 S-04-02-025 15
Crossings using HDD
Construction of pipelines
23 crossing Roads, Rail Roads and 0 S-04-02-026 11
Minor Water Crossings
Major Water Crossing -
24 0 S-04-02-027 15
Conventional Trenching
Specification for Pipeline
25 0 S-04-02-028 43
Construction (Onshore)
Specification for Hydrostatic
26 0 S-04-02-029 22
Testing of Onshore Pipelines
Specification for Pipeline
27 0 S-04-02-030 05
Markers
Specification for Documentation
28 0 S-04-02-031 09
for Pipeline Construction
29 Specification for Blasting 0 S-04-02-032 11
Specification for Detailed
30 0 S-04-02-033 17
Pipeline Route Survey (Onshore)
Welding Specification for
31 0 S-04-02-034 32
Fabrication of Piping
Spec. for Instructions to Vendor
32 0 S-04-02-035 10
for Quality Data Requirement
Page 2 of 7
Spec. for Issue and
33 0 S-04-02-036 09
Reconciliation of Material
Spec. for Pipeline Information
34 0 S-04-02-037 06
Management system
Page 3 of 7
Existing Under Ground Pipe
9 0 S-04-01-009 02
Crossing (Type-I)
Existing Under Ground Pipe
10 0 S-04-01-010 02
Crossing (Type-II)
11 Under Ground Cable Crossing 0 S-04-01-011 02
12 Over Head Power Line Crossing S-04-01-012 02
Typical trench dimension for two
13 or more pipelines in common 0 S-04-01-013 01
trench
14 K.M. Post 0 S-04-01-014 03
15 Typical ROU boundary marker 0 S-04-01-015 02
16 Aerial marker 0 S-04-01-016 03
17 Direction marker 0 S-04-01-017 03
18 Pipeline Warning Sign 0 S-04-01-018 03
Navigable Waterway Pipeline
19 0 S-04-01-019 02
Crossing Warning Sign
Pipeline Road/Highway Cased
20 0 S-04-01-020 02
Crossing
21 Typical Stream Crossings 0 S-04-01-021 02
22 Typical Slope Breakers Details 0 S-04-01-022 03
Bank Protection Details for
23 0 S-04-01-023 03
water crossings
Typical details of railway
24 0 S-04-01-024 03
crossings
Select Backfill for Station
25 0 S-04-01-026 02
Approach
Slope stabilization in ghat/ hill
26 0 S-04-01-027 02
areas
27 Soil stabilization in hilly areas 0 S-04-01-028 03
Typical lined canal cased
28 0 S-04-01-029 02
crossing detail
Typical lined canal crossings
29 0 S-04-01-030 01
(Uncased)
Typical Cross section for ROU
30 0 S-04-01-031 01
preparation in Hilly areas
Page 4 of 7
PA, PC etc
Handle Projections for Spacers
7 0 S-05-01-007 01
and Blinds
T-Strainer Type-1 2"-4" (150#
8 RF, 300# RF and RTJ, 600# RF 0 S-05-01-008 01
and RTJ)
T-Strainer Type-1 6"-24"
9 (150# RF, 300# RF and RTJ, 0 S-05-01-009 01
600# RF and RTJ)
10 Orientation of Orifice Traps 0 S-05-01-010 01
11 Stub-in Standard 0 S-05-01-011 02
Welding of pipe with different
12 0 S-05-01-012 01
thickness
13 Fillet weld details 0 S-05-01-013 01
Welding details for branch
14 0 S-05-01-014 01
connections
Method of cutting and
dimensions of field
15 0 S-05-01-015 01
manufactured concentric
reducers
16 Tolerances for fabrication 0 S-05-01-016 01
Pipe shoe for hot insulated C.S.
17 pipe, size 2" thru 8", Type-S1 0 S-05-01-017 02
(for temp. up to 343°C)
Pipe shoe for hot insulated C.S.
18 pipe, size 10" thru 30", Type-S2. 0 S-05-01-018 02
(for temp. up to 343°C)
Pipe saddle for bare pipe size
19 0 S-05-01-019 02
14” thru 48” type- S6A
Pipe shoe for slope line pipe size
20 0 S-05-01-020 02
2" thru 6" type-S9A/9B/9C
Low support sliding for bare and
21 insulated pipe size 2" thru 36" 0 S-05-01-021 02
type-L1 & L1A
Low support fixed for bare &
22 insulated pipe size 2" thru 36" 0 S-05-01-022 01
type-L3 & L3A.
Low support sliding for bare
23 pipe size 3/4" thru’ 36" type-L5 0 S-05-01-023 01
& L5A.
Low support sliding for bare and
24 insulated pipe size 2” thru 36” 0 S-05-01-024 02
Type-L6
Low support Fixed/Restrained
25 for bare and insulated pipe size 0 S-05-01-025 03
2" thru 36", type-L7 & L7A
Page 5 of 7
Restrained Low support for bare
26 and insulated pipe size 2" thru 0 S-05-01-026 01
36", type-L8 & L8A
Adjustable low support sliding
27 for pipe size 2" thru 6" type- 0 S-05-01-027 01
L10 & L10A
Low support sliding & fixed for
28 pipe size 3/4" thru 11/2"type- 0 S-05-01-028 02
L15.
Low support stanchion for bare
29 & insulated CS/AS/SS pipe 0 S-05-01-029 01
type – L16 and L16A
Adjustable low support with 4
30 bolts for pipe size 8" thru 24" 0 S-05-01-030 02
type-L17 & L17A.
Adjustable low support for bare
31 and insulated pipe size 2" thru 0 S-05-01-031 01
24". type-L18 & L18A
Adjustable low support with
guide & cross guide for bare
32 0 S-05-01-032 02
and insulated pipe size 2" thru
24" type-L19 & L19A.
Pipe clamp for bare pipe size
33 0 S-05-01-033 01
1/2" thru 24” Type C-1
U-bolt for bare pipe size 1/2"
34 0 S-05-01-034 01
thru 24" type-C4
Dummy pipe support for bare
35 0 S-05-01-035 02
pipe size 2" thru 24" type B-39
Dummy pipe support for
36 insulated pipe size 2" thru 24" 0 S-05-01-036 02
type-B40
37 Pipe support brackets type-B42 0 S-05-01-037 01
Guide support for bare size 1/2"
38 0 S-05-01-038 01
thru 24" type-G1
Guide support for bare size 1/2"
39 0 S-05-01-039 02
thru 24" type-G2 & G2A
Cross guide for bare pipe size 2"
40 0 S-05-01-040 02
thru 24" type-G3
Cross guide for bare pipe size 2"
41 0 S-05-01-041 02
thru 24" type-G4.
Anchor for bare pipe size 2" thru
42 0 S-05-01-042 02
24" type-G5.
Supporting arrangement for
43 0 S-05-01-043 01
angle & relief valves type-SP2.
Typical anti vibration support for
44 0 S-05-01-044 01
control valve-SP3.
Page 6 of 7
LAYOUT DRAWING & PORTACABIN PLAN
Layout Sultanpur Dispatch
1 0 0001-00-10-01-6002 01
Terminal
Layout SV-1 (Sultanpur -
2 0 0001-00-10-01-6003 01
Neemrana)
3 Dharuhera CGS & TOP 0 0001-00-10-01-6004 01
Layout Bhiwadi / Chopanki TOP
4 0 0001-00-10-01-6005 01
Station
5 Layout Bhiwadi CGS 0 0001-00-10-01-6006 01
6 Layout SV-2 & Khushkhera CGS 0 0001-00-10-01-6007 01
Layout SV-3, Sultanpur -
7 0 0001-00-10-01-6008 01
Neemrana
8 Layout Neemrana CGS & RT 0 0001-00-10-01-6009 01
Layout Hayatpur TOP (for
9 0 0001-00-10-01-6010 01
Manesar)
10 Layout Manesar CGS 0 0001-00-10-01-6011 01
11 Layout Hayatpur PRS 0 0001-00-10-01-6012 01
12 Layout SV-1 (Gurgaon Line) 0 0001-00-10-01-6013 01
13 Layout Gurgaon Terminal 0 0001-00-10-01-6014 01
14 Porta-Cabin Layout 0 0001-00-10-01-6015 02
Page 7 of 7
ENGINEERING DESIGN BASIS
(PIPELINE ENGINEERIG)
1.0 INTRODUCTION
2.0 SCOPE
ENCLOSURES:
M/s GAIL (India) Ltd., proposes to lay following Natural Gas spur Pipelines (from
Chainsa- Jhajjar pipeline):-
2.0 SCOPE
This document establishes minimum design parameters and basis for design and
detailed engineering of the Pipeline and Associated facilities covered under this
project as defined briefly herein below.
Salient features of the surveyed pipeline route as per pipeline route map no. MAS/
GAIL/ CGJHPL/08/ RM-01/02/03/04, GAIL/ SKP/ GURGAON/ 2008/ R.M./01 (Rev.-
0), and survey report are tabulated herein below:
7.1 General
Pipeline and pipeline stations to be installed as a part of this project shall be designed
and engineered in accordance with the standards/codes referred in section 3.0 of this
document.
7.2 Pipeline
7.2.1 Pipeline shall be designed in accordance with requirements of ASME B 31.8 and OISD
141. The pipeline shall withstand all installation, testing and operating condition/ loads.
All necessary calculations shall be carried out to verify structural integrity and stability
of the pipeline for the combined effect of pressure, temperature, bending (elastic),
soil/pipe interaction, external loads and other environmental parameters as applicable
during all phases of work from installation to operation. Allowable stress limit shall be
as per ASME B 31.8. Such calculations shall include, but are not limited to following:
- Buoyancy control and stability analysis for pipeline section to be installed in areas
subjected to flooding/submergence. Unless specified, specific gravity of installation
in such area shall be at least 1.2.
- Stress analysis at crossing of major rivers, rail and highway etc.
- Crossing analysis of rivers by HDD if applicable.
- Pipeline expansion and its effect on station piping (above ground/below ground).
7.2.2 Pipeline shall also be checked for adequacy against anticipated earthquake loading and
any special measures such as increase in wall thickness/ grade/ select backfill etc. as
required to ensure safety and integrity of the pipeline system shall be implemented.
7.2.3 Mainline shall be provided with bi-directional pigging facilities suitable for handling all
types of pigs including intelligent pigs.
7.2.4 Pipeline and its associated facilities shall be designed using the applicable design code
and as modified below.
The pipeline shall be designed to meet the Location Class as defined in ASME B31.8,
except as modified below.
7.3.2 All piping shall be designed for combined effects of pressure, weight and temperature
during operating conditions without over stressing the piping, valves or equipment. All
piping shall be adequately supported, guided or anchored so as to prevent undue
vibration, deflection or loads on connected equipment such as filters, meters etc.
7.4 Materials
Pipeline and its appurtenances shall be provided with carbon steel materials suitable for
the intended service, as detailed in subsequent paragraphs
7.4.1 Line pipe for main line
Line pipe shall conform to API 5L and Company specifications. Type of line pipe to be
used shall be SEAMLESS/LSAW/ HSAW/EW.
ENGINEERING DESIGN BASIS SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI PIPELINE ENGINEERING 0001-01-04-03-001 Page 8 of 19
Copyright GAIL – All rights reserved
Sr. LINE SIZE GRADE Class - I Class - II Class - III Class -
No. IV
1 18”(457.2 mm) X-70, 6.5 7.9 9.3 11.7
PSL-2
2 12” (323.9 mm) X-60, 6.4 6.4 7.9 9.5
PSL-2
3 10” (273.1 mm) X-60, 6.4 6.4 6.4 7.8
PSL-2
7.5.2 In addition, pipeline shall be provided with minimum 80 micron thick liquid epoxy
internal coating conforming to ISO 15741/API RP 5L2. Extremities of pipe shall be free
from coating over a length of 20± 5 mm.
7.5.3 All above ground piping and structures shall be painted to prevent atmospheric
corrosion. Painting of above ground piping and structures shall be as per specifications.
Painting shall be suitable for normal corrosive environment/corrosive environment, as
applicable, as defined in Painting Specification No. S-05-02-014 for all stations and
terminals.
Insulating joints shall be provided to electrically isolate the buried pipeline from above
ground pipeline. Insulating joints shall be monolithic type and shall allow smooth
passage of pigs. Insulating joints shall be installed in above ground portion of the
pipeline, immediately after the buried/aboveground transition at the scraper stations.
Wherever pressure/ temperature transmitters are used on cathodically protective
pipeline the same shall be electrically isolated by providing insulating joints/ flanges.
7.7 Pipeline Burial
The pipeline shall be buried normally at a depth of 1.0 meter below natural ground level
except river/ rail/ road/ canal/waterways crossing where minimum cover shall be as
Additional soil cover other than specified above shall be provided at locations indicated
by statutory/ local authorities or in areas likely to have an increased risk of impact
damage or third party interference as per agreements between COMPANY and
authorities. In case, any private dwelling, industrial building or place of public assembly
falls within 15 m of pipeline, additional cover of minimum 300 mm shall be provided over
and above the cover indicated in the above table.
7.10 Backfilling
In normal cross-country areas, the pipeline trench shall be backfilled with excavated
soil. Select rockfill/ slope breakers shall be provided in the trench in steep areas (slope
generally 10% and more) to prevent erosion. In case of rivers/water bodies prone to
scour and erosion, the safety cover shall be provided below the predicted scour level. In
addition to the cover, anti buoyancy measures (concrete coating) shall be provided at
river crossings.
Contractor shall keep top 150 mm of excavated top soft soil (free of gravels) aside,
which shall be back filled in the end as top layer.
Select backfill shall be provided at approaches to terminal up to transition point (below
ground/above ground) inside terminal.
Select back fill shall also be provided as applicable for areas prone to seismic activity.
Recommendation of Seismic Analysis Report should be considered for such special
backfill.
Pipeline route shall be examined to establish any drainage requirement in hilly terrain.
In case required, the drainage shall be designed to prevent trench flooding during
construction and protect the integrity of the installed pipeline following completion of all
construction activities.
In rocky areas, the trench bottom shall have sand/soft soil padding of 150 mm. After
laying of pipeline, sand/soft soil padding shall be placed around and on top of the pipe
so that thickness of compacted padding on top of pipe corrosion coating shall be at
least 150 mm.
Disposal of debris and surplus material to designated disposal areas or designated
place(s), as the case may be and as directed by Engineer-in-charge shall be carried out.
Scraper traps shall be provided at the Despatch terminals (Sultanpur) and Receiver
Terminal at Neemrana. The scraper traps shall be bi-directional capable of handling
intelligent pigs and other cleaning pigs. The launching and receiving barrels shall be
designed in accordance with the requirements of ASME B 31.8 and its end closure shall
be designed and fabricated according to ASME Section VIII, Div.1. Adequate
arrangements for launching, retraction, handling and lifting of cleaning and
instrumented pigs shall be provided at the scraper stations. Traps shall be accessible
by walkway/road for movement of equipment, pigs etc. These stations shall be provided
with access road from the nearest metalled road.
ENGINEERING DESIGN BASIS SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI PIPELINE ENGINEERING 0001-01-04-03-001 Page 11 of 19
Copyright GAIL – All rights reserved
Corrosion resistant coating shall be provided on the pipeline up to a minimum length of
500 mm after it comes aboveground / before it gets buried underground at terminals
and scraper stations.
The diameter of barrel of the launcher cum receiver shall be three nominal sizes larger
than the pipeline nominal size. Center line elevation of scraper trap shall be at suitable
height from grade level. Suitable arrangements shall be provided for handling & lifting
of pigs.
The piping system at the terminals and intermediate stations shall be designed to have
sufficient flexibility to prevent pressure and thermal expansion or contraction from
causing excessive stresses on the connected equipment. The piping shall be
designed/fabricated as defined in clause 8.3.
As far as possible, pipeline expansion shall be absorbed by allowing the scraper traps to
move on supports. Installation of anchor block in the under ground pipeline is not
permitted. If required adequate length of trench in approaches to stations shall be
provided with a select backfill to ensure flexibility.
8.2 Sectionalising Valve Stations
Sectionalising valve station shall be provided along pipeline route for isolating sections
of pipeline as per ASME B 31.8 for:
- Limiting the hazard and damage from accidental discharge from pipeline system.
- Facilitating maintenance of pipeline system and
- Complying with the requirements of applicable codes.
The location of sectionalizing valves are indicated in PFD. The requirements of
applicable codes taking consideration of terrain features, requirement of safety and
operation etc. to be taken in to account while providing Sectionalizing Valves.
Sectionalizing valve on the main pipeline shall be ball valves of full bore type, to allow
smooth passage of cleaning and intelligent pigs.
All valves installed at Intermediate facilities, block valve stations, scraper stations and
pipeline sectionalizing valve stations shall be gas actuated/ hand operated and with butt
welding ends. Sectionalizing and Station block valves shall be installed buried and
provided with a stem extension in such a way that the center line of rim of the hand
wheel on a horizontal shaft or center of actuator is at approximately 1.0 m above the
finished ground level. Valve surface shall be provided with corrosion protection coating.
Valve body vent and drain lines shall be extended and terminated above ground.
The valve stations shall be located at a readily accessible location such as near road and
shall be provided with an access road from the nearest all weather metalled road. The
facilities within valve station shall be secured by a chain link fence enclosure with gate.
The location of valve station shall be clear of overhead power lines.
The provisions of remote operated feature shall be as per the operation and control
8.3 Piping
8.3.1 General
This section describes the design requirements of piping applicable for Despatch
station, intermediate pigging stations, sectionalizing valve stations and receiving station.
All piping and equipment shall be designed as per ASME B 31.8. All piping materials
shall be as per Piping Material Specification (PMS).
Utility piping to be provided shall be designed in accordance with the provisions of
ASME B 31.3.
Design shall provide consideration for all loadings like weight, temperature etc.,
significantly affecting the pipe material stresses in addition to fluid pressure.
8.3.2 Piping flexibility/stress analysis
All piping shall be designed for thermal expansion under start up, operating and shut
down conditions without over stressing the piping, valves or equipment. Provisions for
expansion shall normally be made with bends and offsets.
All piping shall be adequately supported, guided or anchored so as to prevent undue
vibration, deflection or loads on connected equipments. Equipments/ valves requiring
periodical maintenance shall be supported in such a way that the valves and equipment
can be removed with minimum temporary pipe supports.
8.3.3 Piping layout
Piping will be located above-ground wherever possible within the terminals.
Piping shall be designed considering skin temperature of piping material under empty
conditions as 65ºC or design temperature of pipeline whichever is higher.
Piping stress analysis shall be carried out to determine allowable pipe movement and
support requirements wherever felt necessary.
Buried piping inside the terminal area will have a minimum depth of cover of 1.2 m.
Where buried pipes come out of the ground, the underground coating on the pipe will
continue for a distance of 500 mm above ground.
Platforms, crossovers shall be provided for ease of operation and maintenance.
Platform for filters shall be provided for maintenance/ operational access.
Painting above ground piping and structures shall be as per specifications enclosed in
the Bid package.
8.4 Welding
Globe Throttling
Ball On/off, Isolation (on main line)
Plug On/off, Isolation (in the terminals)
Check Uni-directional flow
All pipeline valves shall comply with the requirements of API 6D/ relevant PMS. Ball
valves shall have primary metal seated design. In order to minimise potential leak
sources, valves used in mainline shall be with butt-weld ends. Valve installed within the
terminal to isolate the mainline/ pipeline shall also be provided with butt welding ends.
However terminal valves shall be flanged ends. Flanges may be used where frequent
access or removal of equipment is required.
Wherever underground valves are provided, valves shall be provided with a stem
extension in such a way that the centreline of the rim of the hand wheel on a horizontal
shaft or centre of power actuator as approximately 1.0 m above the finished ground
level.
Minimum size of any tapping from the underground pipeline shall be 2" NB and shall be
ENGINEERING DESIGN BASIS SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI PIPELINE ENGINEERING 0001-01-04-03-001 Page 15 of 19
Copyright GAIL – All rights reserved
provided with an isolation ball valve located at a minimum distance from the pipeline.
8.9 Branch Connections
All branch connections or side tap on the piggable lines wherever the branch line
diameter is approx. 40% or more of the main line size, shall be provided with flow tees
to enable smooth passage of all types of pigs. Flow tees for this purpose shall have an
internal pipe housed in a tee.
8.10 Pipeline Bends
In order to accommodate changes in vertical and horizontal alignment in piggable
section of pipeline, elastic bends/cold field bends/hot formed long radius bends shall be
used. Miter bends shall not be used for change in direction. Necessary design/
calculation for arriving Minimum Elastic Bend Radius shall be worked out by Contractor
and shall be ratified by GAIL. Minimum bend radius shall be as follows:
8.12 Specifications
All procurement of materials shall be as per Piping Material Specification (PMS) and
specifications indicated in PMS.
ANNEXURE - A LIST OF CODES AND STANDARDS
In addition to the codes/standards mentioned in para 3.0, the latest edition of the below listed
equivalent codes and standards shall also be used for design of proposed pipeline. The listing
includes, but is not limited to, the following:
ENGINEERING DESIGN BASIS SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI PIPELINE ENGINEERING 0001-01-04-03-001 Page 16 of 19
Copyright GAIL – All rights reserved
1. Line Pipes
API 5L Specification for Line pipe
API 5L1 Recommended Practice for Railroad Transportation
of Line pipe
API 5LW Recommended Practice for Transportation of Line
pipe on Barges & Marine Vessels
2. Valves
API 6D Specification for pipeline valves (Steel Gate, Plug,
Ball and Check Valves)
API 602 Compact Steel Gate Valves-Flanged, Threaded,
Welding & Extended Body ends.
ASTM A694 Forgings, Carbon & Alloy steel for Pipe Flanges,
Fittings, Valves & parts for High Pressure
Transmission Service.
MSS-SP-6 Finishes for Contact Faces of connecting End
Flanges of Ferrous Valves and Fittings.
MSS-SP-25 Standard Marking System for Valves, Fittings &
Unions
BS 5351 Steel Ball Valves for the Petroleum, Petrochemical
and Allied Industries
3. Flanges & Fittings
MSS-SP-44 Steel Pipeline Flanges
ANSI B16.5 Pipe Flanges and Flanged Fittings
Ring-joint Gaskets & Grooves for Steel Pipe
ANSI 16.20
Flanges
ASTM A105 Forgings, Carbon Steel for Piping Components
ASTM A193 Carbon & Alloy Steel Bolts & Studs for High
Temperature Service
API 601 Standard for Metallic Gaskets for Raised-Face Pipe
Flanges & Flanged Connections
ANSI B16.9 Factory Made Wrought Steel Butt Welding Fittings
ANSI B16.11 Forged Fittings, Socket Welded & Threaded
ANSI B16.26 Butt Welding Ends
ASTM A234 Piping Fittings of Wrought Carbon Steel and Alloy
Steel for Moderate and Elevated Temperatures
ASTM A694 Forgings, Carbon & Alloy Steel for Pipe Flanges,
Fittings, Valves & Parts for High Pressure
Transmission Service.
MSS-SP-75 Specification for High Test Wrought Butt Welding
Fittings
ENGINEERING DESIGN BASIS SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI PIPELINE ENGINEERING 0001-01-04-03-001 Page 17 of 19
Copyright GAIL – All rights reserved
MSS-SP-97 Integrally Reinforced Forced Branch Outley Fittings
– Socket Welding, Threaded and Butt Welding
Ends.
PFI-ES-24 Pipe Bending Methods, Tolerances, Processes &
Material Requirements
4. Testing & Welding
ANSI/AWS D1.1 Structural Steel Welding
Standard for Welding Pipelines and Related
API 1104
Facilities
AWS A3.0 Welding Terms and Definitions
AWS A5.1 Welding Electrodes
AWS A5.5 Specification for Low Alloy Steel Covered Arc
Welding Electrodes
ASTM E165 Liquid Dye Penetrant Inspection of Pipeline Welds
ASTM A370 Standard Methods and Definitions for Mechanical
Testing of Steel Products.
ASTM E18 Standard Hardness Test for Metals
ASTM E23 Standard for Impact Test for Metals
ASTM E84 Standard Test Method for Micro-hardness of Metals
ASTM E92 Standard Test Method for Vickers Hardness of
Metallic Materials
ASTM E110 Standard Test Method Indentation Hardness for
Metallic Materials by Portable Hardness Testers
ASTM E709 Standard Guides for Magnetic Particle Examination
MSS-SP-53 Quality Standard for Steel Casting & Forging-
Magnetic Particle Method
MSS-SP-54 Quality Standard for Steel Casting & Forging-
Radiographic Examination
MSS-SP-55 Quality Standard for Steel Castings & Forgings-
Visual Method.
SL NO. DESCRIPTION
1.0 SCOPE
5.0 PIPELINE
6.0 PIPING
7.0 FITTINGS
8.0 BENDS
9.0 FLANGES
10.0 GASKETS
11.0 BOLTING
13.0 VALVES
TABLE - 2 PRESSURE/TEMP & OTHERS DESIGN CONDITIONS FOR VARIOUS PIPING CLASSES
1.1 It is propose to install a Natural gas pipe lines from Sultanpur – Neemrana, Bhiwadi / Chopanki
TOP to Bhiwadi, Hayatpur – Manesar and Hayatpur - Gurgaon in Haryana / Rajasthan states to
initially cater the demand of consumers in Dharuhera, Bhiwadi, Khushkhera, Neemrana,
Manesar, Khandsa and Gurgaon regions. The proposed Natural gas pipeline shall be of 457
mm (18”) OD, approximately 85.28 km long; 323.9 mm (12”) OD, approximately 9 km long and
273.1 mm (10”) OD, approximately 16.40 km.
The scope shall include piping and tap-off points at various locations of Chainsa–Jhajjar spur
pipeline, that is for Bhiwadi, Gurgaon, Manesar, dispatch terminals, Sectionalising Valve stations,
Tap-off terminals, receiving terminals, Spur line and various CGS’s.
This document covers minimum requirements for various piping materials necessary for the design
of the piping/ pipeline and metering skid facilities coming under the project. This specification shall
be read in conjunction with various Codes and Standards of latest edition, as applicable.
2.1 Pipeline and pipeline terminal facilities envisaged as part of this project shall be designed and
engineered primarily in accordance with the provisions of the latest edition of the following codes:
(i) ASME B31.8 - Gas Transmissions and Distribution for pressure Piping
System
(iii) OISD Standard 141 - Design and Construction Requirements for Cross Country
Hydrocarbon Pipelines.
2.2 All codes, standards and specifications referred herein shall be the latest edition of such documents.
2.3 For sake of brevity the initials of the society to which the codes are referred may be omitted in the
specifications, for example, B16.5 is a code referring to ASME; A106 is a code referring to ASTM.
2.4 In addition, GAIL specifications and standards for various piping and pipeline materials shall also
be applicable.
Individual piping class has been generally designed to cover a set of service operating within
pressure-temperature consideration as per ASME B16.5/ B16.34 or part of it. Deviations of material
from class specifications may occur due to specific design conditions and/ or availability. These
deviations are permissible if they equal or better the individual class requirements and shall be
subjected to approval on case-to-case basis.
All materials shall conform to detailed specifications / data sheets for items as applicable.
The piping class designation shall generally consist of three digits made up of a letter, number,
letter e.g. A1A, A3A, A4A, B1A, D1A, E1A, etc. as follows:
B – Class 300
D – Class 600
E – Class 900
The middle number indicates differences in the specifications within the same class rating and
material.
5.0 PIPELINE
5.1 Line pipe material grade and wall thickness details are indicated in Table-I.
6.0 PIPES
6.1 Carbon steel pipe shall be made by open hearth, electric furnace or basic oxygen process only. The
steel used shall be fully killed and made with fine grain structure. The grade and wall thickness of
various sizes of pipes shall be as per piping material specification for the applicable class.
6.2 Pipe dimensions shall be in accordance with ASME B 36.10 for carbon steel ASTM standard pipes;
& API 5L for carbon steel API 5L grade pipes.
6.3 All pipe threads shall conform to American Standard taper as per ASME B1.20.1 NPT, unless
otherwise specified.
6.4 For butt weld end, bevel shall be in accordance with API specification 5L or ASME B 16.25 as
applicable.
7.0 FITTINGS
7.1 Fully killed carbon steel shall be used in the manufacture of fittings. The fitting shall have carbon
equivalent not exceeding 0.45, based on check analysis.
7.2 Threaded joints, if used, shall conform to American Standard taper as per ASME B1.20.1 NPT.
7.3 Dimensions of socket welded/ screwed fittings shall conform to ASME B 16.11. Swage shall be as
per BS 3799.
7.4 Dimensions of steel butt welded fittings shall be as per ASME B 16.9.
7.5 Bore of socket welded fittings shall suit outside diameter (OD) of pipe and its thickness.
7.6 Butt welding ends shall conform to API specification 5L or ASME B 16.25 as applicable. In case of
difference in thickness of matching ends, requirements of ASME B 31.8 shall apply.
7.7 Integrally reinforced forged branch fittings such as Sockolet, Weldolet etc. shall be as per MSS-SP-
97. Fittings not covered in ASME B16.9 and MSS-SP-97 shall conform to manufacturer’s standard.
8.0 BENDS
PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0
GAIL (INDIA) LTD Page 4 of 68
NEW DELHI 0001-01-05-02-001
8.1 Unless otherwise specified for process piping, elbow of radius R = 1.5 D shall only be used.
Minimum Bend Radius D = Specified Outside Diameter
8.2 In order to accommodate changes in vertical and horizontal alignment in piggable section of
pipeline, Elastic bends/ Cold field bends/ Hot formed long radius bends shall be used. Long Radius
Bend shall be used only when indicated in the drawing.
9.0 FLANGES
9.1 Pressure Temperature rating of flanges shall conform to B16.5/ MSS-SP44/ B16.47 Series A, as
applicable.
9.2 Dimensions of flanges shall be in accordance with B16.5/ MSS-5P44/ B16.47 Series A, as
applicable.
9.3 Neck of weld neck (WN) flanges shall suit pipe bore and thickness.
9.4 Bore of socket welded (SW) flanges shall suit pipe O.D. and its thickness.
9.5 Threads for screwed flanges, if used, shall conform to American Standard taper as per ASME B
1.20.1 NPT.
9.6 Sizes for blind flanges shall be indicated by nominal pipe size.
9.7 Unless specified otherwise in Piping Material Specification the flange face finish shall be as per
ASME B16.5.
9.9 Spectacle blind/ spacer & blinds shall be in accordance with ASME B16.48/ manufacturer’s
standard.
9.10 Two jack screws, 1800 apart shall be provided in spectacle blind or spacer & blind assemblies as per
GAIL standards.
10.0 GASKETS
10.1 Spiral wound metallic gasket with compressed asbestos filler shall conform to ASME B16.20/ API
601. All spiral wound gaskets shall be provided with stainless steel centering ring.
11.1 Nuts for stud bolts shall be American Standard Hexagon Heavy Series and double chamfered.
11.2 Dimension and tolerances for stud bolts and nuts shall be as per ASME B18.2.1 and 18.2.2 with full
threading to ASME B 1.1 Class 2A thread for bolts and Class 2B for nuts. Diameter and length of
stud bolts shall be as per ASME B 16.5/ ASME B16.47 with full threading.
11.4 Threads for stud bolts shall be as per ASME B 1.1, as follows:
11.5 Threads for threaded pipe, fitting, flanges and valve shall be in accordance with B1.20.1 taper
threads, unless specified otherwise.
11.6 Heads of jack screws shall be heavy hexagonal type. Jack screw end shall be rounded. Stud bolts
shall be fully threaded with two hexagonal nuts.
12.1 Threaded joints shall be made with 1” wide PTFE jointing tape.
13.0 VALVES
13.1 Valve ends shall be as per valve data sheets for various piping class.
13.2 Sectionalizing valves, Block valves and other isolation valves installed on the main pipeline shall
be ball valves with butt welding ends. All inline isolation valves on the mainline (pipeline) shall be
full bore valves to allow smooth passage of cleaning as well as intelligent pigs.
13.3 All buried valves shall be provided with stem extension, sealant, vent/drain and shall have butt
welded ends as per relevant specification/ data sheet.
13.4 Flange dimensions and face finish of flanged end valves shall conform to clause 9.0 of this
specification.
13.5 Butt welding ends of Butt Welded valves shall conform to ASME B 16.25.
13.6 Face to face and end to end dimensions shall conform to applicable standards.
13.7 Valves shall conform to following standards unless specified otherwise in piping material
specification for various piping class.
13.8 All manual operated valves shall be provided with wrench I hand wheel or gear operator as
specified here in below.
For ANSI class 150 and 300 : Hand wheel operated for size ≤12” NB.
Gear operated for size ≥14” NB.
For ANSI class 600 : Hand wheel operated for size ≤ 10” NB.
Gear operated for size ≥ 12” NB
For ANSI class 150, 300, 600 and 900 - Hand Wheel operated for all size
Gas actuated valves shall be as per P & IDs. The actuator shall have provision for remote operation
as per P & IDs. All gas actuated valves shall have additional provision of hand wheel operation.
Quick opening end closure to be installed on scraper traps shall be designed in accordance with
Section VIII of ASME Boiler and Pressure Vessel Code and equipped with safety locking devices
in compliance with Section VIII, division 1. UG-35.2 of ASME Boiler and Pressure Vessel Code.
In terminal piping, high point vents and low point drains required for the purpose of hydrotesting
shall be of size 0.75”. These vents & drains shall consist of gate valves with blind flange assembly.
Pipeline specialty items viz, scraper traps, Barred tees, insulating joints, LR bends etc. shall be as
per specifications attached elsewhere.
NEW DELHI
LINE PIPE Class Class Class Class -
–I – II – III IV
3. Spur line Hayatpur - Manesar 10 X – 60, PSL-2 SEAMLESS ,EW 6.4 6.4 6.4 7.8
3. Spur Line Hayatpur - Gurgaon 10 X – 60, PSL-2 SEAMLESS ,EW 6.4 6.4 6.4 6.4
TABLE -1
0001-01-05-02-001
REV-0
Page 8 of 68
TABLE – 2
Class Service Design Condition C.A. (mm) Pipe Design
Pressure Temp. Material Code
(Kg/cm2 ) (0 C)
D1A Hydrocarbon 99.93 65 1.5 API 5L X – ASME B
Gas 52/ ASTM 31.8 /
A 106 GR- OISD –
B / Gr.B 141
(Charpy) /
Gr. B PSL-
2 as
applicable
B1A Hydrocarbon 49.0 65 1.5 ASTM A ASME B
Gas 106 GR- B 31.8 /
/ Gr.B OISD –
(Charpy) / 141/ 226
Gr. B PSL-
2 as
applicable
A1A Hydrocarbon 19 65 1.5 ASTM A ASME B
Gas 106 GR- B 31.8 /
/ Gr.B OISD –
(Charpy) / 141 / 226
Gr. B PSL-
2 as
applicable
A3A Utilities 10.5 65 1.5 IS-1239 ASME B
(BLACK) 31.3
J2A Potable Water 10.5 65 0 IS-1239 ASME B
(Galv) 31.3
A93A Fire Water 18.9 65 1.5 IS-1239 ASME B
(Black)/ 31.3
IS-3589
GR 410 as
applicable
CORROSION ALLOWANCE : Above mentioned corrosion allowance is only for station piping.
No corrosion allowance is considered in linepipe.
NOTES
1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE
ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID.
4. CHARPY V-NOTCH TEST & HARDNESS TEST SHALL BE CONDUCTED FOR PIPE, FITTINGS AND
FLANGES.
0.750
1.000
1.250
1.500
2.000
2.500
3.000
3.500
4.000
5.000
6.000
8.000
10.00
Lower Upper
Sch./ Dim.
Item Type Size Size Material Description
Thk STD
(Inch) (Inch)
PIPE 00.500 00.750 S160 B 36.10 ASTMA 106 GR.B PE, SEAMLESS
PIPE 8.000 14.000 6.4 API 5L API 5L GR.B PSL2 BE, SEAMLESS
PIPE 16.000 18.000 6.4 API 5L API 5L GR.B PSL2 BE, SAW
PIPE 20.000 20.000 7.1 API 5L API 5L GR.B PSL2 BE, SAW
SPCR &BLIND 10.000 24.000 B-16.48 ASTM A105 (CHARPY) 150, RF/125AARH
SERVICE : NON CORROSIVE UTILITIES (ABOVE GROUND) – COOLING WATER, INERT GAS,
INSTRUMENT AIR, CONDENSATE
NOTES
1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE
ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID.
SPECIAL NOTES
0.750
1.000
1.250
1.500
2.000
2.500
3.000
3.500
4.000
5.000
6.000
(A3A)
Lower Upper
Sch./ Dim.
Item Type Size Size Material Description
Thk STD
(Inch) (Inch)
ELBOW.90 02.00 06.00 STD B-16.9 ASTM A 234 GR. WPB BW, 1.5D
(CHARPY)
ELBOW.45 02.000 06.000 STD B-16.9 ASTM A 234 GR. WPB BW, 1.5D
(CHARPY)
TRP 00.500 1.500 MANUF B:A105; INT: SS304 SW, Y-TYPE, 800
STD
SERVICE
NON CORROSIVE PROCESS- FLAMMABLE / NON FLAMMABLE, NON LETHAL-
HYDROCARBONS, AROMATICS, AMMONIA, SWEET GAS, FLUSHING OIL AND OTHER
UTILITIES -MP CONDENSATE, INSTRUMENT AIR, PLANT AIR, NITROGEN, AMMONIA GAS
ETC.
NOTES
1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE
ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID.
2. NDT OF WELDS SHALL BE AS FOLLOWS:
3. PIPING DESIGN AS PER ASME B 31.8 & OISD 141 & 226
5. CHARPY V-NOTCH TEST & HARDNESS TEST SHALL BE CONDUCTED FOR PIPE, FITTINGS AND
FLANGES.
SPECIAL NOTES
ITEM SIZE DESCRIPTION
12.000
14.000
16.000
18.000
20.000
0.500
0.750
1.000
1.250
1.500
2.000
2.500
3.000
3.500
4.000
5.000
6.000
8.000
(B1A)
Lower Upper
Sch./
Item Type Size Size Dim. STD Material Description
Thk
(Inch) (Inch)
PIPE 00.500 00.750 S160 B 36.10 ASTMA 106 GR.B PE, SEAMLESS
PIPE 03.000 03.000 STD B 36.10 ASTMA106 GR.B (CHARPY) BE, SEAMLESS
PIPE 04.000 06.000 STD B 36.10 ASTMA106 GR.B (CHARPY) BE, SEAMLESS
PIPE 08.000 08.000 7.9 API 5L API 5L GR.B PSL2 BE, SEAMLESS
PIPE 10.000 10.000 9.3 API 5L API 5L GR.B PSL2 BE, SEAMLESS
PIPE 12.000 12.000 10.3 API 5L API 5L GR.B PSL2 BE, SEAMLESS
PIPE 14.000 14.000 11.1 API 5L API 5L GR.B PSL2 BE, SEAMLESS
PIPE 16.000 16.000 12.7 API 5L API 5L GR.B PSL2 BE, SAW
PIPE 18.000 18.000 14.3 API 5L API 5L GR.B PSL2 BE, SAW
PIPE 20.000 20.000 15.9 API 5L API 5L GR.B PSL2 BE, SAW
ELBOW.45 02.000 16.000 M B-16.9 ASTM A234, GR. WPB BW, 1.5D
CHARPY)
ELBOW.45 18.000 20.000 M B 16.9 ASTM A234, GR. WPB BW, 1.5D
CHARPY)
O’ let group(B1A)
SOCKOLET 00.500 0.750 MSS-SP97 ASTM A 105 SW, 6000
VLV.GATE 02.000 20.000 API-6D BODY-ASTM A 216 GR. WCB FLGD, 300, B-
TRIM-STELLITED, STEM 13% 16.5, RF/ 125
CR. STEEL AARH
VLV.GLOBE 02.000 20.000 BS-1873 BODY-ASTM A 216 GR. WCB FLGD, 300, B-
TRIM-STELLITED, STEM 13% 16.5, RF/ 125
CR. STEEL AARH
VLV.CHECK 2.000 20.000 API -6D BODY-ASTM A 216 GR. WCB FLGD, 300, B-
TRIM-STELLITED, STEM 13% 16.5, RF/ 125
PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0
GAIL (INDIA) LTD Page 27 of 68
NEW DELHI 0001-01-05-02-001
CR. STEEL AARH
VLV.BALL 02.000 20.000 API-6D BODY-ASTM A 216 GR. WCC/ FLGD, 300, B-
A234 GR WPC, TRIM-SEAT 16.5, RF/ 125
AISI 4140+0.003” ENP/ AISI 410 AARH
VLV.BALL 02.000 02.000 API-6D BODY-ASTM A 216 GR. WCC/ BW, 300, B-
A234 GR WPC, TRIM-SEAT 16.25, RF/ 125
AISI 4140+0.003” ENP/ AISI 410 AARH
VLV.PLUG 02.000 20.000 API-6D BODY-ASTM A 216 GR. WCB FLGD, 300, B-
PLUG-A 216 GR. WCB+0.003” 16.5, RF/ 125
ENP AARH
Bolt Group(B1A)
BOLT.STUD 00.500 26.000 B18.2 BOLT: 193 GR.B7,NUT: A194
GR. 2H
NOTES
1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE
ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID.
3. BALL VALVE TO BE USED IN MAIN LINE SHALL HAVE BUTT WELDED ENDS.
5. BARRED TEE SHALL BE WELDED TYPE FOR USE IN MAINLINE ONLY. MATERIAL SHALL BE
AS PER ATTACHED TABLE-3 FOR PIPELINE SPECIALITY ITEMS.
6. LR BEND,IJ,L/R, PIG SIG. SHALL BE FOR USE IN MAINLINE ONLY, MATERIAL AS PER TABLE-3.
10. CHARPY V-NOTCH TEST & HARDNESS TEST SHALL BE CONDUCTED FOR PIPE, FITTINGS AND
FLANGES.
11. ALL BRANCH CONNECTIONS INCLUDING VENT, DRAIN, PRESSURE AND TEMPERATURE
CONNECTION SHALL BE AS PER BRANCH CONNECTION TABLE GIVEN ON NEXT PAGE. THE
BRANCH DETAILS INDICATED IN APPLICABLE STANDARD SHALL BE IGNORED.
12. CORROSION ALLOWANCE OF 1.5 MM HAS BEEN CONSIDERED FOR TERMINAL PIPING AND 0.0
MM FOR MAIN PIPELINE
13. FOR DIMENSIONS OF HANDLE PROJECTION FOR SPACER & BLIND – REFER STD. DRG.-
S-05-01-007
12.000
30.000
14.000
16.000
18.000
20.000
22.000
24.000
26.000
28.000
0.500
0.750
1.000
1.250
1.500
2.000
2.500
3.000
3.500
4.000
5.000
6.000
8.000
Lower Upper
Sch./
Item Type Size Size Dim. STD Material Description
Thk
(Inch) (Inch)
PIPE 00.500 00.750 S160 B 36.10 ASTM A 106 GR.B PE, SEAMLESS
PIPE 02.000 02.000 XS B 36.10 ASTM A106 GR.B (CHARPY) BE, SEAMLESS
PIPE 03.000 06.000 XS B 36.10 ASTM A106 GR.B (CHARPY) BE, SEAMLESS
PIPE 08.000 08.000 14.3 API 5L API 5L GR.B PSL2 BE, SEAMLESS
PIPE 10.000 10.000 12.7 API 5L API 5L X-52 PSL2 BE, SEAMLESS
PIPE 12.000 12.000 14.3 API 5L API 5L X-52 PSL2 BE, SEAMLESS
PIPE 16.000 16.000 17.5 API 5L API 5L GR.X-52 PSL2 BE, SAW
PIPE 18.000 18.000 19.1 API 5L API 5L GR.X-52 PSL2 BE, SAW
PIPE 20.000 20.000 20.6 API 5L API 5L GR.X-52 PSL2 BE, SAW
PIPE 24.000 24.000 19.1 API 5L API 5L GR.X-52 PSL2 BE, SAW
PIPE 28.00 28.00 22.2 API 5L API 5L GR.X-52 PSL2 BE, SAW
FLNG.WN 10.000 24.000 M B- 16.5 ASTM A 694 GR. F-52 (CHARPY) 600, RF/125AARH
FLNG.WN 28.000 30.000 M B-16.47-A ASTM A 694 GR. F-52 (CHARPY) 600,
RF/125AARH
ELBOW.90 02.000 8.000 M B-16.9 ASTM A 234,GR. WPB (CHARPY) BW, 1.5D
ELBOW.45 02.000 8.000 M B-16.9 ASTM A234, GR. WPB (CHARPY) BW, 1.5D
VLV.BALL 26.000 30.000 API-6D BODY-ASTM A 216 GR. WCC/ BW, 600, B-
A234 GR WPC, TRIM-SEAT AISI 16.25, RF/ 125
4140+0.003” ENP/ AISI 410 AARH
VLV.BALL 02.000 30.000 API-6D BODY-ASTM A 216 GR. WCC/ BW, 600, B-
A234 GR WPC, TRIM-SEAT AISI 16.25, RF/ 125
4140+0.003” ENP/ AISI 410 AARH
VLV.PLUG 00.500 01.500 BS-5353 BODY-ASTM A 105, PLUG-A 105 SW, 800 3000, B-
+0.003” ENP 16.11
VLV.PLUG 02.000 24.000 API-6D BODY-ASTM A 216 GR. WCB FLGD, 600, B-
PLUG-A 216 GR. WCB+0.003” 16.5, RF/ 125
ENP AARH
VLV.PLUG 02.000 24.000 API-6D BODY-ASTM A 216 GR. WCB BW, 600, B-16.5,
PLUG-A 216 GR. WCB+0.003” RF/ 125 AARH
ENP
Bolt Group(D1A)
Gasket Group(D1A)
SERVICE
NON CORROSIVE PROCESS-FLAMMABLE / NON-FLAMMABLE, NON-LETHAL-BELOW -29DEG C AND
UPTO -45 DEG C.HYDROCARBONS, XYLENE, METHANOL, NH3, GAS FLARE ETC.
NOTES
1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE
ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID.
2. NDT OF WELDS SHALL BE AS FOLLOWS:
3. PIPING DESIGN AS PER ASME B 31.8 & OISD 141 & 226
7. FOR DIMENSIONS OF HANDLE PROJECTION FOR SPACER & BLIND, REFER Std. SPEC.
S-05-01-007
SPECIAL NOTES
12.000
14.000
0.500
0.750
1.000
1.250
1.500
2.000
2.500
3.000
3.500
4.000
5.000
6.000
8.000
PIPE 00.500 00.750 S160 B 36.10 ASTM A 333 GR.6 PE, SEAMLESS
PIPE 03.000 14.000 STD B 36.10 ASTM A 333 GR.6 BE, SEAMLESS
FLNG.BLIND 00.500 14.000 B-16.5 ASTM A 350 GR. LF2 150, RF/125 AARH
FLNG.FIG.8 00.500 8.000 ASME- ASTM A 350 GR. LF2 150, FF/125 AARH
B16.48
SPCR &BLIND 10.000 14.000 ASME- ASTM A 350 GR. LF2 150, FF/125 AARH
B16.48
Fitting Group (A4A)
O’ let group(A4A)
SOCKOLET 00.500 0.750 MSS-SP97 ASTM A 350 GR.LF2 SW, 6000
VLV.GATE 00.500 01.500 API-602 BODY-ASTM A 350 GR. LF2, SW,800, 3000,B-
TRIM-STELLITED, STEM SS-304 16.11
SERVICE
NON CORROSIVE PROCESS-FLAMMABLE / NON-FLAMMABLE, NON-LETHAL-BELOW -29DEG C AND
UPTO -45 DEG C.HYDROCARBONS, XYLENE, PROPYLENE, LPG, METHANOL, NH3, GAS FLARE ETC.
NOTES
1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE
ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID.
2. NDT OF WELDS SHALL BE AS FOLLOWS:
3. PIPING DESIGN AS PER ASME B 31.8 & OISD 141 & 226
7. FOR DIMENSIONS OF HANDLE PROJECTION FOR SPACER & BLIND, REFER Std. SPEC.
S-05-01-007
SPECIAL NOTES
12.000
14.000
0.500
0.750
1.000
1.250
1.500
2.000
2.500
3.000
3.500
4.000
5.000
6.000
8.000
PIPE 00.500 00.750 S160 B 36.10 ASTM A 333 GR.6 PE, SEAMLESS
PIPE 03.000 10.000 STD B 36.10 ASTM A 333 GR.6 BE, SEAMLESS
PIPE 12.000 14.000 S40 B 36.10 ASTM A 333 GR.6 BE, SEAMLESS
FLNG. SW 00.500 1.50 M B-16.5 ASTM A 350 GR. LF2 300, RF/125 AARH
FLNG. WN 02.000 14.000 M B-16.5 ASTM A 350 GR. LF2 300, RF/125 AARH
FLNG.BLIND 00.500 14.000 B-16.5 ASTM A 350 GR. LF2 300, RF/125 AARH
FLNG.FIG.8 00.500 8.000 ASME- ASTM A 350 GR. LF2 300, FF/125 AARH
B16.48
SPCR &BLIND 10.000 14.000 ASME- ASTM A 350 GR. LF2 300, FF/125 AARH
B16.48
Fitting Group (B4A)
VLV.GATE 00.500 01.500 API- BODY-ASTM A 350 GR. LF2, SW,800, 3000,B-16.11
602 TRIM-STELLITED, STEM SS-
304
VLV.GATE 00.200 24.000 API- BODY-ASTM A 352 GR. LCB, FLGD,300, B16.5,
600 TRIM-STELLITED, STEM SS- RF/125AARH
304
VLV.CHECK 00.500 1.500 BS- BODY-ASTM A 350, GR.LF2, SW,800, 3000, B-16.11
5352 TRIM-STELLITED
VLV.CHECK 02.000 24.000 BS- BODY-ASTM A 352, GR.LCB, FLGD,300, B16.5, RF/125AARH
1868 TRIM-STELLITED
SERVICE
NON CORROSIVE PROCESS-FLAMMABLE / NON-FLAMMABLE, NON-LETHAL-BELOW -29DEG C AND
UPTO -45 DEG C.HYDROCARBONS, XYLENE, METHANOL, NH3, GAS FLARE ETC.
NOTES
1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE
ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID.
2. NDT OF WELDS SHALL BE AS FOLLOWS:
3. PIPING DESIGN AS PER ASME B 31.8 & OISD 141 & 226
7. FOR DIMENSIONS OF HANDLE PROJECTION FOR SPACER & BLIND, REFER Std. SPEC.
S-05-01-007
SPECIAL NOTES
12.000
14.000
16.000
18.000
0.500
0.750
1.000
1.250
1.500
2.000
2.500
3.000
3.500
4.000
5.000
6.000
8.000
PIPE 00.500 00.750 S160 B 36.10 ASTM A 333 GR.6 PE, SEAMLESS
PIPE 03.000 3.000 STD B 36.10 ASTM A 333 GR.6 BE, SEAMLESS
PIPE 12.000 12.000 19.0 B 36.10 ASTM A 333 GR.6 BE, SEAMLESS
PIPE 14.000 14.000 20.6 B 36.10 ASTM A 333 GR.6 BE, SEAMLESS
PIPE 16.000 16.000 22.2 B 36.10 ASTM A 333 GR.6 BE, SAW
PIPE 18.000 18.000 25.4 B 36.10 ASTM A 333 GR.6 BE, SAW
FLNG. SW 00.500 1.50 M B-16.5 ASTM A 350 GR. LF2 600, RF/125 AARH
FLNG. WN 02.000 18.000 M B-16.5 ASTM A 350 GR. LF2 600, RF/125 AARH
FLNG.BLIND 00.500 18.000 B-16.5 ASTM A 350 GR. LF2 600, RF/125 AARH
FLNG.FIG.8 00.500 8.000 ASME- ASTM A 350 GR. LF2 600, FF/125 AARH
B16.48
SPCR &BLIND 10.000 18.000 ASME- ASTM A 350 GR. LF2 600, FF/125 AARH
B16.48
Fitting Group (D4A)
VLV.GATE 00.500 01.500 API- BODY-ASTM A 350 GR. LF2, SW,800, 3000,B-16.11
602 TRIM-STELLITED, STEM SS-
304
VLV.CHECK 00.500 1.500 BS- BODY-ASTM A 350, GR.LF2, SW,800, 3000, B-16.11
5352 TRIM-STELLITED
VLV.PLUG 00.500 1.500 BS- BODY-ASTM A 350, GR.LF2, SW,800, 3000, B-16.11
5353 PLUG:A350 GR.LF2+0.003”
ENP
SPECIAL REQUIREMENT :
SERVICE
FIRE WATER (ABOVE GROUND / UNDER GROUND)
NOTES
1. FOR T-TYPE BW STRAINERS, REFER STD. NO.S-05-01-008 & S-05-01-009
2. FORGINGS ARE ACCEPTABLE IN LIEU OF PLATE MATERIAL.
3. SIZES GIVEN IN PMS ARE NOMINAL BORE FOR O.D. OF IS 3589 PIPES REFER ANSI B36.10.
4. BUTTERFLY VALVE SHALL BE LUGGED WAFER TYPE UP TO 24” AND DOUBLE FLANGED
BODY FOR SIZES BEYOND 24”.
5. PIPE THICKNESS ARE JOB SPECIFIC BASED ON THE SOIL PROPERTIES OF JOB SITE AND
DEPTH OF TOP OF PIPE OF 1.5M. NO LIVE LOAD HAS BEEN CONSIDERED FOR CALCULATION
OF PIPE THICKNESS. LIVE LOADS WHEREVER EXPECTED SHALL BE SUITABLY TAKEN CARE
OF.
6. NDT REQUIREMENT SHALL BE SAME AS FOR CLASS A1A OF GAIL STANDARD S-05-02-012
AND TAC REQUIREMENT FOR RADIOGRAPHY SHALL ALSO BE COMPLIED WITH.
SPECIAL NOTES
12.000
14.000
0.500
0.750
1.000
1.250
1.500
2.000
2.500
3.000
3.500
4.000
5.000
6.000
8.000
Flange Group(A93A)
SPCR &BLIND 10.000 14.000 ASME- ASTM A 105 150, FF/125 AARH
B16.48
Fitting Group(A93A)
ELBOW.90 02.000 6.000 STD B-16.9 ASTM A 234 GR.WPB BW, 1.5D
ELBOW.45 02.000 6.000 STD B-16.9 ASTM A 234 GR.WPB BW, 1.5D
Valves Group(A93A)
VLV.BTRFLY 02.000 24.000 BS-5155 BODY-ASTM A 216 GR. WCB, WAFL, 150, B16.5,
TRIM-13% CR.STEEL, WAF/ 125AARH
Gasket Group(A93A)
CORROSION ALLOWANCE : 0 MM
SPECIAL REQUIREMENT :
SERVICE
POTABLE WATER (ABOVE GROUND), FIRE WATER-SPRINKLER SYSTEM AFTER ORIFICE
NOTES
1. NDT REQUIREMENTS AS PER GAIL STANDARD – S-05-02-012
2. THREADED JOINTS SHALL BE MADE WITH 1” WIDTH PTFE JOINTING TAPE.
3. SURFACES WHERE GALVANISING HAS BEEN BURNT OFF SHALL BE WIRE BRUSHED AND
COLD GALVANISED WITH ZINC COATING COMPOUND.
SPECIAL NOTES
1.000
1.250
1.500
2.000
2.500
3.000
3.500
4.000
5.000
6.000
Flange Group(J2A)
FLNG. SCRD 00.500 06.00 B-16.5 ASTM A 105 (GALV.) 150, FF/125 AARH
FLNG.BLIND 00.500 06.000 B-16.5 ASTM A 105 (GALV.) 150, FF/125 AARH
FLNG.FIG.8 00.500 06.000 ASME- ASTM A 105 (GALV.) 150, FF/125 AARH
B16.48
Fitting Group(J2A)
Valves Group(J2A)
VLV.GATE 00.500 01.500 IS:778 BODY-IS 318 GR.2 LEADED SCRF, CL.2, 3000, B-
CL.2 TIN BRONZE, TRIM-IS320 1.20.1
ALLOY HT2
VLV.GLOBE 00.500 01.500 IS:778 BODY-IS 318 GR.2 LEADED SCRF, CL.2, 3000, B-
CL.2 TIN BRONZE, TRIM-IS320 1.20.1
ALLOY HT2
VLV.CHECK 00.500 1.500 IS:778 BODY-IS 318 GR.2 LEADED SCRF, CL.2, 3000, B-
CL.2 TIN BRONZE, TRIM-IS320 1.20.1
ALLOY HT2
VLV.CHECK 02.000 6.000 IS:5312 BODY-IS 210 GR.FG 200, FLGD, PN1.6, B-16.1,
(PT-1) TRIM-IS 320 ALLOY HT2 FF/125AARH
Bolt Group(J2A)
Gasket Group(J2A)
GASKET 00.500 6.000 B16.21- BUTYL RUBBER FULL FACE, 150, 2MM
ANSI
B16.5
LIST OF ATTACHMENTS
LIST OF DATASHEETS
For Mainline Items, corrosion allowance shall be 0.0 mm except for scraper traps where 3
mm corrosion allowance shall be taken.
FOR
TRANSPORTATION OF GAS
1.0 SCOPE
10.0 WELDING
The requirements stated herein shall be followed for the fabrication of all types of
welded joints of carbon steel main pipeline system and related facilities.
a) All line pipe joints of the longitudinal and circumferential butt-welded and
socket welded types.
b) Attachments of castings, forgings, flanges and other supports to pipes.
c) Welded manifold headers and other sub-assemblies.
d) Welded branch connections.
e) Joints in welded/fabricated piping components.
f) The attachments of smaller connections for vents, drain drips and other
instrument tappings.
Any approval granted by the COMPANY shall not relieve the CONTRACTOR of his
responsibilities and guarantees.
All welding work, equipment for welding, heat treatment, other auxiliary functions
and the welding personnel shall meet the requirements of the latest editions of the
codes, standards and specifications listed below:
a) Code for Gas Transmission and Distribution Piping Systems, ANSI B31.8.
c) Specification for Welding Electrodes and Filler Materials, ASME Sec. II Part C
a) The CONTRACTOR shall provide at his own expense all the welding consumables
necessary for the execution of the job such as electrode/filler wire, oxygen,
acetylene etc. and these shall bear the approval of the COMPANY.
c) The welding consumables shall suitable for the welding process recommended
and the base metal used. The physical properties of the welds produced by an
electrode/ filler wire recommended for the welding of a particular base metal
shall not be lower than the minimum values specified for the base metal, unless
otherwise specified in the welding specification chart and shall correspond to the
physical properties of the class of electrode/ filler wire adopted. The choice of
welding consumables shall be made after conducting the required tests on the
electrode/ filler wire as per relevant standards, and shall be the sole prerogative
of the COMPANY.
d) The CONTRACTOR shall submit batch test certificate(s) from each electrode/
filler wire manufacturer(s) furnishing all details of physical and chemical tests
carried out by them for each batch of electrodes to be used.
e) Electrode/ filler metal qualification test records shall be submitted as per the
attached Exhibit-A in respect of the electrodes/filler metal tested by the
CONTRACTOR for obtaining the approval from the COMPANY.
g) The welding consumables used shall be free from rust, oil, grease, earth and
other foreign matter, which affect the quality of welding.
h) Shielding Gas
The composition and the purity of the shielding gas required by the welding
GMAW and FCAW processes shall bear the approval of the COMPANY. An
appropriate gases or gas mixture of the following quality shall be used.
The CONTRACTOR shall have sufficient number of welding and cutting equipment,
auxiliaries and accessories of sufficient capacities to meet the target schedules.
5.1 All the equipment for performing the preheating or heat treatment, including
transformers, thermocouples, pyrometers, automatic temperature recorders with
suitable calibration arrangements, etc. shall be provided by the CONTRACTOR, at
his own expense and these shall bear the approval of the COMPANY. Adequate
means of measuring current and voltage shall be available.
5.2 Redoing of any work necessitated by the faulty equipment or due to the wrong
operation carried out by the CONTRACTOR shall be done at his own expense.
6.1 Welding of various materials under this specification shall be carried out using the
following process.
6.1.1 Main Line 18”Ø Sultanpur-Neemrana Pipeline, 12”Ø Bhiwadi Line, 10” Ø Manesar
line & 10” Gurgaon Line Semi-automatic Flux Cored Arc Welding for fill and cap
passes, with root pass welding by Surface Tension Transfer Process (STTP) or Gas
Tungsten Arc Welding (GTAW) process and Manual SMAW where Semi-Automatic is
not possible.
6.1.2 However semiautomatic welding processes shall be employed only with the
approval of Engineer-in-Charge. Welding procedure shall be adopted and
consumables used shall be specifically approved. A combination of different welding
process could be employed for a particular joint only after duly qualifying the
welding procedure to be adopted and obtaining the approval of Engineer-in-Charge.
6.1.4 Double jointing of two pipe lengths using Submerged Arc Welding (SAW) process in
a specially laid pipe welding yard is also permitted.
Any deviation desired by the CONTRACTOR shall be obtained through the written
consent of the COMPANY.
6.2 The welding procedure adopted and the consumables used shall be specifically
approved.
The line pipe supplied by the COMPANY shall have bevel ends as specified in the
applicable specification for the line pipe attached with the Bid Package. Any
modification thereto, if required by the CONTRACTOR due to the specific welding
technique, shall be carried out by the CONTRACTOR at his own cost. Before
welding, all the rust and foreign matter shall be removed from the bevelled-ends by
power operated tools. Bevel cleaning shall be effected both inside and outside and
for a minimum distance of 25 mm from the edge of the weld bevel. The bevels shall
be thoroughly inspected at this stage. If any of the ends of the pipe joint is
damaged to the extent that satisfactory weld spacing cannot be obtained and local
repair by grinding cannot be successfully done, the damaged end shall be cut and
re-bevelled with an approved bevelling machine to the satisfaction of the
COMPANY. Manual cutting and weld repairs of bevels is not allowed. Should
laminations, split ends or inherent manufacturing defects in the pipe be discovered,
the lengths of pipe containing such defects shall be removed. For such pipes, the
new bevel shall be examined 100% visually and 100% by dye-penetrant or MPI
method. A report shall examined 100% visually and 100% by dye-penetrant or MPI
method. A report shall be generated after carrying out the tests and submitted to
the COMPANY for approval.
Immediately prior to line-up, the CONTRACTOR shall inspect the pipe ends both
inside and outside for damages, dents, laminations etc. Pipe for welding shall be set
up, correctly spaced, allowing for the temperature changes during welding.
Incorrect alignment shall in no circumstances be sprung into position. Temporary
attachments of any kind shall not be welded to the pipe. Welds joining the sections
of the pipeline, valve installation or similar welds classified as tie-in welds shall be
made in the trench. Otherwise the alignment and welding shall be made alongside
the ditch with the pipe supported on skids and pack pads or other suitable means
approved by COMPANY, for at least 500 mm length above the ground, unless
approved otherwise by the COMPANY in specific cases. Seam orientation of welded
pipes shall be selected to ensure that, at the circumferential welds, the longitudinal
welds shall be staggered in the top 900 of the pipeline, or 250 mm whichever is the
lesser. A longitudinal joint shall pass an appurtenance of a structural element at a
minimum distance of 50 mm. Should a section of the line containing uncompleted
welds fall from the skids, the CONTRACTOR shall immediately inform the
COMPANY.
Every effort shall be made to reduce misalignment by the use of the line-up clamp
and rotation of the pipes to the best fit. For pipe of the same nominal wall
thickness, the offset shall not exceed 1.6 mm. The offset may be checked from
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outside using dial gauges. Any branch connection sleeve, etc. shall be at least 150
mm from any other weld. The welds for fittings shall be so located that the toe of
the weld shall not come within 50 mm of the toe of any other weld. Cold
adjustment is permissible only in cases of slight misalignment and may only be
carried out with a bronze headed hammer. Hot adjustment shall not be permitted.
When welding pipes of different wall thickness is permitted by the COMPANY, a
special transition piece shall be used. This shall have a minimum of 1:4 taper. The
weld in the transition piece shall be subjected to both Ultrasonic and Radiography
Testing.
The root gap shall be accurately checked and shall conform to the qualified welding
procedure. The use of internal line-up clamps is mandatory for pipe diameters 10”
and above. However, in some cases (tie-in welds, flanges, fittings, diameter of
pipe10” etc.) where it is impossible to use internal clamps, an external line-up
clamp maybe used.
The internal line-up clamp shall not be released before the entire first pass has
been completed.
When an external line-up clamp is used, all the spaces between the bars or at least
60% of the first pass shall be welded before the clamp is released and the pipe
shall remain adequately supported on both sides of the joint.
Segments thus welded shall be equally spaced around the circumference of the
pipe. Slag, etc. shall be cleaned off and the ends of the segments shall be prepared
by grinding, so as to ensure continuity of the weld bead.
The parts being welded and the welding personnel shall be adequately protected
from rain and strong winds. In the absence of such protection, no welding shall be
carried out. The completed welds shall be suitably protected in case of bad weather
conditions.
10.0 WELDING
a) The root pass shall be made with the electrodes/filler wires recommended in
the welding specification chart attached. The size of the electrodes used shall be
as per the qualified welding procedure.
b) Position or roll welding (for yard doubler jointing) may be permitted. Separate
procedures shall be submitted and qualified for up hill, down hill, vertical down
and roll welding. The vertical up method of welding shall be used for the root
pass of the tie-ins, special crossings, fittings and special parts, fillet welds,
repairs and when an external line up clamp is used. The down hill welding may
be used for the root run welding of tie-ins and special crossings when (a) the
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edges are machined or have equivalent preparation, (b) line up clamps are used
and the fit up is geometrically and mechanically similar to one of the ordinary
line welding without misalignment or unevenness.
c) The root pass of butt joints shall be executed properly so as to achieve full
penetration with complete fusion of the root edges. Weld projection inside the
pipe shall not exceed 1.6 mm wherever not specified by the applicable code.
g) While the welding is in progress, proper care shall be taken to avoid any kind of
movement of the components, shocks, vibration and stresses to prevent
occurrence of weld cracks.
h) Fillet weld shall be made by Shielded Metal Arc Welding (SMAW) process,
irrespective of the thickness and class of piping. SMAW electrode size shall not
exceed 3.25 mm diameter for the socket joint. At least two passes shall be
made on the socket weld joint.
The first pass shall be carried out by a minimum of two welders/welding heads,
working simultaneously and so placed as to cause minimum distortion of the pipe.
The number of welders/ welding heads and the allowable welding sequences shall
be as those laid down in the Qualified Welding Procedure Specification (QWPS).
Once the deposit of the first pass has been started, it must be completed as rapidly
as possible, reducing interruptions to the minimum. The welding and wire speed
shall be approximately same as that established in the QWPS.
The pipe shall always be adequately supported and must not be bumped or shaken
during welding. The clamp shall be removed as indicated in Clause 8.0. Before
starting the second pass, the first pass shall be cleaned and flattened with rotating
grinders.
The interruption between the completion of the first pass and the starting of the
second pass shall be as per the qualified welding procedures.
The time lapse between the second and the third pass shall be as stated in the
procedure specification, normally not exceeding five minutes. After completion of
the third or following passes, welding operations may be suspended to allow the
joint to cool down, provided the thickness of the weld metal deposited is equal to at
least 50% of the pipe thickness. Upon restarting, depending on the materials, wall
thickness and welding process, a preheating of at least 1000C shall be applied.
Subsequent passes up to weld completion shall be protected to avoid rapid cooling,
if meteorological conditions so dictate. Cleaning between the passes shall be done
carefully to reduce the possibility of inclusions.
The weld bead starting and finishing points shall be staggered from pass to pass.
Arc-strikes outside the bevel on the pipe surface are not permitted. Arc-strike or arc
burn on the pipe surface outside the weld, which are caused accidentally by
electrical arcs between the electrode, electrode holder, welding cable or and the
pipe shall be removed by grinding in accordance with a procedure approved by the
COMPANY and the repair area shall be checked by Ultrasonic or Magnetic Particle or
Dye-Penetrant testing approved by the COMPANY. The pipe wall thickness after
grinding shall not be less than the minimum thickness permitted for the pipe.
Repair of arc strikes by welding is prohibited.
The completed weld shall be carefully brushed and cleaned and shall appear free
from spatters, scales, etc.
The above requirements apply not only to the completed welds but also to the bare
strip at least so wide as to allow full skid examination at both ends of the pipe for a
good Ultrasonic inspection when it is required.
11.0 PREHEATING
a) Preheating requirements for the various materials shall be as per the welding
specification charts.
c) Preheating shall extend uniformly to at least three times the thickness of the
joint, but not less than 50 mm, on both sides of the weld.
d) Preheating temperature shall be maintained over the whole length of the joint
during welding. Temperature indicating crayons or other temperature indicating
devices shall be provided by the CONTRACTOR to check the temperature.
12.1 General
a) The Inspector authorized by the COMPANY shall have free access to all the
concerned areas, where the actual work is being performed. The CONTRACTOR
shall also afford the Inspector all means and facilities necessary to carry out
inspection.
b) The COMPANY is entitled to depute its own Inspector to the shop or field where
pre-fabrication and erection of pipelines are being done, with the following
objectives, but not limited to:
b) COMPANY’S Inspector will review, check and approve the welding procedure
specification submitted and shall release the procedure for procedure
qualification tests. The procedure qualification test shall be carried out by the
CONTRACTOR under field conditions at his own expense. A complete set of the
test results in format as per Exhibit-C attached shall be submitted to the
COMPANY’S Inspector for approval, immediately after completing the procedure
qualification test and at least two (2) weeks before the commencement of actual
work. Standard tests as specified in the code shall be carried out in all cases. In
addition to these tests, other tests like Ultrasonic examination, Radiography,
Macro/Micro examination, Hardness tests, Dye- Penetrant examination, Charpy
V-notch etc. shall be carried out on the specimens following the respective
qualified procedures. It shall be the responsibility of the CONTRACTOR to carry
out all the tests required to the satisfaction of the COMPANY’s Inspector. The
destructive testing of welded joints shall be as per Annexure -1.
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12.3 Welders’ Qualification
a) Welders shall be qualified in accordance with the API 1104 and other
applicable specifications by the CONTRACTOR at his expense. It shall be the
responsibility of the CONTRACTOR to carry out qualification tests of welders.
The butt weld test pieces of the qualification test shall meet the
nondestructive examination requirements specified in Clause 12.5 and
Annexure- 2, 3, 4 (as applicable) of this specification. The COMPANY’s
Inspector shall witness the test and certify the qualification of each welder
separately. Only those welders who have been approved by the COMPANY’s
Inspector shall be employed for actual welding. The CONTRACTOR shall
submit the welder qualification test reports in the standard format as shown
in Exhibit-D and obtain written approval, before commencement of work.
b) The welders shall always have in their possession the identification card as
shown in Exhibit-E and shall produce it on demand by the COMPANY’s
Inspector. It shall be the responsibility of the CONTRACTOR to issue the
identity cards after the COMPANY has duly certified it.
COMPANY shall carry out inspection of all welds as per the latest editions of the
applicable codes and specifications. All finished welds shall be visually inspected for
parallel and axial alignment of the work, excessive reinforcement, concavity,
shrinkage, cracks, under-cuts, dimensions, surface porosity and other surface
defects. Undercutting adjacent to the completed weld shall not exceed the limits
specified in the applicable code/standard.
12.5.1 The non-destructive examination of one hundred percent (100%) girth welds shall
be carried out.The non-destructive examination shall mainly consist of examination
using Automated Ultrasonic Testing (AUT) as detailed in Annexure-3. This shall be
applicable for all welds made by automatic GMAW process with narrow gap edge
preparation and welds made by semi-automatic FCAW process. The CONTRACTOR
shall make all the arrangements for the AUT of work covered by the specification at
his expense. The CONTRACTOR shall furnish all the reports to the COMPANY,
immediately after examination together with the corresponding interpretation
reports on the approved format. The details of the AUT reports along with the joint
identification number shall be duly entered in a register and signed by the
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CONTRACTOR and submitted to the COMPANY for approval. The COMPANY will
review all the AUT records of welds and inform the CONTRACTOR to those welds,
which are unacceptable. The decision of the COMPANY shall be final and binding in
this regard. All the requirements mentioned in the specification shall be arranged
and executed by the CONTRACTOR through his own resources. In addition,
Radiography examination shall be required in the following cases as per Annexure-4
of this specification:
a) On the first 100 welded joints corresponding to each automatic GMAW and
semi automatic FCAW welding procedures used.
12.5.2 All other welds made of FCAW and SMAW processes and the Tie-in joints having
API bevel shall be examined by Radiography. When Radiography is used, the
provisions stated in this para shall be applicable.
- For all production welds, X-ray Radiography by internal crawlers be used. Welds
shall meet the standards of acceptability as set forth in API 1104 and as well as
the requirements laid in subsequent paragraphs.
The CONTRACTOR shall make all the arrangements for the Radiography
examination of work covered by the specification at his expense. The COMPANY
will review all the radiographs of welds and inform the CONTRACTOR regarding
unacceptable welds. The decision of the COMPANY shall be final and binding in
this regard.
12.5.3 All the requirements mentioned in the specification shall be arranged and
executed by the CONTRACTOR through his own resources. In addition,
Ultrasonic inspection is required in the following cases as per Annexure-2 of this
specification:
Weld quality as judged on the basis of the acceptability criteria mentioned below:
ii) In addition to the API 1104 requirements, the welds containing cracks.
including crater cracks regardless of size or location are unacceptable.
Suitable records shall be maintained by the CONTRACTOR on the day to day
work done on welding Radiography, Ultrasonic testing. The CONTRACTOR
shall present the records to the COMPANY on day-to-day basis and whenever
demanded, for approval.
Welds cut out for defects or for other reason may be subjected to destructive
testing. The re-execution of welds shall be carried out by the CONTRACTOR at his
own expense. If the results are unsatisfactory, the welding operations shall be
suspended and may not be restarted, until the causes have been identified and the
suitable measures that guarantee acceptable results have been adopted by the
CONTRACTOR. If it is necessary in the COMPANY’s opinion, the procedure shall be
re-qualified. The weld joint represented by unsatisfactory welds shall stand
rejected, unless investigation proves otherwise.
13.1 With the prior permission of COMPANY welds, which do not comply with the
standards of acceptability, shall be repaired or the joint cut out and re-welded.
Root sealing or single pass repair deposits shall not be permitted at the root. The
internal root defects shall be ground out thoroughly and weld repaired with a
minimum of two layers, with the last layer ground off. However, while grinding for
repairs, care shall be taken to ensure that no grinding marks are left on the pipe
surface anywhere.
The repair shall be subjected, as a minimum requirement to the same testing and
inspection requirements as the original weld. Re-Radiography of the repaired area
shall be carried out. In addition, a minimum of 6” weld on either side of the repaired
area shall be subjected to re-Radiography. A 100% Ultrasonic testing shall be done at
the repaired area externally. Any repaired area that is wide, irregular or rough shall
be rejected and a full cut out shall be done. Single pass repairs shall be subjected to
100% Dye-Penetrant/MP testing.
Repairs are limited to a maximum of 30% of the weld length. Not more than two
repairs are permitted on the same location. All repairs shall be carried out the day
after initial Radiography or earlier. A full report of all repairs made shall be submitted
every day to the COMPANY.
After satisfactory completion of all visual and non-destructive testing, the procedure
test weld shall be set-aside for a period not less than 24 hours. No further work on
the test weld and no cutting of test specimens from the weld shall be performed
until a period of at least 24 hours has expired. Having passed the visual and the
nondestructive inspection, the test weld shall be subjected to mechanical test.
Weld specimens shall be taken from the positions indicated in FIG.1 & 1A of this
specification from areas as free from defects as possible and for this reason it is
necessary to take the previous non-destructive testing report into account. The
minimum number of tests to be carried out is given in Table-1 of this specification.
The test shall be carried out at laboratories approved by the COMPANY. The
specimens shall be prepared in accordance with the figures given in the
paragraphs that refer to the individual test.
Specimens shall be taken from the position indicated in FIG.1, FIG.1A of this
specification. Two (2) ISO type specimens and two (2) API type specimens shall be
taken. The ISO test specimens are shown in FIG.2 of this specification.
1.2.1 Method
The test shall be carried out in accordance with ISO 375.
1.3.1 Preparation
Specification for Nick-Break test with notches thus worked can break in the base
metal, instead of in the fusion zone. Therefore, an alternative test piece may be
used after authorization by the COMPANY with a notch cut in the reinforcement of
outside weld bead to a maximum depth of 1.5 mm measured from the surface of
the weld bead.
1.4.1 Preparation
Specimens shall be taken from the positions indicated in FIG.1 of this specification
and shall be prepared in accordance with ASTM E2 and E3.The width of the
macro section has to be at least three (3) times the width of the weld. The section
is to be prepared by grinding and polishing and etched to clearly reveal the weld
metal and heat affected zone.
1.4.2 Method
1.4.3 Requirements
1.5.1 Preparation
The prepared macro section is to be used for hardness testing using the Vickers
method with 10 kg load. Indentations are to be made along traverses each
approximately 1.0 mm below the surface at both side of the weld.
In the weld metal, a minimum of 6 indentations equally spaced along the traverses
are to be made. The HAZ indentations are to be made along the traverses for
approximately 0.5 mm each into unaffected material, and starting as close to
the fusion line as possible.
One indentation at each side of the weld along each traverse has to be made on
parent adjacent region as well as on the opposite side of the macro section along
the specified traverses.
1.5.2 Method
The test shall be carried out in accordance with recommendation ISO R81, Vickers
hardness, using a laboratory type machine controlled as pre-recommendation ISO
R146 and using a diamond pyramid penetrator set at 2.37 rad (136") with a load
of 10 kg.
1.5.3 Requirements
Hardness value shall not exceed the limit specified in welding specification chart. In
case of a single reading strictly (+10HV) higher than the specified limit, further
indentations shall be made to check if the high value was an isolated case. All the
measured hardness values of the heat-affected zone shall not exceed 100 HV
with respect to the average hardness value of the base metal. If the additional
tests give hardness value within the specification limit, the slightly higher value may
be accepted.
1.6.1 Specimens shall be taken from the position indicated in FIG.1 of this specification.
The test specimens will be prepared in accordance with ISO R 148. Charpy V-
Notch specimens shall have dimensions as given in Fig.3 of the specification.
Three (3) test specimens shall be taken from each sample and they shall be
cut and worked so that their length is transversal and perpendicular to the
weld bead with the notch position as shown in FIG.4 of this specification. The
notch shall be perpendicular to the roller surface. The test specimen width
shall depend upon the pipe wall nominal thickness as per the following table:
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1.6.2 Test Method
The test shall be carried out as indicated in ISO R148 “Beam Impact Test V-Notch”.
Test pieces shall be immersed in a thermostatic bath and maintained at the test
temperature for at least 15 minutes. They shall then be placed in the testing
machine and broken within 5 seconds of their removal from the bath. The test
temperature shall be as mentioned in welding specification chart.
1.6.3 Requirements
Note 1: These values are specified for resistance to brittle fracture only. Where
additional requirements are specified in project data sheet, as for example,
pipeline material with arrest properties i.e. a higher upper shelf Charpy
V Notch energy for resistance against propagating ductile fractures, the
same shall be followed.
Note 2: Only one value is permitted to be lower than average value up to the
value specified.
The Bend test specimens shall be made and tested as per the requirements of API
1104, Nineteenth Edition, September 1999. The dimensions of the Jig for guided
bend test in Figure.9 of API 1104 shall be modified as specified below:
The acceptance criteria shall however be as per para 5.6.4.3 and 5.6.5.3 of API
1104 Nineteenth edition, September 1999.
1.1 GENERAL:
The CONTRACTOR who carries out the Ultrasonic inspections shall have sufficient
no. of qualified personnel, equipment and instruments at his disposal to be carried
out the tests without hindering or delaying the pipeline assembly operations.
The CONTRACTOR appointed shall supply all the requisite instruments to carry out
Ultrasonic inspection at site.
This specification shall state the following information including all the parameters
described in API 1104:
c) Frequency range
e) Coupling medium
f) Inspection technique
I) Record details.
Circumferential welds shall be inspected from both sides using angle probes.
The surface with which the probe comes into contact shall be free of metal
spatter,dirt, iron oxide, and scales of any type. Therefore, it shall be necessary to
clean a strip at least 50 mm wide on both sides of the weld with steel-wire brushes.
The cleaned strip must be at least wide enough to allow one and a half skip
examination.
If echoes of doubtful origin appear during the test, it shall be necessary to inspect a
convenient area on the pipe surface close to the weld, with a straight beam
transducer in order to check whether any manufacturing defects are interfering with
the ultrasonic beam.
The characteristics of the above listed instruments and equipment shall guarantee:
b) Continuous operation.
All the instruments and equipment shall be approved by the COMPANY before being
used. The COMPANY has the authority to reject any item that is considered
unsuitable. The decision of the COMPANY is final. The CONTRACTOR appointed
to carry out Ultrasonic inspections shall also ensure the operational efficiency
and maintenance of the instruments and equipment, and shall immediately
substitute any item rejected by the COMPANY.
1.6 PROBES
The probes used shall have dimensions, frequencies, and a refraction angle suited
to the type of steel, the diameter, and the thickness of the pipeline and to the joint
design.
The efficiency of the equipment, the effective refraction angle of the probe, and the
beam output point shall be checked using a V1 and V2 sample block, IIW type or
the calibration block ASTM E-428. For manual Ultrasonic testing and automated
Ultrasonic testing, the reference sample pieces shall be as described in API
1104, Nineteenth Edition, para 11.4.5.
1.7 CALIBRATION
The operators shall be fully qualified as per a recognized standard (ASME Sec V or
equivalent) and they shall have as minimum level II as described in para 11.4.3,
API 1104, Nineteenth Edition.
The COMPANY has the option of checking the ability of personnel employed for
Ultrasonic testing by means of qualification tests.
Each time that echoes from the weld bead appear during production testing, the
instrument amplification shall be altered to coincide with the reference
amplifications and the probe shall be moved until maximum response is
obtained, paying attention all the time to the probe-tube coupling.
If, under these conditions, the height of the defect echo is equal to or greater than
that of the reference echo, the defect shall be evaluated according to clause 12.5 of
this specification. If the defect has also been detected by the Radiography and/or
Visual examination, the dimensions shall be judged according to the type of
examination that detects the greater defect. Returns that are less than 50% of the
reference echo will not be considered. If returns are above 50% but lower than
100% of the reference echo, and if the operator has good reasons to suspect that
the returns are caused by unfavorably oriented cracks, he shall inform the
COMPANY. Moreover, when there is a defect to be repaired, such defect shall be
removed for a length corresponding to the one where no more return echo is
given.
1.0 INTRODUCTION
5.0 COUPLING
7.0 CALIBRATIONS
8.0 PROCEDURE
The specification shall be applicable for Automated Ultrasonic Testing (AUT) system
suitable for pipeline girth welds. The system shall be based on focused pulse-echo,
tandem or through transmission methods enhanced with mapping image and
augmented by Time Of Flight Diffraction (TOFD) technique.
Automated Ultrasonic Testing (AUT) systems and agencies who have proven track
record and have done a single project of diameter 20” or above and minimum
length of 50 km and also have inspected a cumulative length of 500
km or above on large diameter Pipe lines in the last ten years shall be accepted.
The agency should have been approved by the reputed inspection agencies.
The track record shall be submitted to the COMPANY for approval prior to
engagement.
The system shall meet and exceed the requirements of ASTM E1961-98.
5.0 COUPLING
The coupling shall be obtained by using a medium suitable for the purpose. It shall
be suitable for the temperature used. No residue shall remain on the pipe
surface. A method should be employed to determine that constant coupling is
achieved during examination. An examination of the test piece with its surface
wiped dry should produce a record showing an absence of the couplant recording
signal.
The search unit shall meet all the requirements specified in Para 6.4 of ASTM
E1961- 98.
7.0 CALIBRATIONS
The system shall be optimized and calibrated as stated in Para 7.0 and 8.0 of ASTM
E 1961-98. Static and Dynamic calibration shall be done and the approved
procedure shall clearly state the gain setting fixed for each channel.
The reference standard should be used to verify the scanning sensitivity at the
start of each shift and thereafter at intervals not exceeding two (2) hours or ten
(10) welds.
a) The calibration of an inspection function differs more than +/- 3dB from the
previous calibration
b) The gate settings need to be adjusted with more than +/- 1.5 mm with the
previous calibration – i) after a weld repair, ii) after equipment breakdown.
In case the calibration differs from the initial setting, outside the given tolerances,
the applicable probe(s) coupling shall be checked. If the calibration has to be
changed, the welds before this calibration up to the previous calibration will be
reexamined.
8.0 PROCEDURE
A detailed AUT procedure shall be prepared and qualified for each wall thickness
and joint geometry to be examined prior to the start of any NDT work. Repair
procedure shall be separately qualified for each joint geometry. All the requirements
of ASTM E1961-98 should be met. The procedure as a minimum shall include the
following:
With each transducer positioned for the peak signal response from the calibration
reflector the detection gates are to be set. The gate shall start 2-6mm
(allowance for width of heat affected zone) before the theoretical weld bevel
preparation. The gate ends shall be after the theoretical weld centerline. All
gates will be programmed to record amplitude and/or transit distance information.
The TOFD gate start will be set 1 µSec before the arrival of the lateral wave and
should extend up to the first back wall echo to achieve full cover of wall thickness.
With each transducer positioned for the peak signal response from the calibration
reflector (flat bottom holes), the detection gates are to be set. In this position, the
probe holder is fixed to the probe frame. The equipment sensitivity (echo
amplitude) for all inspection channels shall be set at 80% Full Screen Height (FSH).
Mapping channels in the body of the weld will be used to detect the presence of
porosity and in addition to identify the position of the weld cap reinforcement for
pattern recognition purpose. The sensitivity as a minimum is equal to the related
pulse- echo channels, increased with additional gain to ensure proper detection.
Mapping channels in the root will be used to identify the position of the root
penetration for pattern recognition purpose. The sensitivity as a minimum shall be
equal to the related pulse-echo channels, increased with additional gain to ensure
proper detection. he lateral wave of the TOFD channel sensitivity is set at 80%
FSH.
All the requirements stated in Para 9 and 10 of ASTM E1961-98 shall be followed a
minimum.
11.1 General
With the transit distance measurements and with the information from the mapping
and TOFD channels visible on the result presentation, indications shall be judged
whether they are from the weld geometry or from the defects. The coupling
channels will check for coupling loss; in case of coupling loss, a re-scan shall be
carried out.
Welds shall be evaluated using both the pulse-echo and TOFD criteria shown below.
This shall be performed in parallel and rejection against either of these criteria
shall be cause for rejection of the weld. The exceptions to this are described in
the following notes:
1. All indications in the pulse echo channels should be evaluated which exceed
the threshold level of 20% FSH.
2. Defect length shall be measured for the pulse-echo channels from the point
where the signal exceeds 20% FSH to the point the signal falls below. The
largest height assessed with TOFD or the greatest measured
amplitude with pulse-echo shall be assumed to apply over the whole defect
length.
3. If the indication cannot be resolved by TOFD i.e. the upper and lower flaw
diffraction tips cannot be separately distinguished, no measurement
can be made to determine the defect height. In this case, the
signal from the pulse echo channels will be solely used to determine that
particular area of the scan.
4. Defects shall be assessed for interaction as follows:
a) Horizontal interaction
If the distance between two adjacent defects is less than the length of
the smaller of the two defects, then the defect shall be treated as a
single defect.
b) Vertical interaction
Vertical interaction of defects shall be assessed using TOFD. If the
distance between the two adjacent defects is less then the height of
the shorter of the two defects, than the defect shall be treated as a
single defect. Where the individual defects cannot be resolved by
TOFD for the vertical interaction, then the defects are assumed to
interact and shall be treated as a single defect.
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Copyright GAIL – All rights reserved
5. The maximum allowable accumulated defect length shall be as per the
criteria given in welding specification para 12.5.1.
Weld quality shall be judged on the basis of the acceptability criteria mentioned in
Para 12.5.1 of welding specification.
This annexure covers the Radiography Testing of all types of welded joints of the
main pipeline.
3.0 PROCEDURE
i) Lead foil intensifying screens, at the rear of the film shall be used for all
exposures.
iv) A densitometer shall be used to determine film density. The transmitted film
density shall be between 2.0 and 3.5 throughout the weld. The unexposed
base density of the film shall not exceed 0.30.
3.5 All the girth welds of mainline shall be subjected to 100% Radiography
examination. The CONTRACTOR shall furnish all the radiographs to the COMPANY,
immediately after processing them, together with the corresponding interpretation
reports on approved format. The details of the radiographs along with the joint
identification number shall be duly entered in a register and signed by the
CONTRACTOR and submitted to the COMPANY for approval.
3.6 When the radiation source and the film are both on the outside of the weld and
located diametrically opposite each other, the maximum acceptable length of film
for each exposure shall not exceed the values given. The minimum film overlap, in
such cases, shall be 40mm. The ellipse exposure technique may be used on
nominal pipe sizes of 2 inch and smaller provided that the source of film distance
used is a minimum of 12 inch.
3.7 Three (3) copies of each acceptable Radiography procedure (as per Exhibit-F) and
three (3) copies of Radiography qualification records, shall be supplied to
COMPANY. One set of the qualifying radiographs on the job shall be kept by the
CONTRACTOR's authorized representative to be used as a standard for the quality
of production Radiography during the job. The other two sets shall be retained by
COMPANY for its permanent record.
3.8 Three (3) copies of the exposure charts relating to material thickness, kilo voltage,
source to film distance and exposure time shall also be made available to COMPANY
by the CONTRACTOR.
3.9 The CONTRACTOR shall record for each radiograph on a daily basis (1) radiograph's
number, (2) approximate chainage of weld location, (3) whether or not the welds
meet the specified acceptance standards, and (4) the nature and approximate
location of unacceptable defects observed to correlate to a particular butt weld and
welder on piping drawing and pipeline alignment drawing.
3.11 The CONTRACTOR shall provide all the necessary facilities at site, such as a dark
room with controlled temperature, film viewer etc. to enable the COMPANY to
examine the radiographs.
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Copyright GAIL – All rights reserved
3.12 The CONTRACTOR, if found necessary, may modify the procedure of Radiography
examination suiting to the local conditions prevailing. This shall be subjected to the
approval of the COMPANY.
3.13 COMPANY shall have free access to all the CONTRACTOR's work facilities in the
field.
3.14 Any approval granted by the COMPANY shall not relieve the CONTRACTOR of his
responsibilities and guarantees.
4.2 Whenever possible, pipeline welds will be inspected by placing the radiation source
inside the pipe, on the pipeline axis, with a radiation of 6.28 red. (360) If it is
impossible to place the radiation source inside the pipe, the weld will be inspected
with the source on the outside. An overlap of at least 40 mm at the ends of each
film shall be required to ensure that the first and last location increment numbers
are common to successive films and to establish that no part of a weld has been
omitted.
6.0 PENETRAMETERS
6.1 The Image Quality Indicator (IQI) shall be used for the qualification of the welding
procedure and during normal line production. Radiography sensitivity shall be
measured with the wire image quality indicator (Penetrameter). The Penetrameter
shall be selected according to DIN-54109 or ISO-1027. For radiographs made with
the source on the outside, a Penetrameter shall be placed on each side of the film
with the smaller wire of the Penetrameter turned towards the end of the film itself.
When a complete weld is radiographed in a single exposure using a source inside
the piping, four pentrameters approximately equally spaced around the
circumference shall be used. During the procedure qualification, IQI shall be placed
both on the source side and on the film side. The sensitivity obtained with IQI on
the source side shall not be less than the values shown in FIG.5 of this
specification. The sensitivity limit may be considered to have been reached when
The COMPANY may authorize use of types of IQI other than those planned,
provided that they conform to recognized standards and only if the CONTRACTOR is
able to demonstrate that the minimum sensitivity level required is obtained. For this
demonstration, a test shall be carried out comparing the IQI specified. The
CONTRACTOR shall show up the identification number and other details of the
proposed IQI, which must be visible in the test radiograph.
All films shall be clearly identified by lead numbers, letters, and/or markers. The
image of the markers shall appear on the films, without interfering with the
interpretation. These markers positions shall also be marked on the part to be
radiographed and shall be maintained during Radiography.
8.1 All unexposed films shall be protected and stored properly as per the requirements
of API 1104 standard and ASTM E.94.
8.2 The exposed and unexposed film shall be protected from heat, light, dust and
moisture. Sufficient shielding shall be supplied to prevent exposure of film from
radiation prior to the use of the film for Radiography exposure.
9.0 RE-RADIOGRAPHY
9.1 The weld joints shall be re-radiographed in case of unsatisfactory quality of the
radiographs, at the expense of the CONTRACTOR.
9.2 All the repaired weld joints shall be re-radiographed at no extra cost to the
COMPANY in the same manner as that followed for the original welds. In addition,
the repaired weld areas shall be identified with the original identification number
plus the letter R to indicate the repair.
9.3 When evaluating repair film, radiographers shall compare each section (exposure)
of the weld with the original film to assure repair is correctly being done and
original defects are removed.
9.4 Prior to any repair of welds, the COMPANY will review all the radiographs of welds
that contain unacceptable defects. The final disposition of all unacceptable welds
shall be decided by the COMPANY.
10.2 Certification of all the radiographers qualified as per 10.1 above shall be furnished
by the CONTRACTOR to the COMPANY, before a radiographer will be permitted to
perform production Radiography. The certificate record shall include:
10.3 The radiographers shall be required to qualify with each Radiography procedure
they use, prior to performing the work assigned to him in accordance with the
specification.
11.1 The radiographs shall be processed to allow storage of films without any
discoloration for at least three (3) years. All the radiographs shall be presented in
suitable folders for preservation along with necessary documentation.
12.1 CONTRACTOR shall make necessary arrangements at his own expense, for
providing the radiographic equipment, radiographic films and all the accessories for
carrying out the Radiography examination for satisfactory and timely completion of
the job.
12.2 For carrying out the mainline Radiography examination, the CONTRACTOR shall be
equipped with suitable mobile/stationary type dark rooms. These shall have all the
required facilities for film processing. Film viewer used shall be equipped with the
film illuminator that has a light source of sufficient intensity and suitably controlled
to allow viewing film densities up to 4.0 without damaging the film.
13.1 CONTRACTOR shall be responsible for the protection and personnel monitoring of
every man with or near radiation sources.
13.2 The protection and monitoring shall comply with local regulations.
14.1 The safety provisions shall be brought to the notice of all concerned by display on a
notice board at prominent place at the work spot. The person responsible for the
“Safety” shall be named by the CONTRACTOR.
15.1 To ensure effective enforcement of the rules and regulations relating to safety
precautions, the arrangement made by the CONTRACTOR shall be open to
inspection by COMPANY or its representatives.
16.1 CONTRACTOR shall maintain first aid facilities for its employees and those of
subcontractors.
16.2 CONTRACTOR shall make outside arrangements for ambulance service and for
treatment of industrial injuries. Names of those providing these services shall be
furnished to COMPANY, prior to start of work and their telephone nos. shall be
posted prominently in CONTRACTOR'S field office.
16.3 All critical industrial injuries shall be reported promptly to the COMPANY and a copy
of CONTRACTOR's report covering each personal injury requiring the attention of
physician shall be furnished to the COMPANY.
17.0 NO EXEMPTION
Sheet 2 of 3
C. Impact Test Results
Batch No. :
Welding Positions :
Base Materials :
(1)
(2)
(3)
Remarks :
In combination with :
Position of welding :
Preheat temperature :
Radiography :
H. Conclusions :
Atmosphere Control :
Mode of Cooling :
Notes :
The following documents shall be furnished along with the specifications:
1.0 SCOPE
2.0 DESIGN
3.0 MATERIAL
5.0 MARKING
7.0 INSTALLATION
9.0 DOCUMENTATION
2.0 DESIGN
2.1 Geo-textile bags shall be suitable for filling with Gravel/stone ballast materials for 18”
12” & 10” three layer polyethylene coated pipeline carrying liquid hydrocarbon for anti
buoyancy measures in place of concrete coating.
2.2 Composition and the details of materials shall be as per recommendation of anufacturer
a. Body fabric material must be rated for geo-textile use and as such must be
woven with minimum permeability rating to suit specified Gravel/stone ballast
materials.
c. The center to center spacing between a set of geo-textile bags shall be kept
minimum possible but in no case shall it exceed 7.0 meters in case 18” pipeline
and 5.0 meters in case of 12” pipeline and below.
2.4 Manufacturer shall take prior approval from Owner on details of geo-textile bags and
design calculations.
2.5 The fabric weights to be used in the pipeline should be from a manufacturer with a
minimum of 5 years continuous, successful experience in production of geo-textile
fabric weights for pipeline buoyancy control application. Manufacturing plants must be
an ISO 9002 certified facility to ensure consistency in quality.
2.6 The proposed bags and associated straps etc. shall not be detrimental to the pipeline
coating in any manner.
3.0 MATERIAL
3.2 All material used in the fabrication of geo-textile bags such as webbing, lifting loops,
threads etc. shall be polypropylene material.
3.3 All webbing must have a minimum individual tensile rating of at least 2268 kg. With a
combined safety rating of 4 times the capacity.
3.4 Body fabric must have a maximum elongation rating of 15% and be stable within a pH
range between 2 to 12.
4.1 Geo-textile bags shall be delivered on pallets with a black protective cover for easy
handling and storage.
4.2 Protective cover to be maintained to ensure the proper protection from oil, dirt and
sunlight.
5.0 MARKING
5.1 On each black protective cover the following shall be marked by suitable means
“Maintain cover or provide separate cover on bags until use. Ensure proper protection
from oil, dirt, sunlight etc.”
5.2 Each geo-textile bag shall be marked by indelible paint or other suitable methods with
the following minimum information:
a. Product model
b. Name of Manufacturer
7.0 INSTALLATION
7.1 The geo-textile bags shall be filled by using proper sized filling hoppers with appropriate
stone as recommended by manufacturer.
7.2 While picking up fabric weights for transportation, it shall be ensured that all hooks and
clevises are free of large, sharp defects that may damage the lift straps. Only suitable
devices or bag type slings shall be used during lifting.
7.3 Trailers with rails or strapping to secure the load shall be used for transportation to site.
The bags shall not be stacked.
7.4 Weights are to be kept in upright and leaning in supported position in ROU for easy
accesses to the lifting loops.
7.5 Extra trench width and depth shall be excavated to accommodate the Geo– textile
bags. Backhoe or side boom shall be used for installation of the same.
8.0 DOCUMENTATION
Following documents shall be submitted for review before installation of geo-textile
bags
8.1 All necessary calculations to demonstrate the suitability of proposed geo-textile bags for
pipeline anti-buoyancy measures under the specified design conditions. The
manufacturer shall provide an undertaking that the proposed geo-textile bags are
suitable for 18”/12” & 10”, 3 layer polyethylene coated line pipe. Three layers PE
coating shall be minimum 2.2 mm thick.
8.2 All details of proposed geo-textile bags (such as dimensions, material used etc.) shall be
furnished. Contractor shall highlight any special features if any.
8.3 General arrangement drawings of all items viz. set of geo-textile bags, hopper, loading
arrangement etc.
8.4 Details of all associated equipments (hoppers etc), spares, tools etc required to fill,
transport and install geo-textile bags on the pipeline.
1.0 INTRODUCTION
2.0 RESPONSIBILITY OF
CONTRACTOR
4.0 DOCUMENTATION
6.0 SAFETY
i.) Precommissioning of :
Contractor, along with his bid documents, is required to submit the following:
Clause wise list of deviations, if any, from this technical specification. In the
TECHNICAL SPECIFICATION FOR SPECIFICATION REV-0
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NEW DELHI COMMISSIONING 0001-01-04-02-003 Page 3 of 15
Copyright GAIL – All rights reserved
absence of this, it shall be considered that the bidder has no deviation.
2.1 Precommissioning
Flushing and dry air blowing of under ground & above ground piping at dispatch
and receipt stations, SV stations, all Terminal stations and hook–up point.
Swabbing of pipeline.
Low pressure leak check (with air) for the aboveground section of the pipelines.
Design and supply all temporary line connections, pig launcher/receiver, valves,
instruments, manpower etc. as required during various operations.
All necessary work to perform the job successfully including all modifications that
would be required.
The contractor shall demonstrate to the COMPANY (for COMPANY’s approval) the
successful completion of all of the above-mentioned activities.
In the event of any detail, which is not fully addressed, contractor should warrant
that work shall be performed in accordance with the relevant codes, Company's
specifications and the best recognized Engineering guidelines and practices being
followed in the on-shore pipeline industry.
Drying of the underground pipeline and above ground piping system at dispatch and
receipt stations, above ground piping system at all Terminal stations, CGS/PRS
Station, SV stations and hook-up / tap-off points to a water dew point of 0°C at
atmospheric pressure, and maintain this dew point in the pipeline, till inertisation
and gas-in activities commence.
Inertisation of the pipeline system including above ground piping system at dispatch
and receipt stations, above ground piping system at all Terminal stations, CGS/PRS
Station, SV stations and hook-up / tap-off points.
Gas-in activities including pressurization, carrying out high pressure leak checks and
establishment of flows in the pipeline system including above ground piping at
dispatch and receipt stations, SV stations, all Terminal station, CGS/ PRS station and
hook-up points.
Supply and use of materials and consumables as required for the commissioning
activities.
Design and supply all temporary line connections, pig launcher/receiver, valves,
instruments, manpower etc. as required during various operations.
This shall include preparation of detailed procedures for Drying, Inertisation, Gas-in
/ commissioning operations, high pressure leak check operations, pressurization,
establishing flows and 72 hours run of the pipeline system, and shall address the
sequence and methodology describing all operations, data on materials, equipment,
instruments, consumables, communication systems, necessary calculations, detailed
time schedule and organization chart.
Ensuring all communication facilities are in place and in proper working condition
prior to start of commissioning activities of the pipeline system.
All necessary work to perform the job successfully including all modifications that
would be required.
The contractor shall demonstrate to the COMPANY (for Company’s approval) the
successful completion of all of the abovementioned activities.
In the event of any detail, which is not fully addressed, contractor should warrant
that work shall be performed in accordance with the relevant codes, Company's
specifications and the best recognized Engineering guidelines and practices being
followed in the on-shore pipeline industry.
A) System Checks
The entire facilities shall be checked against the latest P&ID's, Engineering and
Vendor drawings / documents and other design specifications. Any shortcomings
observed shall be listed down in the form of punchlists and duly attended.
All the field instruments like actuated valves, control valves, shutdown valves,
transmitters, solenoid valves, shut down switches, alarms etc. shall be checked
physically and also for their intended application by simulating the operating
condition. It will also include checking of different meters, gauges, action of
actuated valves, control valves, shutdown valves etc.
This is to check that there is proper communication with adequate back-up power
to ensure uninterrupted communication.
This is to ensure safety and also to ensure an uninterrupted power supply during
startup and normal pipeline operation.
This is to check that instrument controls and interlocks are functional as per the
normal operating conditions.
This is to check that utilities like power, nitrogen, UPS system, instrument air, etc.
are available prior to start-up.
3.1.2 Dewatering
3.1.2.1 General
The disposal of the water shall be performed such that no harm is done to the
environment and the Dewatering procedure should indicate this disposal
methodology.
The dewatering operation for pipeline shall consist of a number of dewatering pig
runs and dry air shall be used as propellant for pig trains.
Bi-directional cup pigs shall be used and will be suitable for traversing the entire
length of the pipeline/pipe segment being dewatered. Contractor shall ensure that
all the pigs are designed to prevent damage to the pipeline’s internal coating (if
any).
The contractor shall propose the minimum speed and the backpressure of the pigs
in order that continuous operation will be performed without the pig getting stuck.
Contractor shall submit all the calculations regarding this procedure and a
contingency plan for implementation in case the pigs get stuck.
Contractor shall provide a suitable compressor for oil-free air with sufficient
capacity and pressure.
Upon arrival of the pigs at the receiving end, the Contractor in the presence of
Company's representative shall remove the pigs without delay.
Acceptance criteria
Before proceeding to the next stage of operations, Contractor shall ensure that
bulk of the water has been removed from the pipeline system. Contractor shall
specify when the dewatering phase (for the underground pipeline) and flushing
and dry air blowing (for above ground piping) is finished and shall obtain approval
of the company before proceeding to the next phase.
3.1.3 Swabbing
3.1.3.1 General
The contractor shall submit the detailed procedure and the duration of the
swabbing operation and obtain approval of the company before starting the
operation.
3.2.1.1 General
The pipeline system including the underground pipeline and the above ground
piping at dispatch and receipt stations, SV stations, all Terminal station, CGS/ PRS
stations and hook-up / tap-of points needs to be dried prior to charging natural
gas. Drying is required to prevent internal corrosion of the pipeline & to meet the
supply specification and also as a means of preservation of the pipeline sections
subsequent to the precommisisoning activities. The pipeline shall be dried by using
super dry air / vacuum method or by any other suitable method.
Contractor shall submit the detailed procedure and the duration of the drying
operation and obtain Company's approval on the same prior to start of the drying
operation.
Contractor shall ensure that drying operation is complete before proceeding to the
next step of inertisation. The drying of the pipeline system shall be considered to
be achieved on attaining a water dew point of 0°C at atmospheric pressure and
this water dew point in pipeline shall be continuously maintained till inertisation or
commissioning of the pipeline.
3.2.2.1 General
The aboveground piping sections of the pipeline system shall be checked for leaks
at flange points of piping and equipment, instrument impulse tubing points etc.
This shall be done by pressurizing the system piping / equipment with dry
compressed air (for this purpose, oil free air compressors shall be used) and
testing the system by means of soap solution for leaks.
The contractor shall submit the detailed procedure and the duration of the leak
check operations and obtain approval of the company before starting the
operation.
3.2.4 Inertisation
3.2.4.1 General
Contractor shall carry out inertisation of the entire pipeline system including the
underground pipeline and the above ground piping at dispatch and receipt
stations, SV stations, IP stations and hook-up / tap-of points).
During the Inertisation operation, the dry air left in all the pipeline shall be
replaced by dry nitrogen before admitting the natural gas into the pipeline for safe
commissioning. Depending on the commissioning plan / strategy, sections of the
pipeline system may be taken up for commissioning in steps. One of the suggested
methods for Inertisation of the underground pipeline is by the usage of nitrogen
slugs separated by pigs. Depending on the length of the pipeline portion to be
taken up for commissioning, the amount of the nitrogen used may vary. In
general, the totalised length of the nitrogen slug train must be at least 10% of the
total length of the pipeline under consideration. The last pig in the pig train shall
be propelled by natural gas (during commissioning stage of the pipeline).
In case Vacuum drying procedure is adopted, the pipeline can be inertised under
vacuum condition, followed by gas charging to reduce the time for commissioning
activities.
Nitrogen required for Inertisation purpose of the pipeline and aboveground piping
shall be supplied by the contractor and should be of purity level 99.9% or above.
Nitrogen gas at ambient temperatures (AND NOT LIQUID NITROGEN) and in
completely vaporized and gaseous state shall be used as the inertising medium. In
case the source of gaseous nitrogen is from liquid nitrogen tankers, then all
precautions (including verification of the lowest tolerable temperature of all
components in the system under commissioning) should be ensured.
The contractor shall submit the detailed procedure (in line with the above
suggested method or any other acceptable one) and the duration of the
inertisation operation and obtain approval of the company before starting the
operation. Inertisation shall be followed immediately by charging of pipeline by
natural gas.
Inertisation of all the pipeline may be accepted to be complete when the required
quantity of nitrogen has been introduced into the pipeline. The contractor has to
ensure this condition for safe commissioning of the pipeline. For above ground
piping at dispatch and receipt stations, SV stations, IP stations and hook-up / tap-
of points, the inertisation may be accepted to be complete when the residual
oxygen content in the piping is below 1% (vol/vol).
3.2.6.1 General
Contractor shall carry out gas-in and commissioning activities of the entire pipeline
system including the underground pipeline and the above ground piping at
dispatch and receipt stations, SV stations, IP stations and hook-up / tap-of points.
During introduction of natural gas into the pipeline, natural gas shall be the motive
fluid for driving the last pig of the nitrogen slug train. The pig train speed shall be
maintained at 3 to 4 Km/hr. Maintenance of proper backpressure shall control pig
train speed. Venting shall be controlled at the pig-receiving end to achieve the
desired dynamics. In this fashion, slowly the desired portion of the pipeline shall
be commissioned. Alternatively contractor may propose procedure for introduction
of gas in pipeline under vacuum condition after inertisation with Nitrogen.
Subsequently, the pipeline system shall be slowly pressurized upto its operating
conditions and high pressure leak checks of the pipeline system at flange points,
instrument points etc. shall be carried out with soap solution at regular intervals
during the course of pressurization of
the pipeline system. Once the pipeline system is pressurized at its operating
conditions, normal gas flows shall be established in the pipeline system.
The contractor shall submit the detailed procedure (in line with the above
suggested method or any other acceptable one) and the duration of the
commissioning operation and obtain approval of the company before starting the
operation.
Commissioning shall also include establishing the process control parameters first
at turn down & then at design value stipulated in the process package along with
supplementary instructions, if any, from Company / Company’s Representative.
4.0 DOCUMENTATION
Contractor shall submit for approval of the Company, the complete description,
detailed procedures and time schedule for all of the following activities:
• Pre-commissioning checks
TECHNICAL SPECIFICATION FOR SPECIFICATION REV-0
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• Dewatering
• Flushing
• Swabbing
• Drying
• Low pressure leak check of aboveground piping system with dry compressed
air
• Inertisation
• Gas in and commissioning activities (including pressurization of pipeline system,
high pressure leak check, establishment of flows and 72 hours run).
All these documents should be prepared covering all aspects of HSE, quality
assurance and quality control plans.
Contractor shall ensure that his documents are related to “as-built” conditions of
the pipeline and structure involved.
Documents shall also contain all safety plans, procedures, to be followed while
carrying out the activities.
Upon successful completion of the work, contractor shall prepare a final report of
the work which shall include necessary charts, diagrams, graphs, calculations,
recordings, daily logs, measurements, details of the operation, etc. Report shall
also include all certificates of calibration of instruments required, together with
records of calibration performed at site prior to the start of any operation and the
approved precommissioning and commissioning formats and checksheets.
6.0 SAFETY
Contractor shall follow the safety practices during execution of pre-
commissioning and Commissioning works as detailed in the scope of work. He
shall also maintain and follow all safety practices equivalent or better than those
being practiced by the industry during pre-commissioning and commissioning
activities.
QUESTIONNAIRE
{PRIVATE
NOT
}CLAUSE DESCRIPTION OF CLAUSE AGREED REMARKS
AGREED
NO.
1.0 SCOPE [ ] [ ]
2.0 DEFINITIONS [ ] [ ]
BS
BS 5996 : Specification for the Acceptance Level for Internal Imperfection in
Steel Plate, Strip and Wide Flats based on Ultrasonic Testing.
ASME IX : Boiler & Pressure Vessel code: Welding & brazing quality.
ASME B31.8 : Gas Transmission & Distribution piping system.
SPECIFICATION FOR LONGITUDINAL SEAM DOCUMENT No. REV-0
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Copyright GAIL – All rights reserved
OISD – 141 : Oil Industries safety distribution piping system
API RP 5 L1 : Recommended practice for railroad transmission of line pipe
5.3 MATERIAL
Line pipe furnished to this specification shall be made from steel produced in basic
oxygen (New) or electric arc furnace. The steel used for manufacture of pines shall be
fully killed and fine grained with a grain size of ASTM 7 or finer as per ASTM E 112.
Steel shall be made by continuous casting only.
Pipe Ends
Diameter tolerances for the pipe ends indicated in API Spec 5L Table 8 shall be applicable on
the inside diameter.
The inside diameter, based on circumferential measurement, over a length of 100 mm from
the end shall comply with the tolerances specified in API Spec 5L. Inside diameter is defined
as ID = (OD-2WT.) where ID, OD & WT are the inside diameter, specified outside diameter
and specified wall thickness respectively.
Out of Roundness
Out of Roundness i.e., the difference between the maximum and minimum inside diameter at
pipe ends, shall not exceed the following:
Size Tolerance
<36” : 0.5%of OD
>36 : < 5mm
Out of roundness tolerance indicated in API Spec 5L, Table 8 stands deleted. Out of roundness
tolerances apply to maximum and minimum diameters as measured with a bar gauge, caliper
or device measuring actual maximum and minimum diameter.
Each pipe shall be measured for conformance to above requirements. All dimensions and
tolerances shall be measured and recorded at least 3 times per operating shift (12 hrs.
maximum).
7.3 WALL THICKNESS
In addition to API requirements, the wall thickness of each pipe shall be checked along the
circumference at both ends and at the mid location of pipe body at 12 o'clock, 3 o'clock, 6
o'clock and 9 o'clock positions. The wall thickness tolerance shall comply with the
requirements of this specification.
The tolerances on specified wail thickness shall be (+) 15% and (-) 0%. API Spec 5L Table 9
stands cancelled.
Wall thickness shall be measured and recorded at least 3 times per operating shift (12 hours
maximum).
A Manufacturing Procedure Specification (MPS) outlining the successive steps and associated
inspection procedures from steel making to finished line pipe shall be prepared and submitted
to Purchaser for approval prior to start of production. Manufacture of pipes shall start only
after the approval of Manufacturing Procedure. The approved Manufacturing Procedure shall
be strictly followed in all phases of the production of pipes.
The manufacturing procedure shall as a minimum include the following information.
- Steel/Plate/skelp maker and plant at which steel is produced.
- Steel making process with details of secondary refining process and continuous casting
process, nominal weight of each heat.
- Target chemistry, range of intentionally added elements, limits on heat and product analysis
to be
placed on steel maker.
- Plate/skelp rolling procedure indicating number of passes, their temperature and thickness
reduction
in each pass required by Controlled Rolling Procedure and the finishing temperature.
- Heat treatment procedure document established as per para 5.4.
- Ultrasonic testing of plates/skelp and pipes using automatic and manual equipment including
details of
equipment, techniques, scanning pattern, probe frequency, scanning sensitivity, reference
standard for
calibration, dynamic calibration procedure, method of marking defects and indicating loss of
coupling,
inspection and recording.
- Pipe making procedure including plate edge preparation, forming and any other special
process
proposed.
- Welding procedure specification including the details of welding process, brand name,
classification, size and grade of filler metal and flux, speed of welding, number of electrodes
and polarity of each electrode, welding current and voltage for each wire, edge preparation,
tack welding method and spacing of tack weld, details of seam tracking system for both inside
and outside welding, method of
checking the setup of the system, limits of internal and external weld reinforcement etc.
The following information as applicable shall be furnished at Bid stage with respect to line pipe
to be
supplied.
- Name(s) of proposed Manufacturer(s)
- Authorization letter(s) from Manufacturer(s) where applicable.
- Authorization letter(s) from Manufacturer(s) of steel plates, in case plate manufacturing
facility is not
an integral part of the Supplier’s pipe mill.
- Record of similar supplies made earlier by the Manufacturer for both plates and pipes, giving
complete
details of diameter, thickness, length, grade of plate / pipe, service, year, name of project,
name of client, and contact person.
In particular, details of similar supplies made over the last five years shall be furnished.
Descriptive technical catalog(s) of the proposed Manufacturer(s).
- Copy of valid certificate of Authority to use API monogram as per clause 1.2 of this
specification.
- A clause wise list of technical deviations, if any, from the requirements of this specification
shall be furnished in the Performa enclosed with the Enquiry. Deviations indicated anywhere
else in the offer shall not be considered valid. In case of no deviations, Bidder shall write “NO
DEVIATIONS” in the said performa.
X-RAY FILM
ID Inside Diameter
1 SCOPE
2 REFERENCES
6 MATERIAL REQUIREMENTS
10 MARKING
12 DOCUMENTS
This specification establishes the minimum requirements for the manufacture of helical
(spiral) seam submerged arc welded steel line pipe in accordance with the requirements
of API (American Petroleum Institute) Specification 5L, Forty-Third Edition, 2004 and
makes restrictive amendments to API Spec. 5L. Unless modified and or deleted by this
specification, the requirements of API Spec. 5L shall remain applicable.
The sections, paragraphs and appendices contained herein have the same numbering
that of API Spec 5L in order to facilitate reference. Additional requirements, which are
not specified in API Spec 5L, have also been numbered and marked as "(New)".
The coverage by this specification is limited to line pipe to be used in onshore pipelines
transporting non-sour hydrocarbons in liquid or gaseous phase.
The Manufacturer shall have a valid license to use API Monogram in accordance with
the requirements of API Spec. 5L, Forty-Third Edition, 2004 on line pipe as Product
Specification Level PSL 2.
Line pipe supplied to this specification shall conform to Product Specification Level PSL
2.
1.3 GRADE
1.4 DIMENSIONS
This specification shall be applied to line pipe of size 18 through 48 (both sizes
included)
2.0 References
2.1 The latest edition (edition enforce at the time of issue of enquiry) of following additional
references are included in this specification:
ASTM R 112 : Standard Test Methods for Determining Average Grain Size.
Following paragraphs of API Spec 5L shall be applicable to the line pipe manufactured
as per this specification:
Type of Pipe : Helical Seam Submerged Arc Welded Pipe as per para
5. 1.3.11
Type of Seam Weld : Submerged Arc Weld (Helical Seam) as per para
5.1.4.3
The submerged arc welding equipment shall have an automatic weld tracking system
capable of ensuring accurate positioning of welding head and the welding edges of the
skelp.
5.3 MATERIAL
5.3.3 (New)
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Line pipe furnished to this specification shall be made from steel produced in basic
oxygen or electric arc furnace. The steel used for manufacture of pipe shall be fully
killed and fine grained with a grain size of ASTM 7 or finer as per ASTM B 112. Steel
shall be made by continuous casting only.
The pipes shall be produced from skelp which shall be quenched and tempered or
controlled rolled or combined controlled rolled and accelerated cooled to impart
uniformly fine ferritic grain structure to the finished steel. Other types of heat treatment
shall be agreed upon between Purchaser and Manufacturer.
Junctions of skelp end weld and helical seam welds in finished pipe are not permitted.
6 Material Requirements
Table - 2B: PSL 2 Chemical Requirements for Heat and Product Analyses by Percentage
of Weight
C 0.16 max
Si 0.15 min
0.45 max
S 0.015 max
P 0.02 max
Al 0.07 max
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Nb 0.05 max.
V 0.08 max.
Cr 0.20 max.
Mo 0.10 max.
Cu 0.35 max
Ni 0.20 max
N 0.012 max
B 0.0005 max
Note:
g (New)
Note: h (New)
If alloying elements other than those specified in Table 2B above are added to the
steel, the limits of the additional components shall be agreed with the Purchaser.
Note: i (New)
For heat analysis and product analysis, all the elements listed in Table 2B of this
specification shall be analyzed and reported, even if those are not purposely added but
are present as residuals only.
Boron content shall be considered in CE (PCM) formula even if it is less than 0.0005%.
For pipes of all grades, size and wall thickness, Carbon Equivalent shall comply with the
following limits:
CE (Pcm) ≤ 0.20
CE (IIW) ≤ 0.40
The finished pipe shall conform to the requirements of Table 3B of API Spec 5L and as
modified herein.
The actual yield strength shall be as close as possible to the specified minimum yield
strength (SMYS) but in no case it shall exceed the limits specified here under:
The ratio of body yield strength and body ultimate tensile strength of each test pipe on
which body yield strength and body ultimate tensile strength are determined, shall not
exceed 0.90, when tested using flattened tensile specimen. The ratio between yield
strength and ultimate tensile strength for weld metal of finished pipe shall not exceed
0.90, when tested using cylindrical all weld specimen.
The ultimate tensile strength of the weld shall be equal to or better than the specified
minimum ultimate tensile strength of the base metal.
The minimum elongation of base metal shall be determined in accordance with the
formula given in foot note (a) of Table-3B and shall comply with the minimum values of
API Spec 5L Appendix D. However elongation in no case shall be less than 20%. API
Spec 5L Appendix D stands modified accordingly.
f. (New)
For all pipe sizes and specified wall thickness, additional fracture toughness
requirements as per Supplementary Requirements Appendix-F SR 19 of API Spec 5L
and as modified in this specification shall be applicable for body, weld and heat affected
zone.
For pipe of all grades and specified wall thickness, the Charpy V-notch Impact Test for
determination of Shear Area, in accordance with Supplementary Requirement SR 5A of
API' Spec 5L and as modified in this specification shall be performed. In addition,
whenever line pipes are specified for hydrocarbon service in gaseous phase and
Liquefied Petroleum Gas (LPG) service in Purchase Order, Drop Weight Tear Test in
accordance with Supplementary Requirements SR 6 of API Spec 5L and as modified in
this specification shall be also performed for all pipe size, grade and wall thickness.
6.2.6.1(New)
A test specimen for metallographic & hardness examination shall be taken transverse
to the helical weld, from one finished pipe from each lot of 50 pipes per heat or at least
once per operating shift (12 hrs maximum) whichever is occurring more frequently and
whenever changes of grade, diameter or wall thickness are made and whenever
significant excursions from operating heat treatment conditions are encountered. The
specimen extraction shall be as per Fig. 6.2.6.1 of this specification. The specimen shall
be suitably ground, polished and etched to reveal the macro-structure. The specimen
shall be visually examined using a minimum 10X magnification to provide evidence that
proper fusion has been obtained for the full thickness, and there is proper interpretation
of passes, their alignment and texture of weld zone. In case imperfections or defects
are observed, it will become a cause for re-evaluation of welding parameters and heat
treatment as deemed necessary by Purchaser's Representative.
6.2.6.2(New)
Vickers hardness tests shall be carried out on each specimen taken for metallographic
examination in accordance with ASTM E-92, at locations indicated in Fig. 6.2.6.2 of this
specification i.e. at weld, heat affected zone and body. Indentation in the Heat Affected
Zone shall start as close to the fusion line as possible. The resulting Vickers hardness
Helical pipes shall meet the testing and minimum acceptance criteria set forth in this
paragraph. The residual stress test shall be carried out on the pipe after hydrostatic
test.
One test shall be carried out at the beginning of each shift. Minimum of one test shall
be carried out for pipes of each grade, size and specified wall thickness. In addition,
whenever the production line settings are changed, the first produced pipe shall be
tested for residual stress.
The teat specimen shall be 150mm wide ring cut from one end of the pipe. The
specimen shall either be cut using flame cutting torch or by sawing from the parent
pipe.
The specimen ring shall be severed by flame cutting or sawing parallel to the
longitudinal axis of the pipe. The cut shall be 180 degree from the spiral weld.
(Specimen ring shall be allowed to cool down to ambient temperature prior to cutting)
The increase in circumference, if any, after severing shall be measured using fiducial
marks of known separation on the specimen prior to severing. The residual stress then
shall be calculated using following formula.
S = {(E*t*C)/(12.556 *R2)}-{(F*R2)/t}
Where:
The computed residual stress shall not exceed 10% of the Specified Minimum Yield
Stress (SMYS) of the pipe.
If any specimen fails to meet the requirements of paragraph 6.2.7.5 above, the pipe
may be retested once. The retest specimen shall be obtained from the same end of the
pipe from where the failed specimen was obtained. If the results obtained from the
retest specimen are acceptable, normal test schedule shall be resumed. If the results
obtained from retest specimen are not acceptable, the pipe shall be rejected and testing
shall resume on the next pipe in the production line. If this test also fails all pipes back
to the last acceptable test shall be individually tested and those pipes which pass the
test shall be accepted. All pipes that fail to pass the test shall be rejected. The
manufacturer shall evaluate the reasons for the failure of the test and rectify the same
prior to start of production again. The regular production shall be resumed only after
acceptable test result is achieved.
6.2.7.7 Reporting
(New) All residual stress result shall be recorded as part of the mill report.
7.2 DIAMETER
Pipe Body
The outside diameter of pipe body, as determined by taping the circumference, shall
not deviate by more than the values given below from that given in Table E-6C,
Appendix E. API Spec 5L, Table 7 stands modified accordingly.
Size Tolerance
18 ± 3mm
>36 ± 3mm.
Diameter tolerances for the pipe ends indicated in API Spec 5L Table 8 shall be
applicable on the inside diameter.
Out of Roundness
Out of Roundness i.e., the difference between the maximum and minimum inside
diameter at pipe ends shall not exceed the following:
Size Tolerance
≤36 : 0.5% of OD
>36 : <5 mm
Out of roundness tolerance indicated in API Spec 5L, Table 8 stands deleted. Out of
roundness tolerances apply to maximum and minimum diameters as measured with a
bar gauge, caliper or device measuring actual maximum and minimum diameter.
Each pipe shall be measured for conformance to above requirements. All dimensions
and tolerances shall be measured and recorded at least 3 times per operating shift (12
hrs. maximum).
In addition to API requirements, the wall thickness of each pipe shall be checked along
the circumference at both ends and at the mid location of pipe body at 12 o'clock, 3
o’clock, 6 o'clock and 9 o'clock positions. The wall thickness tolerance shall comply with
the requirements of this specification.
The tolerances on specified wall thickness shall be (+) 15% and (-) 0%. API Spec 5L
Table 9 stands cancelled.
Wall thickness shall be measured and recorded at least 3 times per operating shift (12
hours maximum).
7.5 LENGTH
All pipes shall be supplied with length between 11.5 m and 12.5 m. However pipe with
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length between 10.0mand 11.5 m can also be accepted for a max. of 5% of the
ordered quantity. The minimum average length of the entire ordered quantity in any
case shall be 12.0 m. API Spec 5L Table 11 shall not be applicable. Overall length
tolerance shall be (-) Zero and (+) One pipe length to complete the ordered quantity.
Each pipe shall be measured for conformance to above requirements and all
measurements shall be recorded.
7.6 STRAIGHTNESS
The deviation from a straight line for all pipe sizes shall not exceed 12 mm. Each pipe
shall be checked for conformance to this requirement. Straightness shall be measured
and recorded at least 3 times per operating shift (12 hours maximum).
7.7 JOINTERS
7.8.1 Dents
Disposition of dents shall be carried out in accordance with API Spec 5L para 9.9 (c) or
(d). Dents on weld and heat affected zone (HAZ) are not acceptable.
Forming and welding operations shall be conducted to minimize coil edge offset and
distortion and peaking at the helical or spiral seams. The manufacturer shall provide the
appropriate tooling with 'Vee’ blocks and calibrated dial indicators needed to measure
the distortion and misalignment at the seam. All pipes shall be checked for offset of
skelp edges. Offset shall be measured and recorded at least 3 times per operating shift
(12 hours maximum). Measurements shall be taken at two locations (at a distance of
one to two diameters from each end) on each pipe joint. In case of unacceptable
offsets, the manufacturer shall adjust the forming and welding equipment.
7.8.3 Out-of-Line Weld Bead for Pipe with Filler Metal Welds
Checking of the weld seam misalignment shall also be carried out on metallographic
examination specimen as stated at para 6.2.6.
7.8.4 Height of Outside and Inside Weld Beads - Submerged Arc Welds
The maximum height of outside and inside weld bead shall not be more than 3.2 mm
(1/8 in.) for all specified wall thickness. All pipes shall be checked for weld bead height
using a template having a cut out for weld bead and shall be measured and recorded at
least 3 times per operating shift (12 hours maximum).
Any hard spot having a minimum dimension greater than 2 in. (50.8 mm) in any
direction and hardness greater than 248 HV10 shall be rejected. The section of pipe
containing the hard spot shall be removed as a cylinder.
Sections of the pipe containing cracks, sweats and leaks shall be cut off as per the
requirement of API Spec 5L para 9.9 (c) or (d).
7.8.10 Laminations
Any lamination or inclusion either extending into the face or bevel of the pipe or present
within 25mm from pipe ends is considered defect and pipe containing such defects shall
be cut back until such defects are eliminated.
The acceptance limit and disposition of lamination and other type of defects on the
skelp shall be as per para 9.8.5.4 of this specification.
7.8.12 Undercuts
1. Undercut defects not exceeding 1/32 in. (0.8 mm) in depth and not exceeding
12½% of the specified wall thickness shall be removed by grinding in accordance
with API Spec 5L para 9.9 (a) and as modified in this specification.
2. Disposition of undercuts greater in depth than 1/32 in. (0.8 mm) or 12½% of the
specified wall thickness shall be in accordance with API Spec 5L para 9.9 (c) or (d).
Deviation from the circular arc at the weld seam at pipe ends shall not exceed 1.6 mm.
Each pipe shall be checked for conformance to above requirement. Peaking shall be
measured and recorded at least 3 times per operating shift (12 hrs. maximum). Pipes
not complying to these requirements shall be disposed off as per API Spec. 5L para 9.9
(c) or (d).
7.9.1 General
Unless specified otherwise, the pipe ends shall be bevelled as per API Spec. 5L.
In removing the inside burrs at the pipe ends, care shall be taken not to remove excess
metal and not to form an inside cavity or bevel. Removal of excess metal beyond the
minimum wall thickness as indicated in para 7.3 of this specification, shall be a cause
for rebevelling. In case root face of bevel is less than that specified, the pipe ends shall
be rebevelled and rectification by filing or grinding shall not be done.
Both pipe ends of each pipe shall be provided with metallic or high impact plastic
bevel protectors as per Manufacturer's standard. Bevel protectors shall be of a design
such that they can be re-used by coating applicator for providing on externally anti-
corrosion coated pipes subsequent to coating of line pipe.
Where the steel mill is not a part of an integrated pipe mill, heat analysis shall be
reported by the Manufacturer prior to start of pipe production.
Two pipes per inspection lot shall be analysed. Inspection lot shall be 100 pipes per
heat. Pipes selected shall be such that one at the beginning of the heat and one at the
end of the heat are also represented.
Samples used for product analysis shall be taken from finished pipes. Samples for
product analysis from skelp may be used provided the traceability of samples is
guaranteed.
Tensile properties shall be determined from specimen removed from pipe which has
been subjected to all mechanical and heat treatment operations.
Tensile tests shall be made at the frequency of one test per inspection lot as shown in
Table 13, except as modified below:
For Size >12¾”, Weld Tensile Tests (Column 3 of API Spec 5L) Note "a" of Table 13
shall also be applicable.
The transverse tensile tests shall be carried out on flattened rectangular specimen.
Inside and outside weld reinforcement in excess of pipe wall thickness shall be removed
from the specimen either by grinding or machining. Specimen shall be tested for
ultimate tensile strength only.
A cylindrical all weld tensile test shall be carried out at the time of first day production
test as specified in Annexure-II of this specification to determine the yield strength,
ultimate tensile strength and elongation.
The results of the teat shall meet the minimum requirements of the skelp with regard to
yield, tensile and elongation.
” As an alternate all weld metal tensile test can be carried out at the time of first day
production on the test sample as per ASME Sec.II C. This test shall be repeated in case
any change in batch of wire-flux combination,”
In addition to the specimen taken from the body of the pipe, three transverse
specimens with weld in middle and three transverse specimens with heat affected zone
(HAZ) in the middle shall also be taken.
The minimum test frequency shall be one test (a set of three specimens each for body,
weld and HAZ) per heat per lot of 100 pipes per combination of pipe size and specified
wall thickness.
Test pressure shall be held for a minimum period of 15 seconds for each pipe of all
sizes and grades.
The pressure gauge used for hydrostatic testing shall have a minimum range of 1.5
times and maximum range of 4 times the test pressure. The pressure gauge shall be
calibrated by means of a "Dead Weight" tester only and records shall be maintained.
The test pressure for all sizes and grades of pipe shall be such that hoop stress (fibre
stress) generated is at least 95% of SMYS, computed based on the formula mentioned
in API Spec 5L para 9.4.3 (Note 2).
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9.4.5 Burst Test
(New)
Burst test shall be done on each type of pipe for each size on lowest thickness. Burst
pressure &
location of failure shall be recorded. Technical audit shall be carried out by OWNER /
OWNER’S
representative during manufacturing.
Minimum Burst Test pressure shall not be less than the actual tensile stress factor
computed pressure.
All pipes shall be visually examined both externally and internally (to the extent
feasible) and shall he free of defects in the finished condition.
The Purchaser reserves the right to depute its Representative(s) to perform inspection
and witness tests in all phases of manufacturing and testing starting from steel making
to finished line pipe ready for shipment. Manufacturer shall comply with the provisions
regarding inspection notice: plant access, compliance and rejection mentioned in
Appendix H of API Spec 5L. The Manufacturer shall give the Purchaser reasonable
notice of the starting date of normal production and the work schedule. Any action or
omission on part of Purchaser's Representative shall not relieve the Manufacturer of his
responsibility and obligation to supply material in-strict accordance with this
specification.
All personnel performing NDT activities shall be qualified in the technique applied, in
accordance with latest edition of ISO 9712 or ASNT No. ASNT-TCMA or equivalent.
All NDT shall be performed in accordance with written procedures. These procedures
shall have prior approval of the Purchaser.
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Inspector Qualification
(i) For UT - For UT, at least one level III qualified inspector shall be available to the mill for
overall supervision. A level II inspector is required for shift supervision, manual weld
inspection and calibration of all systems (both manual and automated).
(ii) For alt other NDT methods
Location of NDT equipment in the manufacturer's facility shall be such that final
inspection of weld seam shall be performed after hydro testing.
Skelp Inspection
The longitudinal edges of the skelp shall be 100% ultrasonically inspected over width of
at least 25 mm from the trimmed skelp edge. Remaining skelp shall be ultrasonically
tested for laminations using an oscillating or straight running pattern of probes, so as to
provide inspection coverage of at least 20% of the skelp surface uniformly spread over
the area.
Alternatively, skelp UT inspection can be performed after pipe forming provided all
applicable requirements as specified above are complied with.
Ends Inspection
The full circumference of both ends of each pipe after bevelling shall be 100%
ultrasonically tested for laminations from inside over a circumferential band of at least
25 mm width. In addition, full circumference of both ends of each pipe shall be 100 %
ultrasonically tested over a circumferential width of at least 50 mm with angular probes
to detect cracks, in case of non-availability of angular probes at the mill, the full
circumference of both ends of each pipe shall be inspected with magnetic particle
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technique over a circumferential width of at least 50 mm to detect surface cracks.
Bevel Inspection
Bevel face of all pipes shall be inspected by magnetic particle method to detect defects.
Weld Inspection
Locations showing indications above the allowable limits during ultrasonic inspection
shall be re-examined by radiography, if during production, repeated ultrasonic
indications occur requiring re-inspection by radiography and it appears from
radiographs that the nature of defects causing the ultrasonic indications cannot be
definitely established, the Manufacturer shall prove by other inspection methods (e.g.
by making some cross-sections in accordance with para 6.2.6 of this specification at
locations where such indications occur near the end of the pipe) to the satisfaction of
Purchaser that these are not injurious defects as stipulated in this specification.
Pipe ends not covered by automatic ultrasonic equipment shall be inspected by manual
ultrasonic equipment with same sensitivity and capability as automatic equipment.
Submerged-arc weld seam shall be radio graphically examined for a minimum distance
of 8 in. (200 mm) from each pipe end. The results of radiographic inspection shall be
recorded.
The film used for radiographic inspection of weld seam shall be class 1 or 2 as per
Table-2 of ASTM E 94; with minimum density greater than 1.8 measured in connection
with radiographic image of the welding and shall be suitable to allow a sensitivity of at
least 1.8 percent of nominal wall thickness.
The reference standard shall be ISO wire-type image quality indicator described in
9.8.4.4.
Defects in the weld such as cracks, slag inclusions, porosity and defects in the pipe
material shall be removed by cutting off the section of pipe containing these defects.
The remaining defects-free section of the pipe will be acceptable provided its length is
within the specified minimum length, the weld at the new pipe end contains no defects
other than those permitted.
9.8.5.1 Equipment
All automatic ultrasonic equipment shall have an alarm device, which continuously
monitors the effectiveness of the coupling. The equipment for the automatic inspection
shall allow the localization of both longitudinal and transverse defects corresponding to
the signals exceeding the acceptance limits of the reference standard. The equipment
shall be fitted with a paint spray or automatic marking device and alarm device for
areas giving unacceptable ultrasonic indications. All ultrasonic testing equipment shall
be provided with recording device. In addition, an automatic weld tracking system shall
be provided for correct positioning of the probes with respect to weld centre.
The reference standard (calibration pipe) shall have the same specified diameter and
wall thickness as specified for the production pipe being inspected and shall be of
sufficient length to permit calibration of ultrasonic inspection equipment at the speed to
be used in normal production. The reference standard (calibration pipe) shall also be of
the same material, type and have the same surface finish and heat treatment as the
pipe being inspected.
The reference standard for weld UT shall contain machined notches/holes as per as per
Figure 9.8.5.2 of this specification and as given below;
The reference standard for skelp UT shall contain continuous machined notch of 8 mm
width x ½ t depth, where “t”is the specified wall thickness.
The reference standard for skelp edge UT and pipe ends shall have ¼” inch dia FBH x
½ t depth, where “t” is the specified wall thickness.
If during the above calibration verification, it is found that the equipment has not
functioned satisfactorily in the opinion of the Purchaser's Representative, all the pipes
or skelp already inspected after the previous verification shall be inspected again at
Manufacturer's cost.
Acceptance limit for material edge examination shall be as per criteria laid down for
Acceptance Level E2 of BS 5996:1993, which is reproduced hereunder for ready
reference.
Disposition of any defect shall be as per API Spec L, para 9.9 (c) or (d).
Acceptance limit for material body examination shall be as per criteria laid down for
Acceptance level B4 of BS 5996: 1993 which is reproduced hereunder for ready
reference:
Disposition of any defects shall be as per API Spec 5L para 9.9 (c) or (d).
The average of the four readings shall not exceed 20 gauss and no one reading shall
exceed 25 gauss when measured with Hall-effect gauss meter. All residual magnetism
measurements shall be recorded.
a. Suitable tools to eliminate defects by grinding shall be used. The repaired area shall
be 100% rechecked by magnetic particle or ultrasonic inspection to ensure complete
removal of defects. However for repair of cosmetic type of defects, MPI may not be
conducted if so directed by Purchaser's Representative on case to case basis. The
pipes having a thickness less than the minimum allowed in accordance with this
specification, after repair by grinding shall be treated for disposition in accordance
with API Spec 5L para 9.9 (c) or (d).
b. Repair welding on parent metal is not permitted.
c. In addition to NTD requirement random radiography of 0.1% of the total length
shall be done. The areas to be radiographed shall be at the sole discretion of Third
Party Inspection Agency.
One face and one root guided bend weld test shall be made on samples cut from pipe.
The frequency of testing shall be same as for tensile test as per para 9.3.1.2 of this
specification. The dimension ‘A’ in guided bend test shall not exceed 4.0 times the
thickness of the specimen.
Individual test value for any specimen shall not be less than 80% of the required
minimum average absorbed energy value as per this specification.
9.12 RETESTS
Modalities of recheck analysis shall be as per API Spec. 5L as applicable to the lot being
tested (refer para 9.2.2.1 of this specification). However, during individual testing, each
pipe shall be fully analyzed to meet the requirements of Table 2B of this specification.
In the event that a set of Charpy test specimen fails to meet the acceptance criteria,
the manufacturer may elect to replace the lot (refer para 9.3.5.2 of this specification) of
material involved or alternatively to test two more lengths from that lot. If both the new
tests meet the acceptance criteria, then all pipes in that lot, with the exception of the
original selected length, shall be considered to meet the requirement.
9.13 REPROCESSING
10 Marking
10.1 GENERAL
Marking specified in API Paragraphs and otherwise specified in the Purchase Order shall
be in English language and international system (SI) of units. Marking shall comply with
Appendix-I of API Spec 5L and as modified in this specification.
11.1 COATINGS
Unless otherwise specified in the Purchase Order, the pipes shall be delivered bare, free
of any trace of oil, stain, grease and paint. Varnish coating shall be applied on the
marking area. Bevels shall be free of any coating.
12 Documents
12.1 CERTIFICATION
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Manufacturer shall furnish to Purchaser a certificate of compliance stating that the
material has been manufactured, sampled, tested, and inspected in accordance with
this specification and has been found to meet the requirements. In addition all details
as per Appendix F Supplementary Requirement SR 15 shall also be submitted to
Purchaser/Purchaser Representative during inspection at pipe mill.
In addition to the records indicated in API Spec 5L Table 27, the Manufacturer shall
retain the records of all additional tests and calibration records mentioned in this
specification including the hard copy records of ultrasonic testing carried out on
pipe/skelp as well as pipe ends.
The Manufacturer shall provide six copies of production report in English language
indicating at least the following for each pipe. International system of units (SI) shall be
adopted.
- Pipe number
- Heat number from which pipe is produced
- Pipe length and weight.
- Pipe grade
The Manufacturer shall provide six copies of acceptance certificates which shall include
the results of all tests required as per this specification and performed on delivered
material giving details of, but not limited to, the following:
The certificates shall be valid only when signed by the Purchaser's Representative. Only
those pipes, which have been certified by the Purchaser's Representative, shall be
dispatched from the pipe mill.
In the event of small quantities of pipes supplied against this specification, like those for
bends and other similar applications, as specifically called out in the Purchase Order the
production report may consist of only test certificates required as per SR 15 of API Spec
Purchaser shall be reimbursed by Manufacturer for any pipe furnished on this order that
fails under field hydrostatic test if such failure is caused by a material/manufacturing
defect in the pipe. The reimbursement cost shall include pipe, labour and equipment
rental for finding, excavating, cutting out and installation of replaced pipe in position.
The field hydrostatic test pressure will not exceed that value which will cause a
calculated hoop stress equivalent to 95 percent of specified minimum yield strength.
B 3.1 The defective part of the weld shall be clearly marked on the pipe so that the defect
can be easily located and repaired.
B.3.2 Following requirements shall also be complied with for repair welding:
B.3.4 (New)
The Manufacturer shall also maintain a record of repairs carried out. The records shall
include repair number, pipe identification number, welding procedure applicable and
NDT details.
The radius of male member of the jig used for guided bend tests shall be RA =2.25 t,
where “t” is specified wall thickness of pipe.
C.2.2.5 (New)
For all pipes where fracture toughness test is specified, Charpy V-Notch impact test
as specified shall be included in the Repair Welding Procedure Qualification.
C.2.2.6 (New)
Hardness test as specified in para 6.2.6.2 of this specification shall be included in the
procedure qualification. The location of the hardness measurements is to be indicated
taking into account die new HAZ of the repaired area.
SR5 Fracture Toughness Testing (Charpy V-Notch) for Pipe of Size 4 1/2 or
Larger
SR 5.1 The Manufacturer shall perform Charpy V-notch test for determining Shear Area.
SR 5.3 The specimen shall be full sized or largest obtainable sub size in case pipeline
diameter and thickness does not permit full size specimen
SR 5A Shear Area
SR 5 A.1 Three transverse specimens representing one test shall be taken from one length of
pipe per heat per lot of 100 pipes per combination of pipe size and specified wall
thickness.
SR 5A.2 Unless specified otherwise in the Purchase Order, the specimen shall be tested at
+32°F (0°C), The average shear value of the fracture appearance of the three
specimen shall not be less than 75% and the all heat average for each order, per
diameter, size and grade shall not be less than 80%.
Note: The acceptance criteria of shear area as referred in API Spec. 5L para SR 5A.3 SR
5A.4 and SR 5A.5 stand modified based on above mentioned requirements.
Wherever 'heat' indicated in API Spec 5L SR5A.3, SR 5A.4, SR 5A.5 and SR5A.6 shall
be replaced by 'lot'. Lot shall be as per SR5A.1 as above.
SR6.1 When required as per para 6.2.5.3 of this specification, fracture toughness for all
pipe size, grades and specified wall thickness shall be determined using Drop Weight
Tear Test (DWTT) by the Manufacturer in accordance with the requirements of SR
6.2 thru SR 6.8 of API Spec 5L and as modified in this specification.
SR 6.2 Two transverse specimen shall be taken from one length of pipe per heat per lot of
100 pipes per combination of pipe size and specified wall thickness. Unless specified
otherwise, the test shall be conducted at +32°F (0°C).
SR 6.4 At least 80% of the heats shall exhibit a fracture appearance shear area of 75% or
more for the specified test temperature.
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Note: Acceptance criteria for retesting indicated in API Spec 5L para SR 6.5 stands
modified based on above mentioned requirements. Wherever 'heat' indicated in API
Spec SR6.5 shall be replaced by 'lot'. Lot shall be as per SR6.2 as above.
SR 19.1 Except as allowed by SR 19.2 of API Spec 5L, fracture toughness testing shall be
performed in accordance with the requirements of para 9.3.5.1 and 9.3.5.2 of API
Spec 5L and as modified in this specification, with a test temperature of 32°F (0°C)
or at a lower temperature as specified in the Purchase Order. The required minimum
all-heat average full size absorbed energy value (based on a set of three specimens)
for transverse body specimen shall be the greater of SR 19 (a) of API Spec 5L and
SR 19.1(b). In case longitudinal specimen is applicable as per Table 14 of API Spec.
5L, the minimum average absorbed energy value shall be 13 times that applicable
for transverse specimen. The required minimum average full size absorbed energy
value for weld and HAZ specimen shall also be the greater of SR 19.1(a) and SR
19.1 (b) of API Spec 5L, In addition, the lowest individual absorbed energy value of
the three specimens shall not be less than 80% of the value specified.
H.4 Rejection
If Purchaser Representative rejects pipes repeatedly for any recurring cause, this
shall be adequate reason to refuse final inspection of subsequent pipes until the
cause has been investigated and corrective action taken by the Manufacturer.
1.0 General
1.1 Marking shall also include Purchase Order number/item number, pipe number, heat
number and weight.
Paint used for stencil marking shall withstand a temperature up to 250°C expected
to be experienced during further external anti-corrosion coating operations of line
pipe by coating applicator.
A colour code band shall be marked on inside surface of finished pipe for
identification of pipes of same diameter but different wall thickness, as indicated in
the Purchase Order. The colour code band shall be 50 mm wide and shall be marked
at a distance of ISO mm from the pipe ends.
1.5 Length
Additionally, the pipe number shall be placed by cold rolling or low stress dot
marking on the outside surface of the pipe at an approximate distance of 50 mm
from both ends. In case of non-availability of either cold rolling or low stress dot
marking facility in pipe mill, an alternative marking scheme of a permanent nature
may be proposed by the Manufacturer.
Two lengths each of completely finished pipes of first day's production from two
different heats (i.e. a total of four pipe lengths) shall be selected at random for
testing to verify that the manufacturing procedure results in the quality of pipes
which are in complete compliance with this specification. The pipes thus tested shall
be considered to be the test pipes required per heat or per lot as per relevant
clauses of this specification.
These first day’s production tests shall be repeated upon any change in the
manufacturing procedure as deemed necessary by Purchaser Representative. The
first day production tests shall be carried out on pipes for each wall thickness, each
diameter and each grade of steel. In addition, change of width of coil shall also call
for first day production test.
The Manufacturer shall submit to Purchaser a report giving the results of all tests
mentioned below. The report shall be agreed and signed by Purchaser
Representative, prior to start of regular production.
Note: In the event of small quantities of pipes ordered against this specification, like
those for bends and other similar applications, as specifically called out in the
Purchase Order, the first day production test shall not be carried out. Pipes- in such
case shall be accepted based on regular production tests.
The various tests to be conducted on each pipe shall be as follows. The test method
and acceptance values shall be as per this specification unless specified differently in
this Annexure.
a. Visual Examination
All pipes shall be examined visually for dimensional tolerances and apparent
surface defects.
b. Ultrasonic Examination
The weld seam of all pipes shall be examined ultrasonically by automatic ultrasonic
equipment. All ultrasonic indications suggesting imperfections in the weld shall be
carefully investigated against the corresponding points on the radiographs. If the
ultrasonic indication cannot be fully explained from the radiograph, a cross section
of the weld, at the location of the above-mentioned ultrasonic indication shall be
made in such a way that the nature of the imperfection can definitely be
established.
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c. Radiographic Examination
The weld seam of all pipes shall be examined radio graphically for the entire
length.
d. Mechanical Properties
The mechanical properties of all pipes shall be tested and shall meet the
requirements of this specification. Purchaser Representative will select the places in
pipe from where the test specimen shall be removed.
i.Four (4) weld guided bend test specimen transverse to the helical weld shall be
removed. Of the four specimen, two specimen shall be used for the tact- bend test
and two for the root bend test.
ii.Tensile tests shall be conducted on:
iii.Six (6) weld cross-section specimen, three (3) from each end of pipe joint shall be
taken for metallographic examination. Two of these shall be tested for hardness at
room temperature after etching.
iv.Fracture toughness testing specimen shall be extracted as follows:
The base metal specimen shall be tested at - 40, -10, 0, + 20° C for shear area and
absorbed energy to produce full transition curve. The value at the test temperature
specified in SR 5A and SR 19 of API Spec. 5L and duly modified in this specification
for shear area and absorbed energy respectively shall be complied with. For other
temperatures, the value shall be for information only. The sets of weld and HAZ
specimen shall be tested for absorbed energy only at the same test temperature
applicable as per SR 19 of API Spec. 5L.
v.At points selected by Purchaser, twelve (12) DWTT specimens shall be removed
from base metal in a transverse direction. The sets of 3 base metal specimen shall
be tested at -40, -10, 0, +20°C for shear area to produce full transition curve. The
SPECIFICATION FOR HELICAL (SPIRAL) DOCUMENT No. REV-0
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value at the test temperature specified in SR 6 of API Spec 5L duly modified in this
specification shall be complied with. For other temperatures, the value shall be for
information only. (Note: This test is to be carried out only when required as per para
6.2.5.3 of this specification)
vi.Hardness test shall be conducted on selected pipes as per requirement of para 6.2.6
of this specification.
vii. One specimen from one pipe end shall be taken for residual stress test.
e. In addition, all the tests and inspections require to be conducted as per this
specification shall be conducted on all the pipes selected for testing during first day
production test.
f. In case of any test failure, no re-testing shall be applied and the entire first day
production shall be rejected.
The following information as applicable shall be furnished at Bid stage with respect to line
pipe to be supplied.
- Name(s) of proposed Manufacturer(s)
- Authorisation letter(s) from Manufacturer(s) where applicable.
- Authorisation letter(s) from Manufacturer(s) of skelp, in case skelp manufacturing
facility is not
an integral part of the Supplier’s pipe mill.
- Record of similar supplies made earlier by the Manufacturer for both skelp and pipes,
giving complete details of diameter, thickness, length, grade of skelp / pipe, service,
year, name of project, name of client, and contact person. In particular, details of
similar supplies made over the last five years shall be furnished.
- Histogram for dimensional parameter, chemical analysis and tensile test indicating
minimum, maximum, average and standard deviation for the previous supplies.
- Descriptive technical catalog(s) of the proposed Manufacturer(s).
- Copy of valid certificate of Authority to use API monogram as per clause 1.2 of this
specification.
- A clause wise list of technical deviations, if any, from the requirements of this
specification shall be furnished in the Performa enclosed with the Enquiry. Deviations
indicated anywhere else in the offer shall not be considered valid. In case of no
deviations, Bidder shall write “NO DEVIATIONS” in the said Performa.
X-RAY FILM
1 INTENT OF SPECIFICATION 2
2 SCOPE OF WORK 2
3 COVERAGE 2
4 REFERENCES 2
5 MANUFACTURING PROCESS 2
1.1 This specification establishes the minimum requirements for the manufacture of
Seamless Pipes in accordance with the requirements of API (American Petroleum
Institute) Specification 5L- 2000 (Forty Second Edition).
1.2 Unless modified and referred by this specification the requirements of API Spec. 5L-
2000 shall be valid.
2.1 The scope of the tenderer includes manufacture / supply, inspection / testing , marking
& packaging and despatch of seamless linepipes as indicated in the Material Requisition
(MR).
2.2 All codes and standards for manufacture, testing, inspection, etc, shall be of latest
edition.
2.3 Purchaser also reserves the right to delete or order additional quantities during
execution of order, based on unit rates and other terms & conditions in the original
order.
3.0 COVERAGE
3.1 The coverage by this specification is limited to linepipe covering non-sour hydrocarbons
in liquid or gaseous phase in accordance with API Specification 5L - 2000 (PSL-1 and
PSL-2 requirements, as applicable) covering seamless line pipes of sizes and grades as
indicated in the MR.
4.0 REFERENCES
4.1 All pipes and their dimensions, tolerances, chemical composition, physical properties,
heat treatment, hydrotest and other testing and marking requirements shall Conform to
the latest codes and standards specified in the MR. Deviations, if any, shall be clearly
highlighted in the offer.
The latest edition of following additional references are included in this Specification:
ASTM
ASTM E 92: Test Method for Vickers Hardness of Metallic Materials
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ASTM E 112: Standard Test Methods for Determining Average Grain Size.
BS
BS 5996: Specification for the Acceptance Level for Internal Imperfection in
Steel Plate, Strip and Wide Flats based on Ultrasonic Testing
5.2 Pipes shall be supplied in double random length, i.e. pipe length between 11.5 m and
12.5 m with an average length of 12.0 m.
5.3 Seamless pipes shall not have any circumferential seam joint in a random length.
6.1 All pipes shall be hydrostatically tested. The test mill pressure shall be as follows:
A
CARBON STEEL
S No. : TEST PRESSURE
MATERIAL STD
(i) ASTM A106 GR.B : ASTM A 530
(ii) API 5L GR.B,SEAMLESS : API 5L
(iii) API 5L,E.R.W : API 5L
(iv) API 5L,SPIRAL : API 5L
(v) ASTM A333 GR.3 & 6,SEAMLESS : ASTM A530
B
SEAMLESS ALLOY STEEL
S No. : TEST PRESSURE
MATERIAL STD
(i) ASTM A335 : ASTM A530
GR.P1,P12,P11,P22,P5,Pg
(ii) ASTM A268 TP 405,TP410 : ASTM A530
6.2 Material test certificates (physical properties, chemical composition & heat treatment
report) shall also be furnished for the pipes required.
6.3 Pipe with bevelled ends shall be in accordance with ASME B16.25. Weld contour shall
be as per Figure-2, Type-A.
7.1 All pipes shall be marked in accordance with the applicable codes, standards &
specifications. Additionally, purchase order number, item code and special conditions, if
any, shall also be marked.
7.2 Paint or ink for marking shall not contain any harmful metal or metallic salts such as
zinc, lead or copper which cause corrosive attack on heating.
7.3 Pipes shall be dry, clean and free from moisture, dirt and loose foreign materials of any
kind.
7.4 Pipes shall be protected from rust, corrosion & mechanical damage during
transportation, shipment and storage.
7.5 Rust preventive, used on machined surfaces to be welded, shall be easily removable
with a petroleum solvent and the same shall not be harmful to welding.
7.7 End protectors to be used on bevelled ends shall be securely and tightly attached with
belt or wire.
Table - 2B: PSL 2 Chemical Requirements for Heat and Product Analyses by
Percentage of Weight
Element Product Analysis (percent by weight)
C 0.16 max
Mn 1.50 max (For Grade B to X52)
1.60 max (For Grade X56 to X70)
Si 0.15 min
0.45 max
S 0.01 max
P 0.02 max
Al 0.07 max
Nb 0.05 max
V 0.08 max
Ti 0.04 max (For Grade B to X60)
0.06 max (For Grade X65 to X70)
Cr 0.20 max
Mo 0.10 max
Cu 0.35 max
Ni 0.20 max
N 0.012 max
B 0.0005 max
SPECIFICATION FOR ELECTRIC WELDED DOCUMENT No. REV-0
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Note: g (New)
i. V+Nb+Ti shall not exceed 0.15%.
ii. Cu+Ni shall not exceed 0.40%.
iii. Al/N shall be min. 2.
f. (New) For all pipe sizes and specified wall thickness, additional fracture toughness
requirements as per Supplementary Requirements Appendix-F SR 19 of API Spec 5L
and as modified in this specification shall be applicable for body, weld and heat
affected zone.
Where
D - Specified outside diameter of pipe, mm
t - Specified wall thickness of pipe, mm
1.4 - Peaking factor
e - Strain
Minimum value of 'e' shall be as follows:
Grade of Steel Min ’e' value
Gr. B 0.1425
X-42 0.1375
X-46 0.1325
X-52 0.1250
X-60 0.1125
SPECIFICATION FOR ELECTRIC WELDED DOCUMENT No. REV-0
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X-65 0.1100
X-70 0.1075
6.2.7.3 (New)
Procedure
The mandrel shall be plunged into the specimen, with the weld in contact with the
mandrel, to such a depth that the angle of engagement between mandrel and
specimen reaches 60° (Ref. Fig 6.2.7 of this specification). If the combination of
diameter and wall thickness of pipe and radius of mandrel is such that the angle of
engagement does not reach 60° the mandrel shall be plunged into the specimen
until opposite walls of the specimen meet.
6.2.7.4 (New)
Acceptance Criteria
A specimen which fractures completely prior to the specified engagement of mandrel
and specimen, or which reveals cracks or ruptures in the weld or heat affected zone
longer than 4 mm, shall be rejected. Cracks less than 6 mm long at the edges of the
specimen shall not be cause for rejection. Dye penetrate testing may be used to
positively confirm cracks or openings.
Pipe Ends
Diameter tolerances for the pipe ends indicated in API Spec 5L Table-8 shall be
applicable on the inside diameter for pipe sizes > 14 and on outside diameter for
pipe sizes ≤12”.
The inside diameter, based on circumferential measurement, over a length of 100
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mm from the end shall comply with the tolerances specified in API Spec 5L, Inside
diameter is defined as ID = (OD-2WT.) where ID, OD & WT are the inside diameter,
specified outside diameter and specified wall thickness respectively.
Out of Roundness
Out of Roundness i.e., the difference between the maximum and minimum diameter
(inside for pipe size > 14 and outside for pipe size ≤ 12) at pipe ends shall comply
with the following limits.
Pipe size Tolerance
≤10¾ 2mm
>12¾ 3 mm
Out of roundness tolerance apply to maximum and minimum diameters as measured
with a bar gauge, caliper or device measuring actual maximum and minimum
diameter. Out of roundness tolerance indicated in API 5L Table-8 stands deleted.
Each pipe shall be measured for conformance to above requirements. All dimensions
and tolerances shall be measured and recorded at least 3 times per operating shift
(12 hrs maximum).
7.5 LENGTH
All pipes shall be supplied with length between 11.5 m and 12.5 m. However pipe
with length between 10.0 m and 11.5 m can also be accepted for a max. of 5% of
the ordered quantity. The minimum average length of the entire ordered quantity in
any case shall be 12.0m. API Spec 5L Table 11 shall not be applicable. Overall
length tolerance shall be (-) Zero and (+) One pipe length to complete the ordered
quantity.
Each pipe shall be measured for conformance to above requirements and all
measurements shall be recorded.
7.7 JOINTERS
Jointers on pipes are not permitted.
Plate/Skelp Inspection
The longitudinal edges of the plate/skelp shall be 100% ultrasonically inspected over
a width of at least 25 mm from the trimmed plate/skelp edge. Remaining plate/skelp
9.13 REPROCESSING
This para stands cancelled.
10 Marking
10.1 GENERAL
Marking specified in AP! Paragraphs and otherwise specified in the Purchase Order
shall be in English language and international System (SI) of units. Marking shall
comply with Appendix I of API Spec 5L and as modified in this specification.
12 Documents
12.1 CERTIFICATION
Manufacturer shall furnish to Purchaser a certificate of compliance stating that the
material has been manufactured, sampled, tested, and inspected in accordance with
this specification and has been found to meet the requirements. In addition all
details as per Appendix F Supplementary Requirement SR 15 shall also be submitted
to Purchaser/Purchaser Representative during inspection at pipe mill.
APPENDIX-F
SUPPLEMENTARY REQUIREMENTS (NORMATIVE)
SR5 Fracture Toughness Testing (Charpy V-Notch) for Pipe of Size 4½ or
Larger
SR 5.1 The Manufacturer shall perform Charpy V-notch test for determining Shear Area.
SR 5.3 The specimen shall be fall sized or largest obtainable sub size in case pipeline
diameter and thickness does not permit full size specimen. In case it is not feasible
to obtain transverse specimen, a longitudinal specimen may be taken upon approval
from Purchaser.
SR 5.4 Flattened specimen shall not be used.
SR 5.5 This para stands deleted.
SR 5A Shear Area
SR 5A.1 Three transverse specimens representing one test shall be taken from one length of
pipe per heat per lot of 100 pipes per combination of pipe size and specified wall
thickness.
SR 5A.2 Unless specified otherwise in the Purchase Order, the specimen shall be tested at
+32°F (0°C). The average shear value of the fracture appearance of the three
specimens shall not be less than 75% and the all heat average for each order, per
diameter, size and grade shall not be less than 80%.
Note: The acceptance criteria of shear area as referred in API Spec. 5L para SR 5A.3 SR
5A.4 and SR 5A.5 stand modified based on above mentioned requirements.
Wherever 'heat' indicated in API Spec 5L SR 5A.3, SR 5A.4, SR 5A.5 and SR 5A.6
shall be replaced by 'lot'. Lot shall be as per SR5A.1 as above.
1.5 Length
Actual length shall be marked in metres.
1.7 Die Stamping
Additionally, the pipe number shall be placed by cold rolling or low stress dot
marking on the outside surface of the pipe at an approximate distance of 50 mm
from both ends. In case of non-availability of either cold rolling or low stress dot
marking facility in pipe mill, an alternative marking scheme of a permanent nature
may be proposed by the Manufacturer.
The CONTRACTOR shall be familiar with the requirements of these documents and
shall make them readily available at the coating plant to all persons concerned with
carrying out the works specified in this specification.
3.0 PLANT SCALE AND INSTALLATION
3.1 CONTRACTOR shall size coating plant(s) after evaluating the scale of work and the
time schedule required for the works. Coating plant(s), both new or existing, shall be
installed into a yard whose geometry and dimensions are such as to allow the
execution of a continuous work schedule. For this purpose the CONTRACTOR shall
ensure non-stop work execution owing to prohibitive adverse weather conditions and
install requisite equipment and plant in roofed and adequately weather protected
areas.
4.0 MATERIALS
4.1 The three layer coating system shall comprise of a powder epoxy primer, polymeric
adhesive and a polyethylene top coat. Coating materials shall be suitable for the
service conditions and the pipe sizes involved. The coating materials i.e. epoxy
powder, adhesive and polyethylene compound shall have proven compatibility. The
coating system and materials shall be pre-qualified and approved by COMPANY in
accordance with provisions Annexure I of this specification. CONTRACTOR shall
obtain prior approval from COMPANY for the coating system and coating materials,
4.2 The coating materials Manufacturer shall carry out tests for all properties specified in
para 5.3.1 and 5.3.2 for each batch of epoxy, adhesive and polyethylene compound.
In addition, the Manufacturer shall also furnish Infrared Scan for each batch of epoxy
powder. The coating materials Manufacturer shall issue test certificates as per DIN
EN 10204, 3.1B for each batch of materials supplied to CONTRACTOR and the
same shall be submitted to COMPANY for approval prior to their use.
4.3 In addition to Manufacturer's certificate, the CONTRACTOR shall draw samples from
each batch of epoxy, adhesive and polyethylene in the presence of COMPANY
Representative and test for the following properties at the coating yard at least one
week prior to its use, to establish compliance with the Manufacturer's test
0.926 min.
Specific Gravity @ (MDPE)
c. - ASTM D 792
+ 25°C 0.941 min.
(HDPE)
Water Absorption, 24
e. % 0.05 max. ASTM D 570
hours, @ + 25 °C
Volume Resistivity @ +
f. Ohm-cm 1016min. ASTM D 257
25°C
Dielectric withstand,
g 1000 Volt/sec rise @ + Volts/ mm 30,000 min. ASTM D 149
25°C
Environmental Stress
Crack Resistance
(ESCR) (for F 50) :
k. -Medium Density-
300
Condition "C”
Hours
-High Density- ASTM D1693
Condition "B"
300
Impact Strength
(Min. of 30 impacts on Joules per
b. body along the length. mm of coating 7 min DIN 30670
No breakdown allowed thickness
when tested at 25 Kv)
Indentation Hardness
0.2 max
c. @23+/-2°C mm DIN 30670
0.3 max
@70+/-2°C
Melt Flow
Rate
shall not deviate
f. Heat Ageing (*) - DIN 30670
by more than
35% of original
value
Melt Flow
Rate shall not
9- Light Ageing (*) - deviate by more DIN 30670
than 35% of
regional value
Cathodic Disbondment
mm radius of 15 max.
@ + 65° C after 30
h. disbondment ASTM G42
days
(**)
@ + 65°C after 48 hrs
7 max.
Degree of Cure of
Epoxy. Percentage
Cure, ∆H. % 95 CSA Z
I 0
∆Tg C +3/-2 245.20-98(***)
7.9 COMPANY reserves the right to conduct any or all the test required for qualification
through an independent laboratory or agency at the cost of CONTRACTOR when in
COMPANY's opinion, the results are deemed suspect. COMPANY's decision shall
be final.
C Hardness - Nil
g. pH - 6.5 to 7.5
Tests to determine the above properties shall be carried out in accordance with
"Standard Methods for the Examination of Water and Wastewater" published jointly
by American Public Health Association, American Water Works Association and
Water Pollution Control Federation.
Quality of the deionised water shall be monitored at the start of each shift and at
every four hours interval. Non-compliance of deionised water wrt the above
requirements shall cause for stoppage of the operations.
8.6.3 The pH of the pipe surface shall be determined both before and after the de-ionised
water rinse initially on each pipe and in case of consistent results, the frequency may
be relaxed to once per hour at the discretion of COMPANY Representative. The
measured pH shall be as follows:
Before de-ionised water wash : 1 to 2
After de-ionised water wash : 6 to 7
8.6.4 After the deionised water wash, the pipe shall be dried with dry air and preheated to a
temperature of 65°C to 85°C.
8.6.5 The salt tests shall be carried out after deionised water rinse. One test shall be carried
out at one end of each pipe. The acceptance criteria shall be 2g/cm2. An approved
salt meter (SCM 400 or equivalent) shall be used to carry out salt tests and shall be
calibrated in accordance with the equipment manufacturer's recommendations.
8.7 Abrasive cleaning carried out shall be such that the resultant surface profile Is not
dished and rounded when viewed with 30X magnification. The standard of finish for
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cleaned pipe shall conform to near white metal finish to Sa 2 ½ of Swedish Standard
SIS 055900 latest edition. Surface of pipe after abrasive blast cleaning shall have an
anchor pattern of 50 to 70 microns (Rz), This shall be measured for each pipe by a
suitable instrument such as surface profile depth gauge. In addition the pipe surface
after blast cleaning shall be checked for the degree of cleanliness (Sa 2 ½), degree
of dust and shape of profile. Degree of dust shall comply the requirements of ISO
8502 - 3. Acceptance limit shall be either quality rating 2 or Class 2.
8.8 All pipes shall be visually examined for presence of any shot/grit/loose material left
inside the pipe during blast cleaning. Suitable mechanical means (stiff brush) shall
be employed to remove the same before the pipes are processed further. In
addition, inside surface of the pipe shall also be visually inspected for presence of
any foreign material or shots and grit (free or embedded/sticking to pipe inside
surface). The pipe inside surface shall be examined using sharp floodlight focused at
the middle of the pipe at one end while inspection is carried out visually from other
end. Any foreign material or shots/grit present in the pipe shall be completely
removed by mechanical brush, high pressure air jets, by tilting of pipe, etc.
8.9 At no time shall the blast cleaning be performed when the relative humidity exceeds
85%. The CONTRACTOR shall measure the ambient conditions at regular intervals
during blast cleaning and coating operations and keep records of prevailing
temperature, humidity and dew point.
8.10 The blast cleaned surface shall not be contaminated with dirt, dust, metal particles,
oil, water or any other foreign material, nor shall the surface or its anchor pattern be
scarred or burnished. All blast cleaned pipe surface shall be kept in dust free
enclosure prior to coating. After blast cleaning, all surfaces shall be thoroughly
inspected under adequate lighting to determine anchor pattern, quality of blasting
and identify any surface defects prior to coating application. All surface defects such
as slivers, scab, burns, laminations, welds spatters, gouges, scores, indentations,
slugs or any other defects considered Injurious to the coating Integrity made visible
during blast cleaning shall be reported to the COMPANY Representative and on
permission from COMPANY Representative, such defects shall be removed by filing
or grinding. After any grinding or mechanical repairs, the remaining wall thickness
shall be checked and compared with specified thickness. Any pipes having thickness
less than 95% of specified thickness shall be kept aside and disposed off as per the
instructions of COMPANY Representative. The method employed to remove surface
defects shall not burnish or destroy the anchor pattern or contaminate the surface.
Pneumatic tools shall not be used unless they are fitted with effective air/oil and
water traps. Where burnishing results in destruction of anchor pattern, the anchor
pattern shall be restored by suitable means. Pipes which have damages repaired by
grinding and have ground areas more than 50mm in diameter shall be re-blasted.
Any dust or loose residues that have been accumulated during blasting and/or
during filing/grinding operations shall be removed by vacuum cleaning.
If contamination of surface occurs, the quality of blast cleaning method and process
shall be examined. If the surface roughness is outside the specified limit, the blast
cleaning material shall be checked and replaced.
>80 2 hours
70 to 80 3 hours
<70 4 hours
Any pipe not processed within the above time-humidity requirement shall be
completely re-blasted. Any pipe showing flash rusting shall be re-blasted even if the
above conditions have not been exceeded.
8.15 Pipe handling between abrasive blasting and pipe coating shall not damage the
surface profile achieved during blasting. Any pipe affected by the damage to the
surface exceeding 200mm2 in area and/or having contamination of steel surface
shall be rejected and sent for re-blasting.
Minimum Coating
Pipe Size (Specified Outside Diameter) Thickness (mm)(*)
Normal Type Reinforced
(n) Type (v)
Up to 10 ¾ " (273.1 mm) 2.0 2.7
Over l0 ¾ (273.1 mm) to below 20" (508.0
2.2 2.9
mm)
From 20" (508.0mm) to below 32" (813.0
2.5 3.2
mm)
(*) In case HDPE material is used as top coat, 10% reduction in minimum coating
thickness specified is permissible.
Required coating thickness shall be Normal Type (n), unless otherwise specified.
9.2.3 Coating materials shall be inspected in accordance with the manufacturer's
recommendation prior to coating application and it shall be ensured that the
materials are moisture free. In case the relative humidity exceeds 80%, the adhesive
and polyethylene material shall be dried using hot dry air as per the directions of
COMPANY Representative.
9.2.4 Prior to starting the application of fusion bonded epoxy powder, the recovery system
shall be thoroughly cleaned to remove any unused powder remaining from a
previous line pipe coating application. The use of recycled powder shall be permitted
subject to:
a. Satisfactory qualification of the reclaimed system during PQT stage
b. The proportion of the reclaimed powder in the working mix does not exceed 20%
at any one time.
c. The quality of the recycled powder being routinely checked during production, at
a minimum frequency of once per shift and consistently meets the requirements
stated at para 5.3.1
9.2.5 Dry air, free of oil and moisture shall be used in the coating chamber and spraying
system and filters, dehumidifier/dryer as required along with control & monitoring
system shall be provided for this purpose. Dew point of air used to supply the
fluidized bed, epoxy spray system and epoxy recycling system shall be at least (-)
40°C and this shall be monitored during the regular production.
9.2.6 Air pressure in the epoxy spray guns shall be controlled, continuously monitored and
recorded by using suitable instruments. The air pressure shall be controlled within
the limits established during coating procedure qualification. The monitoring
system shall be capable of rising an alarm activate audio system (hooter) in the
event of change in air pressure beyond the set limits. Any deviation from the pre-set
limits shall be rectified, if immediate rectification is not feasible, the production shall
be stopped until cause of deviation has been removed. Any pipe coated during the
duration of air pressure deviation shall be identified by suitable marking and
rejected. Such rejected pipes shall be stripped and recoated.
9.2.7 Extruded adhesive layer shall be applied before gel time of the epoxy coating has
elapsed and within the window recommended by the manufacturer. The
CONTRACTOR shall establish, to the satisfaction of the COMPANY
Representative, that the adhesive is applied within the gel time window of epoxy and
at the temperature recommended by the adhesive manufacturer. The
CONTRACTOR shall state the minimum and maximum time interval between
epoxy and adhesive application at the proposed pre-heat temperature and
line speed.
13.0 MARKING
CONTRACTOR shall place marking on the outside surface of the coating at one end
of the coated pipe, and marking snail indicate, but not limited to the following
information:
a. Pipe number, Heat number
b. Diameter & Wall thickness
c. Coated pipe number
d. Colour band
e. Any other information considered relevant by COMPANY.
f. Pipe Manufacturer Name
g. Inspection Mark/Punch
CONTRACTOR shall obtain prior approval on marking procedure to be adopted from
the COMPANY.
ANNEX B : (NORMATIVE) DRY FILM THICKNESS (REFER TO SUB CLAUSE 5.3.3 AND
7.1.2)
The intent of this specification is to set forth the minimum requirements for supply /
arrangement of all materials, plant, equipments, plant sites consumables, utilities and
application including all labour, supervision, inspection & test etc for application of
internal epoxy coating.
2. DEFINITIONS
3. ABBREVIATIONS
BS - British Standards
The latest edition of the following codes and standards shall establish the minimum
standards for the work. VENDOR may use alternate standards that meet or exceed
those if approved by OWNER.
The VENDOR shall notify OWNER / CONSULTANT of any conflict between this
specification, the related data sheets, the Codes and Standards and any other
specifications noted herein. Resolution and / or interpretation precedence shall be
obtained from OWNER / CONSULTANT in writing before proceeding with the design &
manufacture.
Each pipeline shall be provided with an internal liquid epoxy coating by the Vendor. The
internal coating shall be as per ISO 15741 – 2001 (E).
5. COATING MATERIAL
The coating material shall typically be a two-pack epoxy paint. It shall not contain any
substances which will be released from the paint film after it has cured and are proven
to be detrimental to the operation of the pipeline and the quality of the gas.
Unless otherwise agreed, the coating material shall be qualified in accordance with 5.2
and 5.3 and shall not be changed after qualification.
The manufacturer of the coating material shall provide on request infrared
spectrograms of the base component and the curing agent component (see 5.2.8)
In addition, the manufacturer shall provide a product data sheet (see 5.6), a health and
safety data sheet and a certificate stating the test results obtained in accordance with
5.2 and 5.3 respectively and, if applicable, deviating test conditions.
The manufacturer shall also provide with every batch of the coating material a batch
test certificate stating the information as given in 5.8.
Unless otherwise agreed, the applied coating shall provide corrosion protection during
storage and transport for a minimum period of one year without significant breakdown
of the coating.
The typical operating-temperature range for this type of coating is between -200C and
110 0C.
Where, subsequently, external coatings have to be applied, care shall be taken not to
allow the internal coating to be damaged by the elevated temperatures which may
occur.
5.2.1. General
The following sub clauses describe the laboratory test methods which are required for
qualification of the coating material.
When determined in accordance with ISO 3251, the non-volatile matter (by mass) of
the coating material shall comply with the value specified by the coating material
manufacturer in the qualification certificate (Table- 2)
5.2.4. Viscosity
When determined by the method specified by the manufacturer, the viscosity of the
ready-mixed coating material shall comply with the value specified by the coating
material manufacturer in the qualification certificate (Table 2)
5.2.5. Density
When determined in accordance with one of the parts of ISO 2811, the density of the
coating material shall comply with the value specified by the coating material
manufacturer in the product data sheet (Table 1)
When determined in accordance with the method described in annex A, the ash
(residue on ignition) of the coating material shall comply with the value specified by the
coating material manufacturer in the qualification certificates (Table 2)
The pot life is considered to be the time taken by the ready-mixed coating material to
reach a condition at which it can no longer be applied satisfactorily. The pot life shall be
specified in the product data sheet (see 5.6)
Infrared spectrograms of the base component and the curing agent component shall be
submitted on request.
5.2.9. Appearance
The appearance and continuity of the coating shall be inspected visually without any
magnification.
If specified, condition the coated test panels using one of the following cycles,
depending on the substrate and on the individuals test. Cycle B and cycle C are optional
and the choice of the conditioning cycle depends on the time available to perform the
test procedure.
Cycle A
Cycle B
- Condition for a minimum of 30 minutes at 18OC to 25OC and ≤ 80% relative humidity
before testing.
Cycle C
- Condition for a minimum of 30 minutes at 18OC to 25OC and ≤ 80% relative humidity
before testing.
Unless otherwise agreed, the dry film thickness of the coating, applied on a glass or
steel panel, shall be between 60 µm and 100 µm except for the test described in 5.3.6
(resistance to neutral salt spray).
Unless otherwise agreed, the dry film thickness shall be measured in accordance with
ISO 2808: 1997, Method No. 2 for glass and Method No. 10 for blast-cleaned steel,
following the procedure given in annex B.
5.3.4. Adhesion
When determined in accordance with ISO 2409, the cross-cut classification of the
coating applied on steel panels and conditioned using cycle B or C (see 5.3.2) shall be
equal to or lower than 1.
When determined in accordance with ISO 2815, the Buchholz hardness of the coating,
applied on glass or steel panels and conditioned using cycle B or C (see 5.3.2) shall
have a value of 94 or more.
The coating, applied on steel panels with a dry film thickness of 60 µm to 75 µm,
conditioned using cycle B or C (see 5.3.2), and with an X-cut down to the substrate at
least 20 mm from any edge, shall be tested in accordance with ISO 7253 for 480 h.
After the test, allow the test panels to dry for at least 30 min at 18OC to 25OC and ≤
80% relative humidity. The coating shall be free from any signs of deterioration, for
example blistering (except in the area within 2.0 mm from the X-cut), cracking and
staining. Any corrosion shall extend not more than 2.0 mm at the most from the X-cut.
It shall not be possible to remove by means of clear plastic tape more than 3.0 mm of
the coating in any direction from the area around the X-cut.
Prepare two different sets of coated test panels, each set consisting of 3 steel panels.
The dimensions of the panels shall be approx. 100 mm X 50 mm X 0.8 mm.
- After ageing, subject the test panels to a bend test in accordance with 5.3.8
The result of the bend test shall comply with the requirement specified in 5.3.8.
Prepare steel panels and condition them using cycle B or C (see 5.3.2). When the panel
are tested in accordance with ISO 6860, the maximum extent of cracking along the
panel from the small and of the mandrel shall be less than or equal to 13 mm, and
there shall be no loss of adhesion.
Prepare steel panels and condition them using cycle B or C (see 5.3.2). When the
panels are tested with annex C, they shall have a generally good appearance when
examined in accordance with 5.2.9 and shall not show any blistering. The adhesion
value shall fulfill the requirements given in 5.3.4 after conditioning for 24 h and 40 h at
18 OC to 25OC and ≤ 80% relative humidity.
Prepare steel panels and conditions them using cycle B or C (see 5.3.2). When the
panels are tested in accordance with ISO 2812 – 2 for 480 h, the coating shall not show
any blistering or appreciable softening.
The examination shall be carried out 3 min after the panels have been removed from
the test liquid.
Prepare steel panels and condition then using cycle B or C (see 5.3.2). When the panels
are tested in accordance with ISO 2812-1:1993, Method No. 1, Procedure a, for 168 h,
the coating shall not show any blistering or appreciable softening. Use the following test
liquid: cyclo hexane; 95% by volume di-ethylene glycol solution in water; hexane;
methanol; toluene and lubricating oil (e.g. compressor shall oil in accordance with ISO
6743-4). The test panels shall be completely immersed in the test liquid.
The examination shall be carried out at 18 0C to 25 0C and ≤ 80% relative humidity 3
min after the panels have been removed from the test liquid. After conditioning for 24 h
at 18 0C to 25 0C and ≤ 80% relative humidity, the adhesion value shall fulfill the
requirements given in 4.3.4. A change in the colour of the coating shall not be
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considered as an indication of inferior coating quality.
Prepare steel panels and condition them using cycle B or C (see 5.3.2). When the
panels are tested in accordance with annex D, the coating shall not show any blistering.
The examination shall be carried out at 18 0C to 25 0C and ≤ 80% relative humidity 3
min after the panels have been removed from the test liquid.
The adhesion value shall fulfil the requirements given in 5.3.4 after conditioning at 18
0
C to 25 0C and ≤ 80% relative humidity for 24 h.
All coating materials and solvents shall be stored in the original container bearing the
manufacturer’s label and instruction. At least the following information shall be shown
on the label:
It necessary to ensure that the goods or services supplied comply in all respects with
the requirements of this International Standard. The coater shall therefore set
up and maintain a quality assurance system as, for example, detailed in ISO 9001.
The purchaser shall have the right to undertake inspection and testing of the coated
goods during any stage of coating at which the quality of the finished goods may be
affected and to undertake inspection or testing of coating materials, or other materials
used, to ensure compliance with the requirement given in 5.2 and 5.3.
Shelf life
Density b
Test method used (see 5.2.5)
Pot life a
(see 5.2.7)
Flash point c
Recommended thinner
Theoretical spreading rate (l/m2 or kg/m2) for a given dry film thickness.
b. Give separately for base component and curing agent component (if
pigmented)
c. Give separately for base component, curing agent component and mixed
coating material.
The qualification certificate shall give, as a minimum, the values of the properties listed
in Table 2.
Date of issue
Name of coating material
Authority of issue
Resistance to chemicals
- Resistance to cyclohexane
a. Separate for base component, curing agent component and mixed coating
material.
b. Separate for base component and curing agent component (if pigmented).
The batch test certificate shall give, as a minimum, the information and test results for
the items listed in Table 3
Date of issue
Batch number
Name of coating
material
Name of coating
material
manufacturer
Production date
c. If required.
d. If pigmented.
6.1 General
6.2
During application of the coating material, all steps in the coating process shall be
assessed and recorded.
The parameters listed in Table 4 shall be included.
Table 4 – Minimum items to be checked and recorded during the coating process
Surface condition
after
surface preparation
Surface cleanliness ISO 8501-1 Twice per shift As specified
Surface profile ISO 8503-2 Twice per shift As specified
Environmental
conditions in the
painting area
Ambient temperature Instrumental At every change of
As specified
Steel temperature Instrumental shift
Relative humidity Instrumental
Flash point instrumental
a. The wet sponge test shall be carried out only if the porosity test on glass
panels constitutes a failure
First check that the surface are free from any foreign matter such as welding flux,
welding spatter, salts, oil or grease. If necessary, wash the surfaces with a high-
pressure jet of fresh water. Removed organic contaminants using detergents or suitable
organic solvents.
Then blast-clean the surfaces to surface preparation grade Sa 1/2 in accordance with
Removed, using suitable methods, any surface irregularities or imperfections which may
have become visible.
Check the surface profile. Unless otherwise agreed, it shall be such that R γ5 (see ISO
8503-1) is between 25 μm and 60 μm.
During and after blast-cleaning and prior to application of the coating material, the
temperature of the steel surface shall be at least 30C above the dew point or the
minimum curing temperature given by the coating material manufacturer, whichever is
the higher.
Before removing each component from its container, stir or agitate it until it is
homogeneous, using equipment which is capable of homogenizing the entire contents
of the container without excessively entraining air into the material. Mix the two
components (base component and curing agent component) thoroughly and, if
necessary, dilute in accordance with the coating material manufacturer’s instructions.
After the material has been homogenized, it shall be continuously mixed at a slow
speed. The mixed paint shall be free of any lumps and pieces of skin. Measure the
viscosity in accordance with the method recommended by the manufacturer and record
it. Check whether it complies with the value specified by the manufacturer and keep it
constant during application procedure.
Check the surface to be coated to see whether it still complies with the specified surface
preparation grade and profile (see 6.2)
Apply the paint in a covered or enclosed space, shielded from wind, blowing dust and
inclement weather, using the application parameters recommended by the coating
material manufacturer and approved by the coater.
The ambient temperature and relative humidity and the temperature of the steel
surface application and subsequent drying/ curing shall be in accordance with the
recommendations of the manufacturer of the coating material. The temperature of the
steel shall be at least 30C above the dew point. In the case of accelerated curing, the
temperature shall be as agreed between the coating material manufacturer and the
coater.
Spray the paint continuously and uniformly on to the whole surface to be coated. The
coating shall be uniform, and particular attention shall be given to achieving the
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specified dry film thickness. Unless otherwise specified or agreed, maintain a cutback
length of (20 + 5) mm.
In pursuance of this duty, each person shall ensure that all the statutory requirement of
the country in which their work, or any part of the work, is carried out are complied
with.
7. PRODUCTION CONTROL
7.1.1. Appearance
Inspect the coating visually for uniformity of colour, smoothness and freedom from
runs, holidays and other defects that could be detrimental to its quality.
Unless otherwise specified or agreed, the minimum dry film thickness of the coating
shall be 60 µm above the peaks in the profile of the substrate and shall be determined
in accordance with Annexure B.
Perform the tests specified in 7.2.2 to 7.2.5 on coating applied by spraying on to steel
test panels, to give dry film thickness specified in 5.3.3. Prepare the test panels as
specified in 6.2 and apply the paint in accordance with the instructions of the coating
material manufacturer. Use conditioning cycle B or C (see 5.3.2). Perform each test at
least in duplicate.
Table 5 shows the required frequency of the tests specified in 7.2.2 to 7.2.5
7.2.2. Adhesion
When determined in accordance with ISO 2409, the cross-cut classification of the
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coating shall be equal to or lower than 1.
When determined in accordance with ISO 2815, the Buchholz hardness of the coating
shall be at least 94.
When determined in accordance with ISO 6860, the maximum extent of cracking along
the panel from the small end of the mandrel shall be less than or equal to 13 mm, and
there shall be no loss adhesion.
When tested in accordance with annex F, the coating shall not show any softening,
wrinkling or blistering.
If the porosity test on a glass panel is deemed a failure, the wet-sponge test given in
Annex G shall be carried out on the surfaces painted with the coating material which
failed the glass –panel test, testing at least ten areas, excluding welds. The coating on
these surfaces shall not have more than 1 pinhole per 100 cm2
Table 5 – Required frequency of, and acceptance criteria for, the production
–control tests specified in 7.2.2.to 7.2.5
9.1. Handling
Coated pipes shall be handled in such a way that no damaged is caused to the coating.
During transportation to the storage area at the coater’s workshop, the coater shall take
all relevant precautions to avoid damaged to the coating.
9.3. Storage
Coated pipes shall be stored in such a way that the quality of the coating will not be
affected.
When loading pipes at the workshop or in the field, all relevant precautions shall be
taken to avoid the possibility of damage to the pipes or to the coating during
transportation.
The coater is responsible for ensuring that all pipes delivered to the purchaser are
correctly coated and the coating is properly cured.
A.1 General
This annex describes a method for determining the ash residue from a coating.
A.2 Apparatus
A.3. Procedure
Weigh, to the nearest 1 mg, between 3g and 5 g of the product into a porcelain crucible
(A.2.1).
Place the crucible in a hood and heat with a low flame until the contents of the crucible
are a dry,
charred mass. Transfer to the muffle furnace (A.2.2) and ignite the residue at red heat
(not exceeding 6000C) until the ash is free of carbon.
Repeat the igniting, cooling and weighing until the difference between successive
weighing does not exceed 1 mg.
Calculate the ash WA, as a percentage by mass, using the following equation:
Where
This annex describes the measurement of the dry film thickness of a coating on a blast-
cleaned steel surface using an instrument based on the permanent-magnet principle or
the inductive-magnet principle.
B.2. Apparatus
Unless otherwise specified or agreed, the minimum dry film thickness of the coating
shall be determined in accordance with ISO 2808:1997, Method No.10, using a single-
pole instrument of the permanent-magnet or inductive-magnet type.
B.3. Procedure
Before use, ascertain that the instrument is in good working order (see manufacturers)
Calibrate the instrument on a smooth, flat, level steel plate, using ISO 2808:1997,
Method No.10. It will then be necessary to determine a “correction factor” by taking a
series of readings on the unpainted blast-cleaned surface and calculating the average.
All readings subsequently taken on the painted surface are then reduced by the
“correction factor” to give the true value of the thickness above the peaks.
For each pipe or fitting tested, at least 8 values shall be recorded. Each value shall be
constituted by the arithmetic mean of 5 different measurement taken very close to the
point at which the thickness is to be measured. When during a series of measurement
an individual dry film thickness value does not meet the specified criterion, a repeat
measurement not more than 10mm from the point of first measurement shall be carried
out. The first value shall then rejected and replaced by the result of the repeat
measurement. The maximum number of repeat measurements permitted is 2.
If any measurement are less than 80% of the nominal dry film thickness (NDFT). Then
the specimen fails this test.
B.4. Results
In cases of dispute the result at one point, recalibrate the instrument and carry out five
measurements, again very close to the point. Recalculate the arithmetic mean of the 5
measurements.
C.2.1 Sealed chamber, capable of resisting the test pressures during the whole of the test
C.2.3 Pressurizing system, capable of increasing the pressure by 1 bar per minute
- lengths of steel pipe approx. 100mm long with a minimum diameter of 80 mm or, if
the diameter is too large for the pipe to fit into the chamber, specimens obtained from
the pipe or fitting.
The surface of the test panels or lengths of the pipe shall be prepared and coated at
the same time and
in the same way as the corresponding production surfaces.
C.4 Procedure
C.4.1 General
Unless otherwise specified by the coating material manufacturer, wait a month after the
coating has been applied to the test panels or lengths of pipe before carrying out any
test.
• 20 h for the 1st to 4th cycles and the 6th to 9th cycles,
• 68 h for the 5th and 10th cycles;
- Release the pressure rapidly over a few minutes (not more than 5 minutes);
- Leave the coating at atmosphere pressure for 4 h to permit the development of any
blisters on the coating, so that a cycle lasts either 24h or 72h (this latter period
corresponds to the weekend, i.e. from Friday to Monday).
Immediately at the end of the 10th test cycle, open the chamber and examine the
appearance of the coating, noting all modifications (corrosion, spots or blisters).In
addition, carry out an adhesion test in accordance with ISO 2409. Repeat the
appearance examination after 24 h and after 48 h, again noting all modifications.
Figure C.1 – Complete set of pressure cycles.
The test is carried out only when the coated pipes are utilized at operating pressures
higher than 100 bar. The test pressure shall be at least the pressure specified for that
pipeline.
Put the specimen in the chamber and then subject it to the specified pressure for 24 h
so that the pressurizing gas can penetrate into the coating.
Release the pressure rapidly over a few minutes (not more than 5 minutes)
Immediately at the end of the test cycle, open the chamber and examine the
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appearance of the coating, noting all modifications (corrosion, spots or blisters).In
addition, carry out an adhesion test in accordance with ISO 2409. Repeat the
appearance examination after 24 h and after 48 h, again noting all modifications.
C.5 Results
Record any degradation observed immediately on removing the specimen from the
chamber and indicates any further changes after 24 h and 48 h.
D.1 General
The test consists of verifying, by evaluation of the visual appearance and determination
of the adhesion, the behavior of the applied coating when subjected to pressure
variation in a liquid environment (water/CaCO3).
D.2.1 Sealed chamber, capable of resisting the test pressure during the whole of the test.
D.2.3 Pressurizing system, capable of increasing the pressure by 1 bar per minute.
- lengths of steel pipe approx. 100 mm long with a minimum diameter of 80 mm or, if
the diameter is too large for the pipe to fit into the chamber, specimens obtained from
the pipe or fitting.
The surfaces of the test panels or length of the pipe shall be prepared and coated at
the same time and in the same way as the corresponding production surfaces.
D.4 Procedure
Unless otherwise specified by the coating material manufacturer, wait a month after the
coating has been applied to the test panels or lengths of pipe before carrying out any
test.
This test is carried out at least 100 bar if the maximum operating pressure is 100 bar or
less. If the operating pressure is higher than 100 bar, the test pressure shall be at least
the pressure specified for that pipeline.
Put the specimen in the chamber and then subject it to the specified pressure specified
for 24 h so that the pressurizing liquid can be penetrate into the coating.
Release the pressure rapidly over a few minutes (not more than 5 minutes).
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Immediately at the end of the test cycle, open the chamber and examine the
appearance of the coating, noting all modifications (corrosion, spots or blisters).In
addition, carry out an adhesion test in accordance with ISO 2409. Repeat the
appearance examination after 24 h and after 48 h, again noting all modifications.
D.5 Results
Record any degradation observed immediately on removing the specimen from the
chamber and indicates any further changes after 24 h and 48 h.
Place a panel inside the pipe to be coated with non-frosted side facing the wall of the
pipe; keep it in position at each end by means of adhesive tape (max. overlap on glass
10 mm). Just before coating, check that the panel is free from dust or pollution. Apply
the coating material to glass panel during the pipe-coating process.
(a) Wet film- Five minutes after application of the coating material, place the glass panel
over an opaque (dark) shield measuring approx. 300 mm x 300 mm with a 50 mm x 20
mm slot in the middle. Hold the panel, together with the shield, 130 mm from an
illuminated 100 W bulb, with the shield facing the bulb. Check for pinholes. More than 5
pinholes shall constitute a failure.
(b) Cured film-If the coating is acceptable in the wet state, allow it to cure for an
additional 30 min in air at 18 oC to 25 oC and a relative humidity of ≤ 80 %, and then
place in a circulating-air oven at (75 + 2 ) oC for a minimum of 30 min. repeat the
examination described above. More than 5 pinholes shall constitute a failure.
Another curing schedule may be agreed between the coater and the coating material
manufacturer.
NOTE : if justified by the prevailing application and drying conditions or the type of
paint used, the test conditions may be modified by agreement between the interested
parties.
G1 General
G.2.1 Adjustable low-voltage wet-sponge tester, equipped with an alarm, an electrode in the
form of a sponge and conductors for connecting the coated pipe or fitting under test to
earth.
G.3 Procedure
Set the test voltage to 9 V. Connect up the instrument, connecting the earth lead, by
means of a crocodile clip, to an uncoated section of the metal of the surface under test.
Moisten the sponge with tap water. Note that too much water will affect the
performance.
Switch on the electrode and move it continuously in connect with the surface of the
coating to be inspected; the rate of travel of the electrode is not limited, but it shall not
be higher than the speed at which it can be demonstrated that a porosity defect can be
detected.
G.4 Results
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CONTENTS
1.0 SCOPE
3.0 MATERIALS
9.0 DOCUMENTATION
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1.0 SCOPE
This specification covers the minimum requirements for design, manufacture and
supply of carbon steel ball valves of size DN 50 mm (2”) and above and ANSI class
150# thru 900# for use in onshore pipeline systems handling non sour
hydrocarbons in liquid or gaseous phase including Liquefied Petroleum Gas (LPG).
This specification does not cover ball valves for sour hydrocarbons (liquid/gas)
service as defined in NACE Standard MR-0l-75.
2.1 All valves shall be manufactured and supplied in accordance with the latest edition
of American Petroleum Institute (API) Specification 6D, Twenty Second edition,
January 2002/ ISO 14313:1999, Petroleum and Natural Gas Industries – Pipeline
Transportation Systems- Pipeline Valves, with additions and modifications as
indicated in the following sections of this specification.
2.2 Reference has also been made in this specification to the latest edition of the
following Codes, Standards and Specifications.
ASME Sec VIII - Boiler and Pressure Vessel Code- Rules for Construction
of Pressure Vessels.
2.3 In case of conflict between the requirements of this specification, API 6D and the
Codes, Standards and Specifications referred in clause 2.2 above, the requirements
of this specification shall govern.
3.0 MATERIALS
3.1 Material for major components of the valves shall be as indicated in Valve Data
Sheet. Other components shall be as per Manufacturer’s standard (suitable for the
service conditions indicated in the data Sheet) and shall be subject to approval by
Purchaser. In addition, the material shall also meet the requirements specified
hereinafter.
All process wetted parts, metallic and non metallic, and lubricants shall be suitable
for the service specified by the Purchaser. Manufacturer shall confirm that all wetted
parts are suitable for treated water/ sea water environment, which may be used
during field testing.
Non metallic parts of the valves (including O-rings, soft seals etc.) intended for
hydrocarbon gas service shall be resistant to explosive decompression.
3.2 Carbon steel used for the manufacture of valves shall be fully killed.
3.3 The carbon equivalent (CE) of valve end connections which are subject to further
field welding by Purchaser shall not exceed 0.45 on check analysis for each heat of
steel used, as calculated by the following formula:
3.4 For valves specified to be used for Gas service or High Vapour Pressure (HVP) liquid
service/ LPG service, Charpy V-notch test on each heat of base material shall be
conducted as per API 6D, Clause -7.5, for all pressure containing parts such as
body, end flanges and welding ends as well as bolting material for pressure
containing parts. Unless specified otherwise, the Charpy V-notch test shall be
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conducted at 0°C. Test procedure shall confirm to ASTM A370. The Charpy V-notch
test specimen shall be taken in the direction of principal grain flow and notched
perpendicular to the original surface of plate or forging. The minimum average
absorbed energy per set of three specimens shall be 27 J with an individual
minimum per specimen of 22 J.
For valves specified to be used for other hydrocarbon services, Charpy V-notch
requirements as stated above are not applicable, unless required by the specified
material standard as a mandatory requirement.
When Low Temperature Carbon Steel (LTCS) materials are specified in Valve Data
Sheet or offered by Manufacturer, the Charpy V-notch test requirements of
applicable material standard shall be complied with.
3.5 For all such valves where Carbon Steel is used as ball material, the ball shall have
75 micrometers (0.003 inches) thick Electroless Nickel Plating (ENP) as per ASTM B
733 with following classification:
3.6 When the valves are specified to be used for Gas service or High Vapour Pressure
(HVP) liquid service, hardness test shall be carried out on each heat of base material
for all pressure containing parts of the valve. A full thickness cross section shall be
taken for this purpose and the maximum hardness shall not exceed 248 HV10 based
on minimum four (4) measurements representing the entire thickness.
For valves specified to be used for Low Vapour Pressure (LVP) liquid service,
requirements as stated herein above are not applicable.
4.1 Valve design shall meet the requirements of API Specification 6D and shall be
suitable for the service conditions indicated in the Valve Data Sheet. The ASME
Boiler & Pressure Vessel Code, Section VIII, Division 1 shall be used to design the
valve body. Allowable stress requirements shall comply the provisions of ASME
B31.3. In addition, corrosion allowance indicated in Valve Data Sheet shall be
considered in valve design. However, the minimum wall thickness shall not be less
than the minimum requirement of ASME B 16.34.
The manufacturer shall have valid license to use API monogram on valves
manufactured as per API 6D.
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4.2 Valve body design shall be either fully welded or bolted. Valve body joints with
threads are not permitted.
4.4 Valves shall be Full bore (FB) or Reduced bore (RB) as indicated in the Valve Data
Sheet. Full bore valves shall be suitable for the passage of all types of pipeline
scraper and inspection pigs on regular basis without causing damage to either the
valve component or the pig. The full bore valve shall provide an unobstructed profile
for pigging operations in either direction. Full bore valves shall be designed to
minimize accumulation of debris in the seat ring region to ensure that valve
movement is not impeded. In case of reduced bore valves, the nominal valve size
indicated in the Valve Data Sheet shall correspond to that of a full bore valve of
smaller nominal diameter as indicated in Table-4.4 of this specification. For sizes of
a particular rating not covered in API 6D, the bore size of reduced bore valve shall
be as per Manufacturer‘s standard.
TABLE - 4.4
Nominal Valve
Nominal Valve size
Nominal Valve Size, Nominal Valve Size, Size
for Reduced Bore
for Reduced Bore
DN mm (NPS
DN mm (NPS inches) DN mm (NPS inches) DN mm (NPS inches)
inches)
50 (2) 50 (2) 600 (24) 500 (20)
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4.5 Ball mounting shall be trunnion or pivot type only. Valve design shall minimize the
possibility of debris ingress into the trunnion as far as practicable.
4.6 Valve seats shall be with primary metal to metal contact. O-rings or other seals if
used for drip tight sealing shall be encased in a suitable groove in such a manner
that it can not be removed from seat ring and there is no extrusion during opening
or closing operation at maximum differential pressure corresponding to valve class
rating. The seat rings shall be so designed as to ensure sealing at low as well as
high differential pressures. Seat design with PTFE inserts is not applicable.
4.7 Valves shall have double block and bleed feature to facilitate complete flush, drain
and venting of the valve body cavity. For valves to be used in liquid service, the
body cavity over-pressure shall be prevented by self-relieving seat rings/assemblies.
A pressure relief hole in the ball is not permitted. Self-relieving seat rings shall
relieve at a body cavity differential pressure not exceeding 50% of the valve class
rating pressure.
4.8 When specified in the Valve Data Sheet, valves shall be designed to withstand a
sustained internal vacuum of at least 1 (one) milli-bar in both open and closed
positions.
4.9 Full Bore valves of nominal valve size 200 mm (8”) & above and Reduced Bore
valves of nominal valve size 250 mm (10”) & above, shall have provision for
secondary sealant injection under full line pressure for seat and stem seals. All
sealant injection connections shall be provided with an internal non-return valve.
Valve design shall have a provision to replace the sealant injection fitting under full
line pressure. Location and arrangement of sealant point shall be as per Fig. 4.9.
4.10 Valves shall be provided with vent and drain connections. Location and arrangement
of vents and drains shall be as per Fig. 4.9. Body vent and drain shall be provided
with valves (Ball or Plug type). Number and size shall be as per Fig. 4.9.
4.11 Valve design shall ensure repair of stem seals/packing under full line pressure.
4.12 Valve design shall be as to avoid bimetallic corrosion between carbon steel and high
alloy steel components, suitable insulation shall be provided as required.
4.13 a) Valve ends shall be either flanged/or butt welded or one end flanged and one
end butt welded as indicated in the Valve Data Sheet. Flanges of the flanged
end cast/ forged body valves shall be integrally cast/ forged with the body of
the valve. Face to face/end to end dimensions shall conform to API 6D. Face
to Face and end to end dimensions for valve sizes not specified in API 6D
shall be in accordance with ASME B 16.10. Face to face and end to end
dimension not shown in API 6D or ASME B16.10 shall be as per
Manufacturer’s Standard and shall be subject to approval by Company.
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b) Flanged end, if specified, shall have dimensions as per ASME B16.5 for valve
sizes upto DN 600 mm (24”) excluding DN 550 mm (22”) and as per MSS-SP-
44/ ASME B16.47 Series A for valve sizes DN 550 mm (22”) and for DN 650
mm (26 inches) and above. Flange face shall be either raised face or ring
joint type (RTJ) as indicated in Valve Data Sheet. Flange face finish shall be
serrated or smooth as indicated in Valve Data Sheet. In case of RTJ flanges,
the groove hardness shall be minimum 140 BHN.
c) Butt weld end preparation shall be as per ASME B16.25. The thickness of the
pipe to which the valve has to be welded shall be as indicated in the Valve
Data Sheet. Valves shall be without transition pups. In case difference exists
between thickness of welding ends of valve and connecting pipe, the welding
ends of valve shall have bevel preparation as per ASME B31.4 or ASME B31.8
as applicable.
4.14 Design of weld end valves shall be such that during field welding operation, soft
seals or plastic components of the valve (where ever used) are not liable to be
damaged. The manufacturer shall furnish necessary field welding instructions and
post weld test procedure to demonstrate integrity and leak tightness of valves after
field welding operations.
4.15 Valve shall be provided with ball position indicator and stops of rugged construction
at the fully open and fully closed positions.
4.16 Full Bore valves of nominal valve size, DN ≥ 200 mm (8”) and Reduced Bore valves
of nominal valve size, DN ≥ 250 mm (10”), shall be equipped with support foot and
lifting lugs. Tapped holes and eyebolts shall not be used for lifting lugs. Height of
support foot shall be kept minimum. The location and size of support foot/ lifting
lugs shall ensure unrestrictive operation of vent/ drain valves.
4.17 When indicated in Material Requisition, valves shall have locking devices to lock the
valve either in full open (LO) or full close (LC) positions. Locking devices shall be
permanently attached to the valve operator and shall not interfere with operation of
the valve.
4.18 Valves shall be suitable for either buried or above ground installation as indicated in
Valve Data Sheet.
4.19 When stem extension requirement is indicated in Valve Data Sheet, the valves shall
have the following provisions.
a) Valves provided with stem extension shall have water proof outer casing.
Length of stem extension shall be as indicated in Valve Data Sheet. The
length indicated corresponds to the distance between centerline of the valve
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opening and the top of mounting flange for valve operating device (gear
operator/ power actuator as applicable).
b) Vent and drain connections and sealant injection lines shall be terminated
adjacent to the valve operator by means of suitable piping anchored to the
valve body. The pipe used shall be API 5L Gr. B / ASTM A 106 Gr. B, with
Sch. 160. Fittings shall be ASTM A105/ASTM A234 Gr. WPB, Socket welded
ANSI class 6000.
c) Stem extension and stem housing design shall be such that the complete
assembly will form a rigid unit giving positive drive under all conditions with
no possibility of free movement between valve body, stem extension or its
operator.
d) Outer casing of stem extension shall have 3/8” or ½” NPT plugs at the top
and bottom, for draining and filling with oil to prevent internal corrosion.
c) For the manual operator of all valves, the diameter of the hand wheel or the
length of operating wrench shall be such that under the maximum differential
pressure, the total force required to operate the valve does not exceed 350N.
Manufacturer shall also indicate the number of turns of hand wheel (in case
of gear operators) required for operating the valve from full open to full close
position.
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d) Direction of operation of hand wheel or wrench shall be in clock-wise
direction while closing the valve. Hand wheels shall not have protruding
spokes.
e) Gear operators, when provided, shall have a self-locking provision and shall
be fully encased in water proof/ splash proof enclosure and shall be filled
with suitable grease.
4.21 All welds shall be made by welders and welding procedures qualified in accordance
with the provisions of ASME Section IX. The procedure qualification shall also
include impact test and hardness test when required as per Clause 3.4 and 3.6 of
this specification and shall meet the requirements as specified therein.
4.22 Repair by welding is not permitted for fabricated and forged body valves. However
repair by welding as per ASME B16.34 is permitted for cast body valves. Repair shall
be carried out before any heat treatment of casting is done. Repair welding
procedure qualification shall also include impact test and hardness test when
required as per Clause 3.4 and 3.6 of this specification and shall meet the
requirements as specified therein.
4.23 The tolerance on internal diameter and out of roundness at the ends for welded
ends valves shall be as per connected pipe specification as indicated in the Valve
Data Sheet.
4.24 Valve stem shall be capable of withstanding the maximum operating torque required
to operate the valve against the maximum differential pressure corresponding to
applicable class rating. The combined stress shall not exceed the maximum
allowable stresses specified in ASME section VIII, Division 1. For power actuated
valves, the valve stem shall be designed for maximum output torque of the selected
power actuator (including gear box, if any) at valve stem.
5.1 The Manufacturer shall perform all inspection and tests as per the requirements of
this specification and the relevant codes, prior to shipment, at his Works. Such
inspection and tests shall be, but not limited to, the following:
5.1.1 All valves shall be visually inspected. The internal and external surfaces of the valves
shall be free from any strikes, gouges, and other detrimental defects. The surface
shall thoroughly cleaned and free from dirt, rust and scales.
5.1.2 Dimensional check on all valves shall be carried out as per the Purchaser approved
drawings.
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5.1.3 Chemical composition and mechanical properties shall be checked as per relevant
material standards and this specification, for each heat of steel used.
All castings shall be wet magnetic particle inspected 100% of the internal surfaces.
Method and acceptance shall comply with ASME B16.34.
c) All valves, with body fabricated from plates or made by forgings, shall be
ultrasonically examined in accordance with the procedure and acceptance
standard of Annexure-E of ASME B16.34. All forgings shall be wet magnetic
particle inspected 100% of the internal surfaces. Method and acceptance
shall comply with ASME B 16.34.
5.1.5 Full inspection by radiography shall be carried out on all welds of pressure
containing parts. Acceptance criteria shall be as per ASME B 31.4 or ASME B3 1.8 as
applicable and API 1104.
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5.1.7 a) All finished wrought weld ends subject to welding in field shall be 100%
ultrasonically tested for lamination type defects for a distance of 50 mm from
the end. Laminations shall not be acceptable.
b) Weld ends of all cast valves subject to welding in field shall be 100% radio-
graphically examined and acceptance criteria shall be as per ASME B16.34.
c) After final machining, all bevel surfaces shall be inspected by dye penetrant
or wet magnetic particle methods. All defects longer than 6.35 mm are
rejected, as are the defects between 6.35 mm and 1.59 mm that are
separated by a distance lessthan50timestheir greatest length. Rejectable
defects must be removed. Weld repair of bevel surface is not permitted.
5.1.8 All valves shall be tested in compliance with the requirements of API 6D. During
pressure, testing, valves shall not have sealant lines and other cavities filled with
sealant, grease or other foreign material. The drain, vent and sealant lines shall be
either included in the hydrostatic shell test or tested independently. No leakage is
permissible during hydrostatic testing. The body cavity self-relieving feature meeting
the requirements of clause 4.7 of this specification shall also be checked.
5.1.9 A supplementary air seat test as per API 6D (Appendix C, Para C.3.3) shall be
carried out for all valves. A bubble tight seal is required without the use of any
sealant. No leakage is allowed. Test pressure shall be held for at least 15 minutes.
5.1.10 Valves shall be subjected to Operational Torque Test as per Appendix C, Para C.6
of API 6D under hydraulic pressure equal to maximum differential pressure
corresponding to the valve rating. For manually operated valves, it shall be
established that the force required to operate the valve does not exceed the
requirements stated in section 4.20 (c) of this specification.
5.1.11 Power actuated valves shall be tested after assembly of the valve and actuator, at
the valve Manufacturer’s works. At least five Open-Close-Open cycles without
internal pressure and five Open-Close-Open cycles with maximum differential
pressure corresponding to the valve rating shall be performed on the valve actuator
assembly. The time for Full Open to Full Close shall be recorded during testing. If
required, the actuator shall be adjusted to ensure that the opening and closing time
is with in the limits stated in Valve Data Sheet.
Hand operator provided on the actuator shall also be checked after the cyclic
testing, for satisfactory manual over-ride performance.
These tests shall be conducted on minimum one valve out of a lot of five (5) valves
of the same size, rating and the actuator model/type. In case, the tests do not meet
the requirements, retesting/ rejection of the lot shall be decided by the Purchaser’s
Inspector.
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5.1.12 Subsequent to successful testing as specified in clause 5.1.8, 5.1.9, 5.1.10 and
5.1.11 above, one (1) valve out of the total ordered quantity shall be randomly
selected by the Company Representative for cyclic testing as mentioned below:
b) Subsequent to the above, the valve shall be subjected to hydrostatic test and
supplementary air seat test in accordance with clause 5.1.8 and 5.1.9.
In case this valve fails to pass these tests, the valve shall be rejected and two more
valves shall be selected randomly and subjected to testing as indicated above. If
both valves pass these tests, all valves manufactured for the order (except the valve
that failed) shall be deemed acceptable. If either of the two valves fails to pass
these tests, all valves shall be rejected or each valve shall be tested at the option of
manufacturer.
Previously carried out test of similar nature shall be considered acceptable if same
has been carried out by manufacturer in last two years. Valves of two sizes below
and two sizes above the size of valve previously tested, and rating similar or one
rating lower of valve tested previously, shall be qualified.
5.2 Purchaser reserves the right to perform stage wise inspection and witness tests as
indicated in clause 5.1 above at Manufacturer’s works prior to shipment.
Manufacturer shall give reasonable access and facilities required for inspection to
the Purchaser’s Inspector. Purchaser reserves the right to require additional testing
at any time to confirm or further investigate a suspected fault. The cost incurred
shall be to Manufacturer’s account.
In no case shall any action of Purchaser or his inspector shall relieve the
Manufacturer of his responsibility for material, design, quality or operation of valves.
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b) Test certificates of hydrostatic and pneumatic tests complete with records of
timing and pressure of each test.
e) All other test reports and certificates as required by API 6D and this
specification.
The certificates shall be valid only when signed by Purchaser’s Inspector. Only those
valves which have been certified by Purchaser’s Inspector shall be dispatched from
Manufacturer’s works.
7.1 Valve surface shall be thoroughly cleaned, freed from rust and grease and applied
with sufficient coats of corrosion resistant paint. Surface preparation shall be carried
out by shot blasting to SP-6 in accordance with “Steel Structures Painting Council -
Visual Standard SSPC-VIS-1”. For the valves to be installed underground, when
indicated in Valve Data Sheet, the external surfaces of buried portion of the valve
shall be painted with three coats of suitable coal tar epoxy resin with a minimum dry
film thickness of 300 microns.
7.2 All valves shall be marked as per API 6D. The units of marking shall be metric
except nominal diameter, which shall be in inches.
7.3 Valve ends shall be suitably protected to avoid any damage during transit. All
threaded and machined surfaces subject to corrosion shall be well protected by a
coat of grease or other suitable material. All valves shall be provided with suitable
protectors for flange faces, securely attached to the valves. Bevel ends shall be
protected with metallic or high impact plastic bevel protectors.
7.4 All sealant lines and other cavities of the valve shall be filled with sealant before
shipment.
7.6 On packages, following shall be marked legibly with suitable marking ink:
a) Order Number
b) Manufacturer’s Name
c) Valve size and rating
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d) Tag Number
e) Serial Number
8.1 Manufacturer shall furnish list of recommended spares and accessories for valves
required during start-up and commissioning.
8.2 Manufacturer shall furnish list of recommended spares and accessories required for
two years of normal operation and maintenance of valves.
8.3 Manufacturer shall quote for spares and accessories as per Material Requisition.
9.0 DOCUMENTATION
9.1 At the time of bidding, Manufacturer shall submit the following documents:
b) Sectional drawing showing major parts with reference numbers and material
specification. In particular a blow up drawing of ball-seat assembly shall be
furnished complying the requirement of clause 4.6 of this specification.
c) Reference list of similar ball valves manufactured and supplied in last five
years indicating all relevant details including project, year, client, location,
size, rating, service etc.
d) Torque curves for the power actuated valves along with the break torque and
maximum allowable stem torque. In addition, sizing criteria and torque
calculations shall also be submitted for power actuated valves.
9.2 With in three weeks of placement of order, the Manufacturer shall submit four
copies of, but not limited to, the following drawings, documents and specifications
for Purchaser’s approval:
a) Detailed sectional drawings showing all parts with reference numbers and
material specifications.
b) Assembly drawings with overall dimensions and features. Drawing shall also
indicate the number of turns of hand wheel (in case of gear operators)
required for operating the valve from full open to full close position and the
painting scheme. Complete dimensional details of support foot (where
applicable) shall be indicated in these drawings.
Manufacture of valves shall commence only after approval of the above documents.
Once the approval has been given by Purchaser, any changes in design, material
and method of manufacture shall be notified to Purchaser whose approval in writing
of all changes shall be obtained before the valve is manufactured.
9.3 Within 30 days from the approval date, Manufacturer shall submit to Purchaser one
reproducible and six copies of the approved drawings, documents and specifications
as listed in clause 9.2 above.
9.4 Prior to shipment, Manufacturer shall submit to Purchaser one reproducible and six
copies of the following:
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STANDARD SPECIFICATION
FOR
PIPELINE PLUG VALVES
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CONTENTS
1.0 SCOPE
3.0 MATERIALS
9.0 DOCUMENTATION
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1.0 SCOPE
This Specification covers the minimum requirements for design, manufacture and
supply of carbon steel plug valves of size DN 50 mm (2 inch) and above and ANSI
class 150# thru 900# for use in onshore pipeline systems handling non sour
hydrocarbons in liquid phase or gaseous phase including Liquefied Petroleum Gas
(LPG).
This specification does not cover plug valves for sour hydrocarbons (liquid/gas)
service as defined in NACE Standard MR-0l-75.
2.1 All valves shall be manufactured and supplied in accordance with the American
Petroleum
Institute (API) Specification 6D, Twenty second edition, January 2002 / ISO
14313:1999, Petroleum and Natural Gas Industries – Pipeline Transportation
Systems – Pipeline Valves, with addition and modification as indicated in the
following sections of this specification.
2.2 Reference has also been made in this specification to the latest edition of the
following Codes, Standards and Specifications:
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MSS-SP-6 : Standard Finishes for Contact Faces of Pipe Flanges and
Connecting-end Flanges of Valves and Fittings.
2.3 In case of conflict between the requirements of this specification, API 6D and the
Codes, Standards and Specifications referred in clause 2.2 above, the requirements
of this specification shall govern.
3.0 MATERIALS
3.1 Material for major components of the valves shall be as indicated in Valve Data
Sheet. In addition, the material shall also meet the requirements specified herein.
Other components shall be as per Manufacturer’s standard, which shall be subject
to approval by Purchaser.
3.2 Carbon steel used for the manufacture of valves shall be fully killed.
3.3 The Carbon Equivalent (CE) of valve end connections which are subject to further
field welding by Purchaser shall not exceed 0.45 in check analysis for each heat of
steel used, as calculated by the following formula:
CE = C+ Mn + Cr+Mo+V+ Ni+Cu
6 5 15
3.4 For valves specified to be used for Gas service or High Vapour Pressure (HVP) liquid
service, Charpy V-Notch test on each heat of base material shall be conducted as
per API 6D, clause 3.7 for all pressure containing parts such as body, end flanges
and welding ends as well as bolting material for pressure containing parts. Unless
specified otherwise, the Charpy V-notch test shall be conducted at 0 °C. The Charpy
V-notch test specimen shall be taken in the direction of - principal grain flow and
notched perpendicular to the original surface of plate or forging. The minimum
average absorbed energy per set of three specimens shall be 27 J with an individual
minimum per specimen of 22 J.
For valves specified to be used for other hydrocarbon services, the Charpy V-notch
requirements stated above are not applicable, unless required by the specified
material standard as a mandatory requirement.
When Low Temperature Carbon Steel (LTCS) materials are specified in Valve Data
Sheet or offered by Manufacturer, the Charpy V-notch test requirements of
applicable material standard shall be complied with.
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3.5 For all such valves where Carbon Steel /S.G. Iron is used as plug material, the plug
shall have 75 microns (0.003 inches) thick Electroless Nickel Plating (ENP) as per
ASTM B733 with following classification:
3.6 When the valves are specified to be used for Gas service or High Vapour Pressure
(HVP) liquid ervice, hardness test shall be carried out on each heat of base material
for all pressure containing parts of the valve. A full thickness cross section shall be
taken for this purpose and the maximum hardness shall not exceed 248 HV10 based
on minimum four (4) measurements representing the entire thickness.
For valves specified to be used for Low Vapour Pressure (LVP) liquid service,
requirements as stated herein above are not applicable.
4.1 Valve design shall meet the requirements of API Specification 6D and shall be
suitable for the service conditions indicated in the Valve Data Sheet. The ASME
Boiler & Pressure Vessel Code, Section VIII, Division 1 shall be used to design the
valve body. Allowable stress requirements shall comply the provisions of ASME
B31.3. In addition, corrosion allowance indicated in Valve Data Sheet shall be
considered in valve design. However, the minimum wall thickness shall not be less
than the minimum requirement of ASME B 16.34.
The manufacturer shall have valid license to use API monogram on valves
manufactured as per API 6D.
4.3 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.
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4.4 Cover shall be bolted to the body and screwed connections are not acceptable.
4.5 Soft seats to achieve a seal between plug and body are not permitted.
4.6 All valves shall have the provision for secondary sealant injection under full line
pressure for seat and stem seals. All sealant injection connections shall be provided
with an internal non-return valve. Valve design shall have a provision (e.g. Ball Type
Check Valve/Needle Valve) to replace the sealant injector fitting under full line
pressure. Location and arrangement of sealant injection points shall be as per
Figure-4.6.
4.7 When specified in the Vale Data Sheet, valves shall be designed to withstand a
sustained internal vacuum of at least 1 (one) milli-bar in both open and closed
position.
4.8 Valve design shall ensure repair of gland packing under full line pressure.
4.9 a) Valve ends shall be either flanged or butt-welded or one end flanged and one
end butt welded as indicated in the Valve Data Sheet. Flanges of the flanged
end cast body valves shall be integrally cast with the body of the valve. Face
to face/end to end dimensions shall conform to API 6D.
b) Flanged end shall have dimensions as per ANSI B16.5 for valve sizes upto DN
600 mm (24”) (excluding DN 550 mm (22”)) and as per MSS-SP-44 /ASME
B16.47 Series A for valve sizes DN 550 mm (22”) and for DN 650 mm (26”)
and above. Flange face shall be either raised face or ring joint type as
indicated in Purchase Requisition. In case of RTJ flanges, the groove
hardness shall be minimum 140 BHN.
c) Butt weld end preparation shall be as per ASME B 16.25. The thickness of
the pipe to which the valve has to be welded shall be as indicated in the
Valve Data Sheet. Valves shall be without transition pups. In case difference
exists between thickness of welding ends of valves and connecting pipe, the
Data Sheet shall be considered in valve design. However the minimum wall
thickness shall not be less than the minimum requirement of ASME B 16.34.
The welding ends of valve shall have bevel preparation as per ASME B31.4/
B31.8 as applicable.
4.10 Valves shall be provided with plug position indicator and stops of rugged
construction at the fully open and fully closed positions.
4.11 When indicated in Material Requisition, valves shall have locking devices to lock the
valve either in full open (LO) or full close (LC) position. Locking devices shall be
permanently attached to the valve operator and shall not interfere with operation of
the valve.
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4.12 Valves shall be suitable for either buried or aboveground installation as indicated in
Valve Data Sheet.
4.13 When stem extension requirement is indicated in Valve Data Sheet, the valves shall
have the following provisions:
a) Valves provided with stem extension shall have waterproof outer casing.
Length of stem extension shall be as indicated in Valve Data Sheet. The
length indicated corresponds to the distance between centerline of the valve
opening and the top of mounting flange for valve operating device (gear
operator/power actuator as applicable)
b) Seat sealant injection lines shall be extended and terminated adjacent to the
valve operator by means of suitable piping anchored to the valve body/ stem
housing. The pipe used shall be API 5L Gr. B/ ASTM A106 Gr. B, with Sch.
160. Fittings shall be ASTM A105/ ASTM A234 Gr. WPB, Socket welded ANSI
Class 6000.
c) Stem extension and stem housing design shall be such that the complete
assembly will form a rigid unit giving positive drive under all conditions with
no possibility of free movement between valve body, stem extension or its
operator.
d) Outer casing of stem extension shall have ¾” or ½” NPT plugs at the top
and bottom, for draining and filling with oil to prevent internal corrosion.
c) For the manual operator of all valves, the diameter of the hand wheel or the
length of operating Wrench shall be such that under the maximum
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differential pressure, total force required to operate the valve does not
exceed 350N. Manufacturer shall also indicate the number of turns of hand
wheel (in case of gear operator) required to operate the valve from full open
to full close position.
e) Gear operators, when provided, shall have a self-locking provision and shall
be fully encased in water proof/splash proof enclosure and shall be filled with
suitable grease.
4.15 Repair by welding is not permitted for fabricated and forged body valves. However
repair by welding as per ASME B 16.34 is permitted for cast body valves. Repair
shall be carried out before any heat treatment of casting is done. Repair welding
procedure qualification shall also include impact test and hardness test when
required as per Clause 3.4 and 3.6 of this specification and shall meet the
requirements as specified therein.
4.16 The tolerance on internal diameter and out of roundness at the ends for welded
ends valves shall be as per connected pipe specification as indicated in the Valve
Data Sheet.
4.17 Valve stem shall be capable of withstanding the maximum operating torque
required to operate the valve against the maximum differential pressure
corresponding to applicable class rating. The combined stress shall not exceed the
maximum allowable stresses specified in ASME section VIII, Division 1.
For Power Actuated Valves, the valve stem shall be designed for maximum output
torque of the selected power actuator (including gear box, if any) at the valve stem.
5.1 The Manufacturer shall perform all inspection and tests as per the requirements of
this specification and the relevant codes, prior to shipment, at his Works. Such
inspection and tests shall be, but not limited to, the following:
5.1.1 Visual and dimensional check on all valves shall be carried out as per the Purchaser
approved drawings.
5.1.2 Chemical composition and mechanical properties shall be checked as per relevant
material standards and this specification, for each heat of steel used.
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b) Body castings of valves shall be radio-graphically examined as per ASME
B16.34. Procedure and acceptance criteria shall be as per ASME B16.34. The
extent of radiography shall be as follows:
All castings shall be wet magnetic particle inspected 100% of the internal
surfaces. Method and acceptance shall comply with ASME B 16.34.
5.1.5 a) 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 B16.34.
b) After final machining, all bevel surfaces shall be inspected by dye penetrant
or wet magnetic particle methods. All defects longer than 6.35 mm are
rejected, as are the defects between 6.35 mm and 1.59mm that are
separated by a distance less than 50 times their greatest length. Rejectable
defects must be removed. Weld repair of bevel surface is not permitted.
c) All finished wrought weld ends subjects to welding in field shall be 100
percent ultrasonically tested for lamination type defects for a distance of 50
mm from the end. Laminations shall not be acceptable.
5.1.6 All valves shall be tested in compliance with the requirements of API 6D. The
sealant lines shall be either included in the hydrostatic shell test or tested
independently. No leakage is permissible during hydrostatic testing.
5.1.7 A supplementary air seat test as per API 6D Appendix C3 shall be carried out for all
valves.. No leakage is allowed. Test pressure shall be held for at least 15 minutes.
5.1.8 Valves shall be subjected to Operational Torque Test as per API 6D Appendix C4
under hydraulic pressure equal to maximum differential pressure corresponding to
the valve rating. For manually operated valves, it shall be established that the force
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required to operate the valve does not exceed the requirements stated in section
4.14(c) of this specification.
5.1.9 Power actuated valves shall be tested after assembly of the valve and actuator, at
the valve Manufacturer’s works. At least five Open-Close-Open cycles without
internal pressure and five Open-Close-Open cycles with maximum differential
pressure corresponding to valve rating shall be performed on the valve actuator
assembly. The time for full open to full close shall be recorded during testing. If
required, the actuator shall be adjusted to ensure that the opening and closing time
is within the limits stated in Valve data sheet.
Hand operator provided on the actuator shall also be checked after the cyclic
testing, for satisfactory manual over-ride performance.
These tests shall be conducted on minimum one valve out of a lot of five (5) valves
of the same size, rating and actuator model/type. In case the tests do not meet the
requirements, retesting/rejection of the lot shall be decided by purchaser’s
Inspector.
5.2 Purchaser reserves the right to perform stage wise inspection and witness tests as
indicated in clause 5.1 above at Manufacturer’s works prior to shipment.
Manufacturer shall give reasonable access and facilities required for inspection to
the Purchaser’s inspector. Purchaser reserves the right to require additional testing
at any time to confirm or further investigate a suspected fault. The cost incurred
shall be to Manufacturer’s account.
In no case shall any action of Purchaser or his inspector shall relieve the
Manufacturer of his responsibility for material, design, quality or operation of valves.
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d) Test report on operation of valves conforming to clause 5.1.8 and 5.1.9 of
this specification.
e) All other test reports and certificates as required by API 6D and this
specification.
The certificates shall be valid only when signed by Purchaser’s Inspector. Only those
valves which have been certified by Purchaser’s Inspector shall be dispatched from
Manufacturer’s works.
7.1 Valve surface shall be thoroughly cleaned, freed from rust and grease and applied
with sufficient coats of corrosion resistant paint. Surface preparation shall be carried
out by shot blasting to SP-6 in accordance with “Steel Structures Painting Council -
Visual Standard SSPC-VIS-l”. For the valves to be installed underground, when
indicated in Valve Data Sheet, the external surfaces of buried portion of the valve
shall be painted with three coats of suitable coal tar epoxy resin with a minimum
dry film thickness of 300 microns.
7.2 All valves shall be marked as per API 6D. The units of marking shall be metric
except nominal diameter, which shall be in inches.
7.3 Valve ends shall be suitably protected to avoid any damage during transit. All
threaded and machined surfaces subject to corrosion shall be well protected by a
coat of grease or other suitable material. All valves shall be provided with suitable
protectors for flange faces, securely attached to the valves. Bevel ends shall be
protected with metallic or high impact plastic bevel protectors.
7.4 All sealant lines and other cavities of the valve shall be filled with sealant before
shipment.
7.6 On packages, the following shall be marked legibly with suitable marking ink:
a) Order Number
b) Manufacturer’s Name
d) Tag Number.
e) Serial Number
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8.1 Manufacturer shall furnish list of recommended spares and accessories for valves
required during start-up and commissioning.
8.2 Manufacturer shall furnish list of recommended spares and accessories required for
two years of normal operation and maintenance of valves.
8.3 Manufacturer shall quote for spares and accessories as per Material Requisition.
9.0 DOCUMENTATION
9.1 At the time of bidding, Manufacturer shall submit the following documents:
b) Sectional drawing showing major parts with reference numbers and material
specification.
c) Torque curves for the power actuated valves along with break torque and
maximum allowable stem torque. In addition, sizing criteria and torque
calculations shall also be submitted for power actuated valves.
d) Reference list of similar plug valves manufactured and supplied in last five
years
indicating all relevant details including project, year, client, location, size,
rating, service etc.
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 Purchaser’s approval:
a) Detailed sectional drawings showing all parts with reference numbers and
materials specification.
b) Assembly drawings with overall dimensions and features. Drawing shall also
indicate the number of turns of hand wheel (in case of gear operators)
required for operating the valve from full open to full close position and the
painting scheme.
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c) Fabrication details of all valves.
Manufacture of valves shall commence only after approval of the above documents.
Once, the approval has been given by Purchaser, any changes in design, material
and method of manufacture shall be notified to Purchaser whose approval in writing
of all changes shall be obtained before the valve is manufactured.
9.3 Within 30 days from the approval date, Manufacturer shall submit to Purchaser one
reproducible and six copies of all approved drawings, documents and specifications
as listed in clause 9.2 above.
9.4 Prior to shipment, Manufacturer shall submit to Purchaser one reproducible and six
copies of the following:
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ABOVE GROUND UNDER GROUND
INSTALLATION INSTALLATION
FIGURE- 4.6
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SPECIFICATION
FOR
GAS POWERED VALVE ACTUATORS
1.0 SCOPE
5.0 COATING
8.0 SHIPPING
9.0 DOCUMENTATION
ATTACHMENTS
- SKETCH-I
- SKETCH-2
- GAS COMPOSITION
1.1 This specification, together with the applicable data sheet, covers the minimum
requirements for the design, manufacture, inspection, testing and shipping of valves
actuators complete with accessories for quarter tarn ball valves.
1.2 This specification indicates the minimum supply requirements and does not relieve the
vendor from his responsibilities concerning the design and the safe operation of the
supplied equipment.
13 The valve manufacturer shall also be responsible or proper operation of the actuator
that shall develop a torque or a thrust sufficient to conveniently open aid close the
valve always with in the limits established by the resistance of the mechanical
elements of the valve itself.
1.4 Valve and actuator shall be supplied as a single assembly co in all respect and ready
for installation at site.
Reference is made in this specification to the latest edition of the following ea: standards
and specifications:
Purchaser Specification
3.1 For sizing the actuator, Valve manufacturer shall fl to the actuator manufacturer the
following information:
a) The maximum break-away torque or thrust required at the valve stem with manual/
remote operation to open and close a valve at the shut off pressure in the line. The
actuator shall be sized at 10 kg/cm2(g) gas pressure and meeting the safety factor of
1.25 as required by the valve operation at the maximum differential pressure
corresponding to valve class rating.
d) As a result of points (a) to (c) the minimum required torque or thrust output of the
actuator.
e) Maximum allowable torque or thrust output of the actuator depending on the type
and size of valve.
3.2 Actuator manufacturer shall provide the complete model no. decoding for actuators,
limit switches and solenoid valves.
3.3 Complete details of Gas/Hydraulic circuit with complete sequencing of port fro open to
close and close to open position shall be furnished in the offer for review.
3.4 Manufacturer shall furnish the detailed calculation for actuator sizing after placement
of order. The calculation so furnished by manufacturer shall satisfy the sizing criteria
as per above clauses. Manufacturer shall agree to upgrade the actuators offered to
meet the sizing criteria without any price and schedule impact.
3.5 Manufacturer shall furnish the detailed calculation for actuator sizing after placement
of order. The calculation so furnished by manufacturer shall satisfy the sizing criteria
as per above clauses. Manufacturer shall agree to upgrade the actuators offered to
meet the sizing criteria without any price and schedule impact.
4.1 The actuator shall be powered by Natural Gas from the main pipeline. The gas
powered actuator shall operate at 10 kg/cm (g). A typical scheme for tapping the gas
4.2 Actuator shall be direct gas operated scotch yoke or rotary vane type with manual
hydraulic override. The actuator shall he provided with a hydraulic pump or manual
operation If there is no gas pressure available to actuator it shall be possible to
actuate Direct Pneumatic Actuator by means of Nitrogen bottles or similar pressure
source. Actuator: manufacturer shall furnish the capacity and set pressure of nitrogen
bottles for at least two opening and two closing stroke of the actuator.
4.3 The actuator shall be suitable for gas operating conditions and ambient temperature
as specified in data sheets. The presence of methanol in the gas shall not affect the
service of the Actuator.
4.4 All materials in contact with natural gas shall he suitable for the gas composition
attached with this specification.
4.5 The actuator and its accessories shall be suitable for outdoor installation and have
weather proof enclosure as per IP 55 as a minimum.
Solenoid valves shall be of flame proof design certified for IEC Zone-1, Gas Gr. II A &
II B, Temp. Class 13 or equivalent with moulded continuous duty coils and stainless
steel valve body.
Vendor shall furnish hazardous area certificates for the above items certified by a
Statutory body such as FM, UL, BASEEFA, PTB etc. In addition for above electrical
items/ instruments supplied for projects in India, approval from CCE (Chief Controller
of Explosive) shall be furnished, irrespective of the place of manufacture and the
same is mandatory. In case CCE certificate is not available now for any item, vendor
to confirm that the same shall he furnished before shipment.
4.6 All pressure containing parts shall be designed to ASME Section VIII.
4.7 a) The actuator shall be suitable for direct mounting to the valve without
changing the standard top works of the valve and shall have the capability to
but mounted or removed from the valve when the valve is in service, The
actuators shall he flanged and bolted directly on the valve body or extension.
The connection between actuator and the valve or between the operator, the
outer casing of the extension and the valve shall be such that there is no
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movement between these connections when the valve is actuated by the
actuator under any load.
4.8 Provision shall be made to prevent accidental pressure build up in the actuator.
4.9 The construction of the actuator and its controls shall be such that proper manual
operation and maintenance can be carried out by skilled personnel without the risk of
being injured e.g. by moving parts.
4.10 A position indicator on the actuator shall show the valve in the open, closed or
partially open positions.
4.11 Bearings shall be factory packed with grease and shall not require additional
lubrication for the life of the actuator.
4.12 Unless specified otherwise in the data sheet, the actuator be equipped with limit
valves which immediately shut off the gas supply to actuator when the valve reaches
one of its end positions.
4.13 Actuator shall be provided with pressure gauges for pneumatic and hydraulic systems.
The pressure gauges for the hydraulic system shall be in circuit with the pressure
relief system.
4.14 In selection of pressure regulator due consideration shall be given to the effect of
cooling of gas at the regulator and its down stream section,
4.15 A high pressure dehydrating fiter cartridge shall be provided to remove condensate,
moisture, foreign particles and any corrosive contaminants from pipeline gas.
4.16 The sound level of the gas escaping into the atmosphere when the actuator is in
operation shall not exceed 90 dBA, measured at a distance of 1 meter.
4.17 The actuator shall be operated by either of the following two methods:
a) For the remote control, the actuator shall have a solenoid valve, limit switches,
relays, etc. and shall be suitable for remote and local operation as per
description in the attached Actuator Data Sheet(s).
4.18 a) The actuators shall be provided with limit switches for open and close
positions. The position of switches shall be adjustable near the valve open and
close positions. The limit switches shall be wired upto terminal block and shall
be numbered for proper identification. The limit switches shall have 2 sets of
contacts for each open and close position. The contact rating shall be as
specified in the data sheet. The power solenoid valves shall he cut-off when
the actuator has travelled to extreme positions (close and open).
b) The limit switches shall he wired in the actuator control circuit by the vendor so
as to cut off power to die actuator once the end positions of the valve are
reached. This is required to dc-energize the solenoid valves in the steady state
condition and failure of electrical power will not affect the valve position.
4.19 The stroke of the Actuator shall he easily adjustable in steps of maximum 0.5° for Ball
Valves.
4.20 Speed control nozzles for adjusting the valve speed over a wide range shall be
provided.
4.21 If remote control is required, a lock/ remote switch shall be installed to prevent
remote control during maintenance work. This switch shall be provided with a hole 12
mm in diameter for locking with pad lock in either position. This local/ remote switch
shall be wired upto the junction box as per circuit diagram.
4.22 All control accessories, pneumatic and hydraulic, shall be mounted in an enclosure
and shall be fully wired and tubed. The enclosure shall he weatherproof as per IP 55
9or equivalent.
4.23 All bleed and vent connections wherever required shad be piped outside the actuator
cabinet so as to prevent gas pocketing inside the actuator cabinet. The actuator will
be of an automatic self purging design such that any gas pocket in the actuator will
be eliminated.
4.24 Vendor shall be responsible for integrating the potential free NO or NC contacts of
Remote Telemetry Unit (RTU’s) for open and close command in interlock circuit.
These commands will be of momentary type with 1 sec duration.
4.26 The interconnecting cabling, interconnecting pipe work between the actuator and the
valve, adapters, tubing, cable glands, junction box are in manufacturer’s scope of
supply.
4.27 The actuator shall be supplied totally self-contained, wired, tubed and mounted on
ball valve. In case of a separate control box, wiring and tubing between control box
and actuator is in the vendor’s scope. Three metres of 3/4” tubing set including all
connectors between the actuator and the control box and three metres of
interconnecting piping work upstream & downstream of the valve and the control box
shall be provided. Owner shall provide 20 mm (3/4’) SW tapping on process main line
for line gas tapping.
4.28 Threading connections shall be NPT as per ANSI B 2.1 and flange connection as ANSI
B 16.5/ANSI B16.47. The tubing, fitting and valves shall be stainless steel with Swage
Lock fitting or equivalent.
5.0 COATING
The actuator. including gear boxes and piping, shall be coated as described below:
5.2 Shot blast as per Swedish Standard No. SIS 055900 latest edition SA 2.5 one layer
PrimerEpoxyPolyamide DET 75 microns intermediate layer Epoxv-Polyamide DFT 25
microns, final layer Epoxy- Polyamide DFT 75 microns. Total DFT 175 microns and
color RAL 5012 (light blue).
a) Test and check covered by point 6.1 after assembly with ball/plug valve.
b) No load test (DP=0) or load (DP max) Operations with the minimum required feeding
pressure (10 kg/cm)
6.4 Dimensional check on actuators shall be carried out as per the Purchaser approved
drawings.
In no case shall any action of Purchaser or his inspector relieve the Manufacturer of
his responsibility for material design, quality or operation of actuators.
7.0 NAMEPLATE
Actuator shall have a SS name plate attached firmly to it at a visible place and reporting
the following information:
8.0 SHIPPING
8.2 The actuator shall be supplied pre-assembled except piping/ tubing, actuator, actuator
control unit, tanks and other accessories shall be packed separately.
8.3 Protective grease oil coating shall be applied on the surface to protect them from
rusting.
8.4 Package shall be marked legibly with suitable marking ink the following:
a) Order number
b) Package number
c) Manufacturer’s name
e) Tag number
9.0 DOCUMENTATION
9.1 At the time of bidding the manufacturer shall submit the following documents in
accordance with EN10204 3. IC:
a) A detailed specification sheet for valve actuator providing all the details regarding
type, materials of construction for various parts etc.
e) Actuator sizing calculations including relation between required toque of valve and
actuator output torque.
f) Information asked for vide section 3.0 of this specification and actuator sizing as per
Actuator Data Sheet.
j) Parts list.
n) Information regarding the past experience on similar actuators including (a) Size
(b)Numbers (c) Name of Installation (d) Owner (e) Name of Contact Person (f) Date
of Installation.
o) Technical Catalogue giving detailed technical specification and other information for
each type of actuator and its accessories covered in the bid.
9.2 Within 30 days from the date of Purchase Order manufacturer shall submit copies of
the following for Purchaser’s review and approval.
d) Complete assembly drawing of the ball valve matching with the actuator offered.
The approval of these drawings/ documents will not absolve vendor of the responsibility
with respect to correct operation of the actuator. Manufacturer’s quotation, catalogues,
drawings, operating and maintenance manuals etc. shall be in English language.
10.1 Manufacturer shall furnish list of recommended spares and accessories for actuators
required during start-up and commissioning.
10.2 Manufacturer shall furnish list of recommended spares and accessories required for
two years of normal operation and maintenance of actuators.
10.3 Manufacturer shall quote for spares and accessories as per Material Requisition.
1.0 SCOPE
4.0 MATERIALS
9.0 DOCUMENTATION
This specification covers the minimum requirements for the design, manufacture and
supply of following carbon steel flanges and fittings of size upto DN 400 mm (16”) to be
installed in pipeline systems handling hydrocarbons in liquid or gaseous phase including
Liquefied Petroleum Gas (LPG):
- Flanges such as welding neck flanges, blind flanges, spectacle blinds, spacers and
blinds etc.
This specification does not cover the above-mentioned items, which are to be installed
in pipeline systems handling sour hydrocarbons (liquid/gas) service as defined in NACE
Standard MR-01-75
2.1 Reference has been made in this specification to the latest edition of the following
Codes:
ASME B31.4 - Pipeline Transportation System for Liquid Hydrocarbons and Other Liquids
ASTM A370 - Standard Test Methods and Definitions for Mechanical Testing of Steel
Products
MSS-SP-25 - Standard Marking System for Valves, Fittings, Flanges and Unions
MSS-SP-97 - Forged Carbon Steel Branch Outlet Fittings-Socket Welding, Threaded and
Butt welding Ends.
STANDARD SPECIFICATION FOR SPECIFICATION REV-0
GAIL (INDIA) LTD SEAMLESS FITTINGS & FLANGES
NEW DELHI (UPTO 400 mm/ 16”) S – 04 – 02 – 013 Page 3 of 7
Copyright GAIL – All rights reserved
2.2 In case of conflict between the requirements of this specification and the requirements
of above referred Codes and Standards, the requirements of this specification shall
govern.
Manufacturer who intends bidding for fittings must possess the records of a successful
proof test, in accordance with the provisions of ASME B 16.9.
4.0 MATERIAL
4.1 The Carbon Steel used in the manufacture of flanges and fittings shall be fully killed.
Material for flanges and fittings shall comply the material standard indicated in the
Purchase Requisition. In addition, the material shall also meet the requirements
specified hereinafter.
4.2 Each heat of steel used for the manufacture of flanges and fittings shall have Carbon
Equivalent (CE) not greater than 0.45 calculated from check analysis in accordance with
the following formula:
4.3 For flanges and fittings specified to be used for Gas service or High Vapour Pressure
(HVP) liquid service, Charpy V-notch test shall be conducted on each heat of steel.
Unless specified otherwise, the Charpy V-notch test shall be conducted at 00 C in
accordance with the impact test provisions of ASTM A- 370 for flanges and fittings.
The minimum average absorbed impact energy values of three full-sized specimens
shall be 27 joules. The minimum impact energy value of any one specimen of the three
specimens analyzed as above shall not be less than 80% of the above mentioned
average value.
For flanges and fittings specified to be used for other hydrocarbon service, the Charpy
V-notch test requirements as stated above are not applicable, unless required by the
specified material standard as a mandatory requirement.
When Low Temperature Carbon Steel (LTCS) materials are specified in Purchase
Requisition for flanges and fittings, the Charpy V-notch test requirements of applicable
material standard shall be complied with.
4.4 For flanges and fittings, specified to be used for Gas service or High Vapour Pressure
(HVP) liquid service, hardness test shall be carried out in accordance with ASTM A 370.
Hardness testing shall cover at least 10% per item, per size, per heat, per
manufacturing method. A full thickness cross section shall be taken for this purpose and
the maximum hardness shall not exceed 248 HV10. For flanges and fittings, specified to
STANDARD SPECIFICATION FOR SPECIFICATION REV-0
GAIL (INDIA) LTD SEAMLESS FITTINGS & FLANGES
NEW DELHI (UPTO 400 mm/ 16”) S – 04 – 02 – 013 Page 4 of 7
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be used for other hydrocarbon services, the hardness requirements stated above are
not applicable.
4.5 In case of RTJ flanges, the groove hardness shall be minimum 140 BHN.
5.1 Flanges such as weld neck flanges and blind flanges shall conform to the requirements
of ASME B16.5.
5.2 Spectacle blind and spacer & blind shall conform to the requirements of ASME B16.48.
5.3 Fittings such as tees, elbows, reducers, etc. shall be seamless type and shall conform to
ASME B 16.9 for sizes DN 50 mm (2”) and above and ASME B16.11 for sizes below DN
50 mm (2”).
5.5 Type, face and face finish of flanges shall be as specified in Purchase Requisition.
5.6 Flanges and fittings manufactured from bar stock are not acceptable.
5.7 All butt weld ends shall be bevelled as per ASME B16.5/ ASME B16.9/MSS-SP-97 as
applicable.
6.1 The Manufacturer shall perform all inspections and tests as per the requirement of this
specification and the relevant codes, prior to shipment at his works. Such inspections
and tests shall be, not but limited to the following:
6.1.1 All flanges and fittings shall be visually inspected. The internal and external surfaces of
the fittings shall be free from any strikes, gauges and other detrimental defects.
6.1.2 Dimensional checks shall be carried out on finished products as per ASME B16.5 for
flanges, ASME B16.48 for spacers and blinds and ASME B16.9/ MSS-SP-97 as applicable
for fittings and as per this specification.
6.1.3 Chemical composition and mechanical properties shall be checked as per relevant
material standards and this specification, for each heat of steel used.
6.2 Purchaser’s Inspector reserves the right to perform stage wise inspection and witness
tests, as indicated in clause 6.1 of this specification at Manufacturer’s Works prior to
shipment. Manufacturer shall give reasonable notice of time and shall provide, without
charge, reasonable access and facilities required for inspection, to the Purchaser’s
Inspector.
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.
9.1 Prior to shipment, the Manufacturer shall submit six copies of the test certificates as
listed in clause 7.0 of this specification.
1.0 SCOPE
4.0 MATERIALS
9.0 DOCUMENTATION
This specification covers the minimum requirements for the design, manufacture and
supply of following carbon steel flanges and fittings of size DN 450 mm (18") and above
to be installed in pipeline systems handling hydrocarbons in liquid or gaseous phase
including Liquefied Petroleum Gas (LPG):
Flanges such as weld neck flanges, blind flanges, spectacle blinds, spacers and
blinds, etc.
This specification does not cover the above-mentioned items, which are to be installed in
pipeline systems handling sour hydrocarbons (liquid / gas) service as defined in NACE
Standard MR-01-75.
2.1 Reference has been made in this specification to the latest edition of the following
Codes, Standards and Specifications.
2.2 In case of conflict between the requirements of this specification and the
requirements of above referred Codes and Standards, the requirements of this
specification shall govern.
Manufacturer who intends bidding for fittings must possess the records of a successful
proof test in accordance with the provisions of ASME B16.9 / MSS-SP-75, as applicable.
4.0 MATERIAL:
4.1 The Carbon Steel used in the manufacture of flanges and fittings shall be fully
killed. Material for flanges and fittings shall comply the material standards indicated
in the Purchase Requisition. In addition, the material shall also meet the
requirements specified hereinafter.
4.2 Each heat of steel used for the manufacture of flanges and fittings shall have
Carbon Equivalent (CE) not greater than 0.45 calculated from check analysis in
accordance with the following formula:
CE = C + Mn + Cr+ Mo + V + Ni+Cu
6 5 15
4.3 For flanges and fittings specified to be used for Gas service or High Vapour
Pressure (WP) liquid service, Charpy V-notch test shall be conducted on each heat
of steel. Unless specified otherwise, the Charpy V-notch test shall be conducted at
0' C in accordance with the impact test provisions of ASTM A 370 for flanges and
MSS-SP-75 for all fittings.
The minimum average absorbed impact energy values of three full-sized specimens
shall be 27 joules. The minimum impact energy value of any one specimen of the
three specimens analysed as above, shall not be less than 80% of the above
mentioned average value.
For flanges and fittings specified to be used for other hydrocarbon service, the
Charpy V-notch test requirements as stated above are not applicable, unless
required by the specified material standard as a mandatory requirement.
When Low Temperature Carbon Steel (LTCS) materials are specified in Purchase
Requisition for flanges and fittings, the Charpy V-notch test requirements of
applicable material standard shall be complied with.
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.
5.1 Flanges such as weld neck flanges and blind flanges shall conform to the
requirements of ASME B16.5 up to sizes DN 600 mm (24") excluding DN 550 mm
(22'9, and MSS-SP-44 for sizes DN 550 mm (22") and ASME B16.47 (Series A) for
sizes DN 650 mm (26") and above.
5.2 Spectacle blind and spacer & blind shall conform to the requirements of ASME B
16.48 up to sizes DN 600 mm (24"). For sizes DN 650 mm (26") and above,
spectacle blind and spacer & blind shall conform to Manufacturer's standard.
5.3 Type, face and face finish of flanges shall be as specified in Purchase Requisition.
5.4 Fittings such as tees, elbows, reducers, etc. shall be either welded or seamless
type. All fittings shall comply with the requirements of MSS-SP-75.
5.5 Fittings such as weldolets etc. shall be manufactured in accordance with MSS-SP-
97.
5.6 Tees shall be manufactured by forging or extrusion method. Stub-in or pipe to pipe
connection shall not be used in the manufacture of tees. The longitudinal weld
seam shall be kept at 90 degree from the extrusion. Fittings shall not have any
circumferential weld joint.
5.7 All butt weld ends shall be beveled as per ASME B16.5 / MSS-SP-44 / ASME B16.47
as applicable for flanges and MSS-SP-75/MSS-SP-97 as applicable for fittings.
5.8 The reinforcement of inside weld seam shall be removed for a distance of 100mm
from each end of welded fittings.
5.9 All welds shall be made by welders and welding procedures qualified in accordance
with provisions of ASME Sec. IX. The procedure qualification shall include Charpy
V-notch test for weld heat affected zone and hardness test in accordance with
clause 4.3 and 4.4 of this specification respectively.
5.10 Repair by welding on flanges and parent metal of fittings is not permitted. Repair
of weld seam by welding shall be carried out by welders and welding procedures
duly qualified as per ASME Section IX and records for each repair shall be
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NEW DELHI 450 MM (18”) AND ABOVE S-04-02-014
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maintained. Repair welding procedure qualification shall include all tests, which are
applicable for regular production welding procedure qualification.
6.1 The Manufacturer shall perform all inspections and tests as per the requirement of
this specification and the relevant codes, prior to shipment at his works. Such
inspections and tests shall be, not but limited to the following:
6.1.1 All flanges and fittings shall be visually inspected. The internal and external
surfaces of the fittings shall be free from any strikes, gauges and other detrimental
defects.
6.1.2 Dimensional checks shall be carried out on finished products as per ASME B16.5 /
MSS-SP-44 / ASME B16.47 as applicable for flanges, ASME B 16.48 for spacers and
blinds and ASME B 16.9 / MSS-SP-75/MSS-SP-97 as applicable for fittings and as
per this specification.
6.1.3 Chemical composition and mechanical properties shall be checked as per relevant
material standards and this specification, for each heat of steel used.
a) All butt and repair welds for welded fittings shall be examined 100 % by
radiography. Acceptance criteria shall be as be ASME B 31.4 or ASME B 31.8
as applicable and API 1104.
b) When elbows of size ≥ 18" NB are manufactured, the first elbow of each
radius, diameter and wall thickness shall be ultrasonically checked for
sufficient wall thickness in areas where a minimum wall thickness is to be
expected. This shall be followed by random inspection of one out of every
three elbows of the same radius, diameter and wall thickness.
c) All finished wrought weld ends subject to welding in field, shall be 100%
tested for lamination type defects by ultrasonic test. Any lamination larger
then 6.35 mm shall not be acceptable.
6.2 Purchaser's Inspector reserves the right to perform stage wise inspection and
witness tests, as indicated in clause 6.1 of this specification at Manufacturer's
Works prior to shipment. Manufacturer shall give reasonable notice of time and
a) Test certificates relevant to the chemical analysis and mechanical properties of the
materials used for manufacture of flanges and fittings as per relevant standards
and this specification.
8.1 After all inspection and tests required have been carried out; all external surfaces
shall be thoroughly cleaned to remove grease, dust and rust and shall be applied
with standard mill coating for protection against corrosion during transit and
storage. The coating shall be easily removable in the field.
8.2 Ends of all fittings and weld neck flanges shall be suitably protected to avoid any
damage during transit. Metallic or high impact plastic bevel protectors shall be
provided for flanges and fittings.
8.3 Flange face shall be suitably protected to avoid any damage during transit.
8.4 All flanges and fittings shall be marked as per applicable dimension /
manufacturing standard.
9.0 DOCUMENTATION:
9.1 Prior to shipment, the Manufacturer shall submit six copies of the test certificates
as listed in clause 7.0 of this specification.
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CONTENTS
1.0 SCOPE
3.0 MATERIAL
8.0 DOCUMENTATION
SPECIFICATION REV- 0
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1.0 SCOPE
This specification covers the minimum requirements for manufacture and supply of
long radius bends made from Carbon Steel line pipes for use in onshore pipeline
systems handling hydrocarbons in gaseous or liquid phase including Liquified
Petroleum Gas (LPG).
Reference has been made in this specification to the latest edition (edition enforce
at the time of issue of enquiry) of the following codes, standards and
specififcations:
In case of conflict between the requirement of above reference documents and this
specification; the requirements of this specification shall govern.
3.0 MATERIAL
3.1 Bends shall be fabricated from steel line pipe. The type of pipe to be used for
fabrication of bends shall be indicated in the Work Order. Pipe with positive wall
thickness tolerances shall be used for fabrication of bends.
3.2 Unless specified otherwise in the Work Order, the line pipes for fabrication of bends
shall be procured by Owner.
3.3 Heat treatment shall be carried out for all finished bends inn case it is established
during bending procedure qualification that heat treatment is required to meet the
specification requirements. Heat treatment procedure shall be such that the
mechanical properties and steel microstructure of the finished bends comply with
the minimum requirements specified in the applicable line pipe specification
referred under clause 2.0. When TMCP and OLAC steels and micro alloyed steels
are used, specific approval of the proposed heat treatment shall be obtained before
bending process is employed. The finished product shall be evaluated for
mechanical properties and micro structural stability.
3.4 Mechanical testing of test bends performed during the bend manufacturing
procedure qualification as per section 9.0 of this specification, shall ensure that all
bends made according to the Company approved bend manufacturing procedure
have the required mechanical properties and destructive testing of production bend
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is not required. However, company reserves the right to require destructive testing
whenever production bending parameters or heat treatment parameters deviate
from those established in the Company approved bend manufacturing procedure.
4.0 MANUFACTURE
4.1 Material grade, bend size, bend radius an bend angle shall be as indicated in the
PO. Unless specified otherwise , the bending radius for bends shall be minimum six
times the specified outside diameter.
4.2 Bends shall be manufactured by high frequency induction heating and forming
method. Once the bending operation has commenced no stoppage shall be
permitted until the entire bend has been completed. If bending temperature,
bending rate, cooling medium volume or heat treatment temperature- depart from
the company approved bend manufacturing procedure, then the pipe shall be
discarded and another bend shall be made in its place.
4.3 When bending SAW or Electric Welded Pipes, the longitudinal seam shall be located
in the plane of minimum deformation or neutral axis. Acceptable tolerance on
location of the longitudinal weld seam shall be ± 50.
4.4 All bends shall be provided with a tangent length at both ends. Tangent length shall
be 500 mm or pipe outside diameter whichever is more.
4.5 Unless otherwise specified differently in the PO, the bevels at the ends shall be as
per the relevant pipe specification.
4.8 Bulges, dents and flat areas shall not appear within 100 mm front end of the bend.
For the remaining part of the bend these deviations from the original contour of the
pipe are permitted provided these deviations do not exceed 6.0 mm. The same
shall not extend (in any direction) over a distance of more than 25 % of normal
diameter of the bend.
4.9 The excess weld material at the inside of the bend in case of bends made from
SAW pipes, shall be removed over a distance of 100 mm at both ends.
4.10 Tolerances
The dimensions of bends shall be controlled to make sure that they are
manufactured according to the tolerances indicated below, in addition to the
requirements of MSS-SP-75. However, the ends of finished pipe bend shall meet the
dimensional tolerances of the relevant pipe specification referred in clause 2.0.
4.10.1 Following tolerances shall be applicable for Bend Angle and Bend Radius:
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Bend Angle :± 0.50 from the specified angle
Bend Radius :± 1 % of bending nominal radius (radius as indicated in clause
4.1 above).
4.10.2 The manufacturer shall measure the wall thickness of the pipe before bending
along both the inside and outside radii of the bend between and including the start
and stop points of the bend arc angle, at intervals approximately equal to pipe
diameter or 300 mm whichever is less. The wall thickness shall be measured
ultrasonically after bending at the same locations as measured before bending. In
addition, the wall thickness of the tangents shall also be measured. These
measurements shall be taken at four equally spaced locations around the pipe
circumference. The measured wall thickness shall be at least equal to :
where:
4.9.3 Out of roundness tolerance on the body and ends of the bend shall be as follows:
Body
The measurements shall be made over the circumference of the bend either at
distances approximately equal to pipe diameter or 300 mm whichever is less.
Minimum three measurements shall be taken for each bend.
Ends
Out-of-roundness over a length of 100 mm from the end shall comply with the
requirements of relevant company specification.
4.9.4 Off-Plane
Off-Plane of bends shall not exceed (θ/ 90) X 10 mm, where θ is the bend angle in
degree or the tolerance limit specified in MSS-SP-75, whichever is less. The
measurement shall be in accordance with MSS-SP-75.
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5.1 The manufacture shall perform all inspection and tests as per the requirements of
this specification and MSS-SP-75 prior to shipment, at his works. Such inspection
and tests shall be as a minimum, but not limited to the following:
b) Visual inspection
d) Check heat treatment, if carried out, as required and maintain its records.
- All seam welds of bends manufactured from SAW pipes shall be 100%
radiographed and seam welds of bends manufactured from EW pipe
shall be 100% ultrasonically tested. The acceptance criteria shall be
relevant pipe specification.
- The full circumference of both ends of each bend after beveling shall
be ultrasonically tested for laminations over a length of 25 mm and
acceptance limits shall be as per pipe specification as per relevant
pipe specification.
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performed or witnessed by Company’s Inspector shall in no way
relieve the Manufacturer’s obligation to perform the required
inspection and tests. Under no circumstances any action of the
Company’s Inspector shall relieve the Manufacturer of this
responsibility for the material and quality of bends.
The Certificate shall be valid only when signed by Company’s Inspector. Only
those bends which have been certified by Company’s Inspector shall be
dispatched from Manufacturer’s works.
7.2 All loose and foreign material like rust, grease, etc. shall be removed from inside
and outside of the bends.
7.3 One coat of antirust paint shall be applied on the bends for protection during transit
and storage. Type of paint shall be as agreed upon with the company.
7.4 Both ends of all bends shall be suitably protected to avoid any damage during
transit by means of metallic or high impact plastic bevel protectors.
7.5 Package shall be marked legibly with suitable marking ink to indicate the following:
a) Order Number
b) Package Number
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c) Manufacturer’s Name
8.0 DOCUMENTATION
8.2 At the time of bidding, bidder shall submit the following documents:
8.3 Within three weeks of placement of order, the manufacturer/ contractor shall
submit bend manufacturing procedure including manufacturing, inspection, testing
procedures, quality control manual and quality plans.
a) Sequence of Operation
g) NDT procedures
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only after the bend manufacturing procedure has been qualified and approved by
company.
Once the approval has been given by Company any change in material and method
of manufacture and quality control shall be notified to company whose approval in
writing of all such changes shall be obtained before the bends are manufactured.
8.4 Within 30 days from the approval date, Manufacturer shall submit to Company the
approved drawings, documents and specifications as listed in clause 8.3 above.
8.5 Prior to shipment, the Manufacturer shall submit test certificates as listed in section
6.0 of this specification.
9.1 Prior to start of production bending, Manufacturer shall demonstrate the suitability
of the proposed manufacturing procedures for producing pipe bends including the
post-bending heat cycle, that meet the requirements of this specification, by
mechanically testing additional bend(s) (test bends). The bending procedure shall
be qualified in the presence of company representative.
9.2 Test bends shall be made by using the pipe specified in clause 2.0 of this
specification. One test bend is required per ‘heat-lot’ where a heat lot is deemed to
include all bends of the same diameter, wall thickness, mill heat number and bend
forming parameters such as, bending temperature, bending rate, cooling medium
volume & heat treatment temperature (excluding bend angle). The test bend shall
be bent to an angle of 900.
9.3.1 All finished test bends shall meet the requirement of dimensional tolerances,
inspection and non-destructive testing requirements specified in section 4.0 & 5.0
of this specification.
9.3.2 In addition all test bends shall be subjected to following mechanical testing to
confirm that the bends manufactured meet all mechanical property requirements of
relevant linepipe specification. Test procedure and acceptance criteria shall be in
accordance with the relevant linepipe specification. The test specimen shall be
taken from the bent portion of the bend only.
a) Tensile test
One tensile test shall be conducted on the base material of finished test
bend, to establish yield strength, ultimate tensile strength and elongation.
The specimen shall be taken longitudinal or transverse to the axis as
specified in the relevant pipe specification. In case of bends of 450 mm
(18”) NB and larger, the specimen shall be taken at inside radius and one at
outside radius of bend.
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b) All Weld Tensile Test
In case of bends fabricated from SAW Ppipes, an all weld tensile test shall be
conducted to establish yield strength, ultimate tensile strength and
elongation of weld material on bend.
For bends manufactured from SAW pipes one face and one root guided bend
test shall be performed. For bends manufactured from EW pipes, reverse
bend test shall be carried out. Test method and acceptance criteria shall be
same as mentioned in applicable pipe specification.
d) Hardness Test
Charpy –V- notch test temperature shall be the same as specified in the
relevant pipe specifications. Three base material specimens shall be taken
longitudinal or transverse to the axis as specified in the relevant pipe
specification. In case of bends fabricated from SAW and EW pipes, three
transverse weld material specimens shall be taken with weld in the middle.
In case of bends of 450 mm ( 18”) NB and larger, the base material
specimens shall be taken at the outside radius of the bend.
Should test bends fail to comply with the above requirements, the bend
manufacturing procedure shall be disqualified. The manufacturer shall revise the
manufacturing procedure and re-qualify the same at his own cost and time.
SPECIFICATION REV- 0
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STANDARD SPECIFICATION
FOR
FLOW TEE (BARRED TEE)
1.0 SCOPE
9.0 MARKING
This specification covers the basic technical requirements for design, manufacture,
inspection, testing, coating and painting & supply of Pipeline Flow Tees (Barred
Tees) (above ground / under ground) to be installed in pipeline system
transporting Natural Gas. All Tees shall be suitable for Bi-directional movement of
Inspection tools / pigs.
Reference has also been made in this specification to the latest edition of the
following codes, standards and specifications:
3.1 The design code, design factor, rating, corrosion allowance, grade of
material, nominal diameter and nominal wall thickness of mating main pipe
and branch pipe shall be as stated in the Material requisition.
3.2 Tees with branches 25% or more than the main pipeline diameter shall have
a configuration of bars as indicated in Annexure-A. The bars shall be made
of mild steel, ASTM Grade hardness tested applications, and shall be full
penetration welded using a qualified procedure.
3.3 The Tees shall be designed to the design code as stated in the material
requisition, and shall be manufactured to MSS SP-75 as appropriate and the
requirements of this specification. Full encirclement Tee shall not be
allowed.
3.4 The Tees shall meet or exceed the strength requirements of the matching
pipe as calculated by ASME B 31.8.
3.5 Data supporting the design in form of calculations and drawings shall be
submitted for approval prior to commencement of manufacture. Design shall
be in strict accordance with the appropriate design code. Documented data
of successful proof tests according to the relevant standard shall be
submitted in support of the design.
3.6 The wall thickness of weld ends at the bevel of main run and branches of
Tees shall have a bevel thickness no greater than 1.5 times the nominal wall
thickness of the mating pipe. A 1:4 taper on the outside diameter at the
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ends of the pipe will be acceptable, if the wall thickness of the body of the
Tee exceeds this dimension.
3.7 Vendor shall check & confirm the number of bars (as stated in Appendix-A)
required for Tees.
3.8 All pipeline Tees shall be suitable for passage of instrumented inspection
tools in either direction.
3.10 Material of the ends to be field welded by purchaser shall have carbon
equivalent less than or equal to 0.45 based on check analysis, for each heat
of steel, calculated according to the following formula.
Mn Cr + Mo + V Ni + Cu
CE = C+ -------- + --------------------- + ---------------
6 5 15
3.11 When specified in data sheet, hardness test shall be carried out as per
ASTM A370 for each heat of steel used. The maximum hardness of base
metal, weld metal and heat affected zone of all pressure parts shall be 248
HV10, unless specified otherwise.
3.12 When specified in the Data Sheet, charpy V-notch test shall be conducted
on each heat of base material, weld metal and heat affected zone of all
pressure containing parts such as body, welding ends in accordance with
the impact test provisions of ASTM A 370 at a temperature of 0° C. The
charpy impact test specimens shall be taken in the direction of principal
grain flow and notched perpendicular to the original surface of the plate of
forging. Average impact energy value of three full sized specimens shall be
27 joules. Minimum impact energy value of any one specimen shall not be
less than 80% of the average impact energy specified. No specimen shall
exhibit less than 80% shear area.
3.13 The Tees shall be manufactured from material, which meets the specified
minimum yield strength of the mating pipe and shall be as indicated in the
data sheet.
3.14 The material for flow Tee shall consist of blooms, billets, slabs, forging
quality bar, plate, seamless or fusion welded tubular products with filler
metal added.
3.15 The material shall be as per MSS SP-75 or suitable API Standard 5L pipe to
achieve tensile properties as indicated in the data sheet.
3.16 The fittings shall be heat treated by normalizing, quenching and tempering
to achieve the same strength of line pipe.
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3.17 Fittings shall not be machined from bar stock or solid forged billets.
3.19 A ring of material may be required from the main run of pipe for weld
procedure qualifications for the main pipeline. Rings shall be 400mm
minimum in length and subject to the same forging and heat treatment as
the supplied Tee.
4.1 MANUFACTURE:
4.1.1 Tees shall be made by forging the branch from a suitable pipe and / or a
pre-bent fabrication and shall have a maximum of one seam weld only.
Circumferential welds are not permitted. Seamless fittings are preferred.
4.1.2 The chemical and physical properties of the material shall meet the line pipe
specifications.
4.1.4 Double sided submerged Arc welding is required for the longitudinal weld in
the main run. Single sided weld requires specific approval from Purchaser.
4.2 QUALIFICATION:
4.2.1 A Tee shall be qualified when it passes all production testing as required by
clause 5.3 of this specification. The qualification is valid for the main and
branch nominal pipe size combination, per grade, heat treatment and
manufacturing route only. However, a Tee with an equal branch will qualify
for Tees with the same main OD with smaller branch OD’s of the same
grade or lower grades.
4.2.2 A test ring from the main run and prolongations of the forged branch of the
Tee shall be tested to qualify the manufacturing route per size, grade, and
heat treatment and material source.
4.2.3 Welds and body shall be tested in accordance with clause 5.3 of this
specification. Testing shall be carried out per steel source per heat.
4.2.4 The full penetration welds for the bars shall be qualified to ASME Sec. IX or
other welding code approved by Purchaser.
4.2.5 All welding, including weld repairs, shall be performed in accordance with
the procedure approved by Purchaser and welders qualified in accordance
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with ASME Sec. IX and API 1104. Welding procedures required for non-sour
service applications shall also include the hardness tests.
4.3.1 One tensile test to include the weld (if present) and one tensile test to
include the body of the main run, one tensile test to include the extruded
branch. Specimens shall be transverse.
4.3.2 The Charpy V-Notch test shall consist of three specimens. Longitudinally
welded Tees shall include one set in the body and four sets to be taken
from the weld (if present), one set to be taken from each of the weld
centerline, fusion line, fusion line + 2mm, fusion line + 5mm. One set
shall be taken from the extruded branch. All charpy specimens shall be
transverse.
4.3.3 Proof tests (Bursting tests) as per MSS SP-75. However, this
requirement can be waived by Purchaser, where documentary evidence
is provided for the design of Tee proven by previous proof testing, in
support of the design by the vendor.
5.1 GENERAL:
5.1.1 All personnel, performing the non-destructive tests (NDT) shall be qualified
in the technique applied, in accordance with ASNT-TC-1A Level II by a third
party, or equivalent approved by the Purchaser.
5.1.3 All NDT shall be performed in accordance with written procedures. These
procedures shall have the prior approval of the Purchaser.
5.1.4 NDT shall be carried out on Tees after all mechanical testing, manufacturing
stages and heat treatment have been completed.
5.2.1 100% Visual inspection shall be carried out. The body of every fitting shall
be inspected internally and externally for surface defects.
5.2.2 The surfaces of the fitting shall be free from all dents, gouges, laps, score
marks, arc strikes, under cuts or other detrimental defects.
5.2.3 Welds shall be inspected visually for 100% of the length, both outside and
inside. The requirement of workmanship shall be as per the connected line
pipe.
5.2.4 Defects shall be removed by grinding or by weld repair except that welding
is not allowed on the body of the Tee. Weld repairs shall be qualified and
carried out in accordance with the applicable line pipe specification.
5.3.1 100% Radiographic testing of all seam welding shall be carried out in
accordance with ASME Sec VIII, Div 1, Clause UW – 51. For Butt welds in
Tees, with a thickness greater than 20mm (0.8 inches) , radiographic
inspection may be replaced with Ultrasonic inspection at the discretion of
Vendor.
5.3.2 For the acceptance of radiographic films, the technique used shall result in
sensitivity better than 2% of thickness of the weld metal and a relative film
density of 2 to 3.5 in the weld metal.
5.3.4 The penatrameter used shall be of the wire type in accordance with ISO
1027. The selection of penatrameter wire diameters shall be based on a
sensitivity of 2% of weld metal thickness. Penatrameter must be placed
source side.
5.3.5 Magnetic particle inspection (MPI) of 100% surface of the Tees, all bevel
ends and all welds shall be in accordance with the requirements of ASTM
E709. The wet method shall be used, use of probes is unacceptable.
Relevant linear indications greater than 3mm in bevel ends shall require re-
beveling. Any ground surface shall be re-inspected by MPI to verify that the
indication has been removed. The beveled surface shall be free from defects
such as cracks, laps or laminations visible to the naked eye as revealed by
MPI.
5.3.6 Ultrasonic tests (UT) shall be carried out on all bevel ends of all fittings, in
accordance with ASTM E709. Relevant linear defects greater than 3mm are
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non-acceptable. Longitudinal edges and body of plate for seam welded
fittings shall be tested in accordance with applicable specification of line
pipe. UT shall be as per applicable line pipe specifications.
5.3.7 All repairs shall include a minimum preheat of 1000C, unless the qualification
test shows that a higher temperature is necessary.
5.3.8 Each repair welding procedure shall be qualified on a pipe section under
realistic conditions in accordance with API 5L Appendix-C and this
specification.
5.4.1 Each Tee shall confirm to the dimensional requirements of ASME B 16.9 or
MSS SP-75 as appropriate and the additional requirements of this section.
5.4.2 The ends of each fitting shall be tested for out of roundness using an
internal ring gauge with a diameter of 5mm (0.2 inch) less than the nominal
internal diameter. The gauge shall pass freely into each end of the fitting for
a distance of 100mm when held perpendicular to the fitting axis.
5.4.3 The tolerance for the internal diameter of the run pipe part of the Tee shall
be within 0 to +1.5mm (0 to 0.059 inches) of the nominal dimension of the
connecting pipe at the ends.
5.4.4 End bevel preparation for the Tees shall be in accordance with API 5L. If
necessary, the ends shall be machined such that the maximum wall
thickness at the ends of the Tee is no greater than 1.5 times the nominal
wall thickness of the mating pipe. A taper of 1:4 is permitted on out side
only to reduce the thickness of the Tee body to meet the thickness of the
weld bevel.
5.4.5 A gauging Pig shall be passed through the main run of each Tee. The pig
shall consist of two aluminum plates of at least 3mm thick, joined by a rigid
rod through their centers. The diameter of the plates shall be 95%
(tolerance 0 to +1mm) of the nominal inside diameter of the main pipe. The
Pig shall pass without sticking or damage to the Tee.
5.4.6 The gap produced when a flat plate perpendicular to the Pipe Axis is held
against the machined bevel of main and branch pipe ends shall be within
+3.0mm.
After sand blasting and cleaning the surface (SA 2 ½) of the Barred Tee, the
following coating shall be applied.
7.1 Material test certificates and manufacturer test reports shall be traceable to
each Tee within the Vendor Fabrication Book, which shall be part of the QC
Data bank.
7.2 The pressure containing and load bearing / stressed materials shall be fully
covered by the material test certificates which shall bear Equipment tag
numbers, Purchase order numbers and any other Purchase order
requirements.
The vendor shall submit shipping and handling procedures to Purchaser for
approval. The procedures should adequately address storage, shipping and
handling in view of the long voyage from manufacturing locations and climatic
extremes at the job site. An appropriate design of end cap shall be fitted to each
opening to protect the butt weld ends and prevent ingress of foreign material.
9.0 MARKING:
The vendor shall mark each fitting with the information specified below as a
minimum. The markings shall be painted on the outside surface and shall be
executed white block capitals of minimum height ¾ inch.
Project Name
Manufacturer’s name and unique identification number of the fitting
Nominal header pipe diameter (inches) and wall thickness (mm)
Nominal branch pipe diameter (inches) and wall thickness (mm)
Material Grade
Design Pressure and test Pressure (when applicable)
Purchase Order and Item Number
Cast number
During the fabrication, the Vendor shall submit certification and inspection
documents to the Purchaser as specified in the Purchase order. Documents shall
include the following as minimum.
Quality Plan
1.0 SCOPE
3.0 MATERIALS
8.0 GUARANTEE
9.0 SPARES
10.0 DOCUMENTATION
2.1 Reference has also been made in this specification to the latest edition of
the following codes, standards and specifications:
ASTM A 194 : Carbon and alloy steel nuts for bolts for
high pressure or temperature
3.0 MATERIALS:
3.3 Material of the ends to be field welded by purchaser shall have carbon
equivalent less than or equal to 0.45 based on check analysis, for each heat
of steel, calculated according to the following formula.
Mn Cr + Mo + V Ni + Cu
CE = C+ -------- + --------------------- + ---------------
6 5 15
3.4 For Materials of Barrel, Neck, Charpy V-notch test shall be conducted at
-20°C and 00C. The minimum transverse impact energy values of three full
sized specimens (10mm x 10mm as per ASTM E23) shall be as under:
MINIMUM AVERAGE
TEST MINIMUM
MATERIAL VALUE
TEMPERATURE SINGLE VALUE
(FOR SPECIMENS)
BASE METAL AND (-) 200C 35 J 27 J
WELD 00 C 100 J 75 J
Impact test shall be carried out on samples with the notch at the following
locations for the weld zone:
Weld Metal
Fusion line
Fusion line + 2mm
Fusion line + 5mm
Shear area at the fracture surface shall be recorded. The shear area shall be
determined for base metal samples only. The required levels are 85%
average fibrous shear, and 75% individual minimum.
The test specimens shall be in a transverse direction with the notch axis
oriented through the pipe wall /plate wall thickness.
3.5 For Scraper Traps, hardness test shall be carried out as per ASTM A370 for
each heat of steel used. A full thickness cross section shall be taken for this
purpose and the maximum hardness of the base material, weld metal and
heat affected zone (HAZ) of all the pressure containing parts shall not
exceed 248 HV10. The maximum difference in hardness of Base metal, Weld
metal and Heat affected zone (HAZ) of pressure containing parts of the
traps shall be less than 80 points Vicker’s HV10.
Certified mill test report, showing the chemical and physical properties for
each item of material furnished by the Manufacturer, shall be witnessed /
reviewed by third party Inspection agency (TPIA).
4.1.1 The cylindrical portion of the trap shall be designed as per design code and
design factor indicated in the data sheets. Quick end closure shall be
designed as per sec. ASME Sec. VIII, Div. 1 for design conditions indicated
in data sheets. A corrosion allowance of 3mm shall be considered in design
of the traps. Quality of welding shall be such that weld efficiency factor of
1.0 is achieved.
4.1.2 The trap shall be capable of handling instrumented pigs, model like Linalog
360 of AMF Tuboscope or British gas magnetic inspection vehicle or
equivalent and scraper pigs as specified in scraper Trap data sheet.
4.1.3 The trap body and neck, diameter has been indicated in the data sheet.
Trap length to suit the purpose and thickness to meet the class rating shall
be suggested by the manufacturer and approved by the purchaser.
Circumferential weld on scraper trap body and neck shall not be permitted.
4.1.5 Vents and drains shall be provided on each trap. The trap shall be provided
with a suitable slope and the drain location shall be such that complete
drainage of the trap is possible. Sizes for vent and drain shall be as
indicated in data sheet. In case of Scraper Receiver, the minimum slope
shall be 1:100 downwards the end closure where as in case of Launcher it
shall be 1:100 downwards the pipe line.
4.1.7 End connections of traps shall be flanged or butt welded as indicated in data
sheet.
a) Flanged ends, if specified shall have dimension as per ASME B16.5 for
sizes up to 24" NB (excluding 22 NB) and as per ASME B16.47 / MSS-
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SP-44 for sizes 22 NB and 26 NB and above. Flanges shall be as
indicated in data sheets.
b) Butt weld ends if specified shall have ends prepared as per ASME
B16.25. However, end preparation for butt welding ends having
unequal thicknesses with respect to connecting pipe shall be as per
ASME B31.4/ ASME B31.8 as applicable.
4.1.8 The quick opening end closure shall be of quick actuating GD band lock type
or equivalent design. The design of the quick opening end closure shall be
in accordance with design code adopted for the adjoining pig trap as stated
in the data sheet. The design of the end closure shall be robust and should
consider fail safe design of the opening mechanism and allow opening and
closing by one man in a period of approximately one minute without the use
of additional devices.
The closure shall also consist of a safety relief system allowing the opening
only when there is no pressure in the trap. Safety bleeder device shall alert
operator of possible hazard unless pressure in the pig trap is relieved
completed.
Screwed type or plug-in types of end closures are not acceptable. End
closures of size 24" and above shall be fitted with worm gear operator for
the opening of the closure.
Hinge of the closure shall be so designed that the weight of the end closure
is fully supported with out sagging. The end closure shall be designed in
accordance with safety requirement of ASME Sec. VIII Div. 1, Clause UG-35.
End closure hinge axis shall be horizontally aligned, not withstanding any
slope on the barrel section.
4.1.9 Traps shall be provided with a pig indicator in the middle of the neck and
the indicator shall conform to the specification issued for the purpose. Pig
indicator shall be suitable for bi-directional operation and shall have visual
flag and manual reset. The same shall also have provision for remote
indication. Refer Pig Signaler Data Sheet.
4.1.10 The Scraper trap shall be supplied with Pig Handling system, Jib Crane and
Winch for pulling the SS tray and Pig as mentioned below.
Pig handling trolley shall be designed from structural steel and shall be
suitable to move on rail through a gear train.
Trolley shall be designed to contain pig tray which will contain pig. Trolley
shall have proper braking system. Pig tray shall have perforated holes and
shall be suitable to contain any type of pig, including intelligent pig.
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Tray shall have proper strengthening system to avoid bending with load.
The tray shall be provided with suitable stops. Lock bracket shall be
provided such that the tray does not stop within the Launcher / Receiver.
Rear end of the tray shall be provided with suitable lug to enable retrieval of
the tray by hooks.
The handling system (for inserting and retracting the intelligent pigs from
the equipment) shall be complete with handling devices. In case any rails
are required for sliding of the handling system, the same shall be provided
by the Scraper Launcher / Receiver manufacturer.
Winch to push tray and pig inside the launcher / receiver shall be provided.
Jib Crane shall be designed as per IS: 3177, IS: 3832, IS: 3938 of latest
edition and shall be mounted on a structural column.
Jib Crane shall swivel 3600 with one person and shall have antifriction
bearing for swivel operation.
Crane shall be balanced with load at maximum span and shall have counter
weight if required. Suitable locking and braking system shall be provided.
End stoppers shall be provided for trolley movement.
Crane shall be tested with 1.5 times of rated load at maximum radius.
Deflection test shall be as per IS: 807 of latest edition. Wire ropes used for
hoisting and traveling shall be checked as per IS: 6594 and IS: 3973 latest
edition.
Jib crane shall be designed to be operated by one man for all operations.
4.1.11 Fabricated steel supports, minimum two numbers at suitable spacing shall
be provided with traps for mounting on concrete blocks. These supports will
not be subjected to pipeline anchorage forces. The material of support shall
be compatible with trap material for welding purposes. All welds shall be
examined by magnetic particle method.
4.1.12 Completed assembly shall be stress relieved as per the provisions of the
design codes.
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4.1.13 Welds shall be made by welders and welding procedures qualified in
accordance with the provisions of ASME Sec. IX. The procedure qualification
shall include impact test and hardness test when required as per clause 3.4
& 3.5 of this specification and shall meet the requirements as specified
therein.
4.1.14 Repair by welding on parent metal is not allowed. Repair of welds shall be
carried out only after specific approval by purchaser's representative for
each repair. The repair welding shall be carried out by the welders and
welding procedures duly qualified as per ASME Section IX and records for
each repair shall be maintained. The repair welding procedure qualification
shall include impact test and hardness test when required as per clause 3.4
& 3.5 of this specification and shall meet the requirements as specified
therein.
4.1.15 The traps shall be equipped with a half internal removable filtering basket
consisting of a punched plate with a least five rows of drain holes.
4.1.16 The filtering basket shall slide on guides on wheels and in all cases the
material of the parts being in contact with each other shall be of the anti
spark type.
4.1.17 The tolerance on internal diameter and out of roundness at the ends for the
welding end of the neck (at the end where connecting pipeline will be
welded) shall be as per applicable connected pipe specification as indicated
in the data sheet.
4.1.17 Opening for nozzles shall be from material conforming to the same
requirements as the pressure containing parts, and adequately reinforced as
per ASME B31.8. All nozzles shall be flushed with the inside contour of the
barrel.
The nozzles shall be terminated with weld neck type raised faced flanges
conforming to ASME B16.5/16.47.
4.2 FABRICATION:
4.2.1 General:
The inside of the trap barrel shall be free from obstructions which could
prevent the free rolling of spheres, or travel of pigs or carriers. All inside
welds shall be ground smooth and nozzle ends shall be made to suit inside
curvature of barrel.
The inside diameter of the minor barrel of the trap and the main flange shall
match the inside diameter of the pipeline on which it is to be installed.
4.2.2 Welding:
Welding shall be performed with procedures and operators who have been
qualified in accordance with the design code and ASME code Section IX.
All main seam welds and nozzle to shell welds shall be of full penetration
type. Double side welding shall be carried out wherever possible. Single
welded butt joints are permitted for circumferential joints and will be 100%
radiographically tested.
All weld spatters and arc strikes shall be removed by grinding prior to
inspection and testing of welded joints.
Diameter and out of roundness tolerances for the minor barrel shall be in
accordance with the requirements of Project Specification for Line Pipe.
5.1 The manufacturer shall perform all inspections and test as per the
requirements of this specification and the relevant codes prior to shipment
at his works. Such inspections and tests shall be, but not limited to, the
following:-
5.1.1 All traps shall be visually inspected. Undercuts, overlaps, craters and
other unacceptable defects on the welds shall be removed and / or
welded.
5.1.3 Dimensional check shall be carried out as per the approved drawings.
5.1.4 If the traps are provided with welded reinforced attachments, tell-tale
holes shall be provided in order to test with dry air at 7 bar g
pressures and checked with foam agent for leaks. This shall be
carried out prior to the final hydrostatic pressure test.
5.1.5 Hydrostatic test shall be conducted for all scraper traps complete in
all respects including mounting of pig indicators at a pressure equal
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to 1.5 times the design pressure. The test pressure shall be held for a
minimum period of four hours.
The temperature of the trap material and test liquid shall not be less
than 10ºC during the hydrostatic test.
5.1.6 A minimum of two closing and opening cycles shall be performed and
correct operation of both quick opening closure and safety system
shall be ascertained after the pressure cycles. No excessive force
should be required to operate the mechanism.
7.1 After all inspection and tests required have been carried out; all external
surfaces shall be thoroughly cleaned to remove grease, dust and rust.
Surface preparation shall be carried out by shot blasting to SP-6 in
accordance with "Steel Structures Painting Council Visual Standard - SSPC-
VIS-1". Machined parts shall be coated with anti-rust removable paint and
non machined parts shall be applied with two coats of protective paint.
Manufactures shall indicate the type of paint used in the drawings submitted
for approval.
7.2 Marking shall be done on a stainless steel plate and affixed to the body by
means of corrosion resistant fasteners. Marking shall include the following:-
a) Manufacturer's Name
b) Trap/ Neck Diameter, Thickness
c) Material
d) ASME Class Rating
e) Tag Number
f) Design Pressure
g) Design Temperature
h) Test Pressure
i) Design Factor
j) Year of Manufacture
k) Empty weight of the trap assembly.
7.3 Equipment shall be drained of test liquid, cleaned and thoroughly dried prior
to shipment. Surfaces subject to atmospheric corrosion or rusting shall be
coated with rust preventive. External non-painted surfaces including bolting
and flange faces also shall be coated with rust preventive designed for at
least six months of storage.
7.4 All components shall securely anchor to the skid and package supports.
7.5 All opening, flange facings, etc., shall be sealed with waterproof coverings
for shipping. Threaded coupling shall be provided with steel plugs.
7.6 Two extra O-rings and the closure actuation tool shall be attached to the
inside of the barrel to prevent loss. The scraper barrels shall be handled in
such a manner to prevent damage, including damage to the bevel or
closure. Service bolting and gaskets shall be suitably rated and properly
marked.
7.7 Flanged openings shall be protected with one-piece plywood cover and
rubber gasket. Plywood covers shall be 3/8 inch thick, for flanges 6 inches
and smaller, ½ inch thick for 8 inch through 12 inch flanges, and ¾ inch
thick for larger sizes.
7.8 A minimum of four 3/8 inch bolts shall be used for flanges 12 inches and
smaller end eight 3/8 inch bolts for larger flanges.
7.9 Large washers shall be used on the flange side of the bolt. Suitable washers
shall be used on the plywood side of all such covers.
7.10 Only those traps, which have been inspected and certified by the
purchaser’s inspector shall be supplied.
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8.0 GUARANTEE:
8.1 Manufacturer shall guarantee that the trap along with accessories is in
compliance with the requirements of this specification for materials and
workmanship. Manufacturer shall replace or repair all parts which should
result defective due to inadequate design or the workmanship. In case the
defect can not be eliminated, Manufacturer shall replace the trap without
any delay. Any defect occurring within the time period specified elsewhere
Shall be repaired making all necessary modifications and repair of defective
parts free of charge to the purchaser.
9.0 SPARES:
9.1 Manufacturer shall furnish list of recommended spares and accessories for
Scraper Traps required during start up and commissioning. As a minimum,
the commissioning spares shall include 200% extra consumable spares viz.
gaskets/ o-rings/ seals etc. for each trap. Cost of such spares shall be
included by the Manufacturer in the item rates indicated in Purchase
Requisition.
10.0 DOCUMENTATION:
10.1 Manufacturer shall furnish the following documents at the time of bidding:-
(e) Vessel weight data, Erection weight, Operational weight, Maximum weight
(m) Reference list of similar supplies for the past seven years including project,
client year of supply & contact person.
Failure to provide this information may exclude the manufacturer’s bid from
Evaluation.
10.2 Within three weeks of placement of order, the manufacturer shall submit
four copies of, but not limited to, the following drawings, documents and
specifications for approval.
Once the above said documents have been approved by the Purchaser, any
changes in design, material and method of manufacturer shall be notified to
the Purchaser, whose approval in writing of all changes shall be obtained
before the traps are manufactured.
10.3 Within four weeks from the approval date Manufacturer shall submit one
reproducible and six copies of all approved drawings, documents and
specification as listed in clause 10.2 of this specification.
10.4 Prior to shipment, the manufacturer shall submit one reproducible and six
copies of the following:
Sl.No. Description
1.0 SCOPE
2.0 MATERIALS
7.0 GUARANTEE
9.0 DOCUMENTATION
2.0 MATERIALS:
2.1 All materials used in the manufacture of the main components of the pig
signallers shall be as indicated in the data sheets. Other components shall
be as per manufacturer's standard suitable for the service conditions
indicated in Annexure – I and data sheets which will be subject to approval
by Purchaser.
2.3 Material of the ends to be field welded by purchaser shall have carbon
equivalent less than or equal to 0.45 based on check analysis, for each heat
of steel, calculated according to the following formula.
Mn Cr + Mo + V Ni + Cu
CE = C+ -------- + --------------------- + ---------------
6 5 15
2.4 The maximum hardness of Base metal, Weld metal and Heat affected zone
(HAZ) of pressure containing parts of the traps shall be 248 points Vicker’s
HV10.
3.3 Design of pig signallers shall be such that any possibility of signaler being
operated by line pressure is eliminated.
3.4 Design of pig signallers shall also be such that repair and installation of
internals/ accessories are possible under pressure, without removing the
unit from the line.
3.6 Pig signalers shall be fitted with sealed, weather proof and explosion proof
micro switch for remote signal indication. The area classification and rating
of micro switch shall be as indicated in data sheet. Suitable for installation in
NEC class I Division 1, hazardous area. Micro switch shall have the following
rating:
3.7 All welds shall be made by welders and welding procedures qualified in
accordance with the provision of ASME Section IX. The procedure
qualification shall include hardness test and shall meet the requirements of
clause 2.4 of this specification
3.8 Whenever specified in the data sheet, pig signallers shall be provided with
extension, suitable for installation on underground pipeline.
4.1 Manufacturer shall perform all inspection and tests required to supply the
signallers as per the requirements of this specification.
4.5 The welding end shall be inspected ultrasonically over the entire
circumference for lamination type defects. Any lamination larger than
6.35mm shall not be acceptable.
4.6 Hydrostatic test shall be conducted at a pressure equal to 1.5 times the
design pressure. Hydro test duration shall be 15 Minutes.
6.1 Exterior surface of the pig signallers shall be thoroughly cleaned, freed from
rust and grease and applied with sufficient coats of corrosion resistant paint.
Manufacturer shall indicate the type and corrosion resistant paint used in
the drawings submitted for approval. In case of pig signallers with
extension, the buried portion shall be coated with three coats of coal tar
epoxy resin. The minimum dry film thickness shall be 300 microns.
6.2 A corrosion resistant metal tag shall be permanently attached with each
unit, with the following marking:-
i) Manufacturer’s name
ii) Suitable for installation in_______mm dia. pipeline
iii) ANSI Rating
iv) 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 GUARANTEE:
7.1 Manufacturer shall guarantee that the pig signallers comply with the
requirements stated in this specification and in the purchase order.
Manufacturer shall replace or repair all parts found to be defective due to
inadequate engineering or quality of material. Manufacturer shall replace the
signaler without delay, if the defect or malfunctioning cannot be eliminated.
7.2 Any defects occurring within the time period specified elsewhere shall be
repaired making all necessary modifications and repair of defective parts
free of charge to the purchaser.
8.0 SPARES:
8.1 Manufacturer shall furnish list of recommended spares and accessories for
Pig Signalers required during start up and commissioning. Cost of such
spares shall be included by the Manufacturer in the item rates indicated in
Purchase Requisition.
9.0 DOCUMENTATION:
9.1 At the time of bidding, bidder shall submit the following documents:-
9.2 Within three weeks of placement of order, the manufacturer shall submit
four copies, but not limited to, of the following drawings, documents and
specifications for approval.
Once the approval has been given by Purchaser, any change in design,
material, etc. shall be notified to the Purchaser whose approval in writing for
all changes shall be obtained before Pig Signallers are manufactured.
9.3 Within four weeks from the approval date, Manufacturer shall submit one
reproducible and six copies of the approved drawings and specifications as
listed in 9.2 of this specification.
9.4 Prior to shipment, Manufacturer shall submit one reproducible and six copies
of following:
1.0 SCOPE
3.0 MATERIALS
8.0 GUARANTEE
9.0 DOCUMENTATION
2.1 Reference has been made in this specification to the latest edition of the
following Codes, Standards and Specifications.
g) MSS-SP-53 (Quality standard for steel castings and forgings for valves
flanges and fittings and other piping components - magnetic particle
examination method)
3.0 MATERIALS
3.1 Material for the pressure containing parts of the insulating joints shall be as
indicated in the data sheets. Material for pups shall be equivalent or
superior to the material of connecting pipeline which is indicated in the data
sheets. Other part shall be as per manufacturer's standard suitable for the
service condition indicated in Insulating Joint Data Sheets and shall be
subject to approval by Purchaser.
3.2 Insulating joints, which are subject to field welding by purchaser, shall have
carbon equivalent (CE) not exceeding 0.45 based on check analysis for each
heat of steel calculated according to the following formula:
3.3 When specified in the IJ Data Sheet, charpy V-notch test shall be conducted
on each heat of base material, weld metal and heat affected zone of all
pressure containing parts such as body, welding ends in accordance with
the impact test provisions of ASTM A 370 at a temperature of 0° C. The
charpy impact test specimens shall be taken in the direction of principal
grain flow and notched perpendicular to the original surface of the plate of
forging. Average impact energy value of three full sized specimens shall be
27 joules. Minimum impact energy value of any one specimen shall not be
less than 80% of the average impact energy specified. No specimen shall
exhibit less than 80% shear area.
3.4 Carbon steel used for the manufacture shall be fully killed
3.5 When specified in data sheet, hardness test shall be carried out as per
ASTM A370 for each heat of steel used. The maximum hardness of base
metal, weld metal and heat affected zone of all pressure parts shall be 248
HV10, unless specified otherwise.
3.6 Insulation material shall be minimum 20 mm thick and shall comply section
5, NACE RP 0286.
4.1 Mechanical
4.1.1 Insulating joints shall be of integral type fabricated by welding and with
pups on either side as shown in data sheet. A corrosion allowance as
indicated in data sheet shall be considered in design. Bolted and threaded
joints are not acceptable.
4.1.2 All materials used for the manufacture of the insulating joint shall be in
accordance with clause 3.0 of this Specification.
4.1.3 Insulating joints shall be designed using the design principles of ASME
Section- VIII Div. 1. The design shall be checked for the following two
cases:
Case-I: Design Pressure (as per Data Sheet) + Axial Force (F)
The allowable stress in this case shall be less than or equal to 0.5 x
SMYS of insulating joint material.
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GAIL (INDIA) LTD STANDARD SPECIFICATION FOR
INSULATING JOINTS Page 4 of 9
NEW DELHI S-04-02-019
Copyright GAIL – All rights reserved
Case-II: Hydrostatic Test Pressure
The allowable stress in this case shall be less than or equal to 90% of
SMYS of insulating joint material.
All design parameters shall be as per Insulating Joint Data Sheet. Detailed
calculations shall be submitted for Purchaser approval.
4.1.4 Insulating joint design and materials shall be capable of being vacuum
tested to 1 millibar.
4.1.5 The joint between pipe pup pieces and main forging shall be full penetration
butt weld type. Weld design shall be such as resulting in a weld joint factor
of 1.0.
4.1.6 Butt weld ends shall have ends as per ASME B16.25. However, end
preparation for butt welding ends having unequal thickness with respect to
connecting pipe, shall be as per ASME B31.4/ B31.8 as applicable.
4.1.7 The reinforcement of inside weld seam, in case pups fabricated from LSAW
pipes, shall be removed for a distance of at least 50mm from each end.
4.1.8 Insulating joints shall allow free passage of scraper/ instrumented pigs. The
internal bore shall be same as that of connecting pipe including its
tolerances.
4.1.9 The insulating joint shall be formed by sandwiching and locking in positions
the insulating material in a bell and spigot type of joint. The joint shall be
assembled in such a way that its various components are firmly locked in
position and the completed joint is capable of withstanding stresses due to
designed operating conditions and field hydrostatic testing.
4.1.11 All welds shall be made by welders and welding procedures qualified in
accordance with the provisions ASME section IX. The procedure qualification
shall include impact test and hardness test and shall meet the requirements
of clause 3.3, 3.5 of this specification.
4.1.12 Repair welding on parent metal is not allowed. Repair of welds shall be
carried out only after specific approval by purchaser's representative for
each repair. The repair welding shall be carried out by welders and welding
procedures duly qualified as per ASME section IX and records for each repair
shall be maintained.
4.1.13 Internal diameter at the welding end shall not vary more than + 1, -3 mm
from the nominal internal diameter.
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GAIL (INDIA) LTD STANDARD SPECIFICATION FOR
INSULATING JOINTS Page 5 of 9
NEW DELHI S-04-02-019
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4.1.14 Out of roundness measured at the root face of the welding ends shall not
be more than 0.5% of the specified inside diameter.
4.2 Electrical
4.2.1 The average dielectric strength of the insulating joint shall be minimum 15
kilo Volts.
4.2.2 Two cleats as shown in data sheet shall be provided on the pups on either
side of the insulating joint for connecting 10 mm2 and 50 mm2 cables for
measurement/ shorting purposes. Cleats shall be attached to the insulating
joint by welding.
5.1 The manufacturer shall perform all inspection and tests as per the
requirements of this specification and the relevant codes, prior to shipment
at his works. Such inspection and tests shall be, but not limited to the
following:
a) 100% radiography shall be carried out on all butt & repair welds of
pressure containing parts. Acceptance limits shall be as per API 1104.
Welds, which in purchaser's opinion can not be inspected by
radiographic methods, shall be checked by ultrasonic or magnetic
particle methods. Acceptance criteria shall be as per ASME Section
VIII Appendix-12 and Appendix-6 respectively.
5.1.6 After the hydrostatic test insulating joints shall be tested with air at 5
kg/cm2 for 10 minutes. The tightness shall be checked by immersion or with
a frothing agent. No leakage will be accepted.
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.
5.2 Purchaser reserves the right to perform stage wise inspection and witness
test as indicated in Para 5.1 at Manufacturer's works prior to shipment.
Manufacturer shall give reasonable notice of time and shall provide without
charge, reasonable access and facilities required for inspection to the
purchaser's Representative. Inspection and tests performed/witnessed by
the Purchaser's Representative shall in no way relieve the Manufacturer's
obligation to perform the required inspection and test.
7.1 Insulating joint surface shall be thoroughly cleaned, freed from rust and
grease and applied with sufficient coats of corrosion resistant paint. Surface
preparation shall be carried out by shot blasting to SP-6 in accordance with
"steel structures painting council - Visual standard SSPC-VIS-l". External
surfaces of buried insulating joints shall be painted with three coats of
suitable coal tar epoxy resin with a minimum dry film thickness of 300
microns. Manufacturer shall indicate the type of corrosion resistant paint
used, in the drawings submitted for approval.
7.2 Insulating joints shall be marked with indelible paint with the following
data:-
a. 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
7.3 Insulating joints shall be suitably protected to avoid any damage during
transit. Metallic bevel protectors shall be provided to weld ends.
7.4 Only those insulating joints which have been inspected and certified by
Purchaser shall be shipped.
8.0 GUARANTEE
8.1 The manufacturer shall guarantee that the materials used comply with the
requirements of this specification.
8.2 Manufacturer shall replace or repair insulating joints found defective due to
inadequate engineering or quality of material.
8.3 Manufacturer shall replace the insulating joint without delay if the defect or
malfunctioning can not be eliminated.
8.4 Any defects occurring within 12 months from the date of installation or
within 30 months from the date of dispatch, whichever is earlier shall be
repaired making all necessary modifications and repair of defective parts
free of charge to the purchaser.
9.0 DOCUMENTATION
9.3 Within three weeks of placement of order, the Manufacturer shall submit
four copies of the following drawings, documents and specifications for
approval.
Once the approval has been given by purchaser, any changes in design,
material and method of manufacture shall be notified to the Purchaser
whose approval in writing of all changes shall be obtained before the
insulting joints are manufactured.
9.4 Within four weeks from the approval date, Manufacturer shall submit one
reproducible and six copies of the approved drawings, documents and
specifications as listed in 9.3 of this specification.
9.5 Prior to shipment, the manufacturer shall submit one reproducible and six
copies of the test certificates as listed in clause 6.0 of this specification.
1.0 SCOPE
2.0 FUNCTION
Pipeline insulators shall be used to support the carrier pipe inside the casing pipe and
electrically isolate the carrier pipe from the casing pipe at the cased crossings.
- Resist corrosion.
- Have high electrical insulating value and low water absorption, thus preventing
leakage and maintain electrical isolation between carrier and casing pipes.
3.0 DESIGN
The arrangement of insulator shall be generally in accordance with Fig. 3.0. It shall be
made in segments duly held together with cadmiudXYLAN plated bolts and nuts, to be
supplied with casing insulators.
The number of segments shall be two for pipe diameters upto DN 300 rnm (12"). For
larger diameter, the number of segments may be more than two, but their number shall
be kept minimum.
The skid height shall be such that it is slightly less than the value obtained by following
formula:
4.0 MATERIAL
STANDARD SPECIFICATION FOR CASING SPECIFICATION REV-0
GAIL (INDIA) LTD INSULATORS AND END SEALS
NEW DELHI S – 04 – 02 - 020 Page 3 of 8
Copyright GAIL – All rights reserved
Casing insulators shall be made of injection moulded high density polyethylene or other
material, equivalent or superior, as approved by OWNER.
SCOPE
This specification covers the minimum requirements of design, material, fabrication and supply
of casing end seals intended to be used for pipeline cased crossings.
FUNCTION
Casing end seals are intended to be used for sealing the annular space between casing pipe
and carrier pipe at casing ends so as to prevent ingress of moisture and water.
DESIGN
The seals shall be suitable for the casing and carrier pipe diameters as applicable for each
case. The casing end seal shall be flexible to cater for the expansion and contraction of carrier
and casing pipes and shall be able to tolerate both angular and concentric misalignment of
casing pipe without loss of sealing efficiency.
The design of the casing end seals shall permit easy installation of the seal to the cased
pipeline crossing.
It shall provide moisture-proof seals when installed for the entire anticipated life of the buried
pipeline.
Manufacturer shall obtain prior approval from OWNER on casing end seals design/drawings.
MATERIAL
The casing end-seals shall be made of heat shrink high density radiation cross linked
polyethylene with an adhesive having a melt point suitable for the pipeline service temperature
and ambient temperatures foreseen during construction. End seals material shall be resistant
to heat, cold, vibration, impact, abrasion, corrosive fluids, disbonding, organic and bio-
deterioration. Manufacturer shall confirm compatibility of end seals with carrier pipe coating.
b) Adhesive
Manufacturer shall furnish material test certificates of the components used in the
assembly of casing end seals as per the requirements of this specification.
1.0 The manufacturer shall replace, at no extra cost, any material not conforming to the
material and performance requirements of this specification.
2.0 Manufacturer shall submit detailed specification of the materials used in the assemblies,
along with instructions for handling, use and installation of the material for OWNER
approval prior to procurement.
3.0 Manufacturer shall submit all the documents, test reports, records and other
information to OWNER for record after approval as per clause 2.0 above. Number of
Copies (Hard copies / soft copies etc.) shall be as indicated in CONTRACT document.
1.1 This specification establishes the minimum requirements of materials, equipment and
installation of field joint anti-corrosion coating of buried onshore pipelines factory
coated with either three layer polyethylene or fusion bonded epoxy coating, by heat
shrink wraparound sleeves or by cold applied tapes conforming to DIN EN 12068 -
"Cathodic Protection - External Organic Coatings for the Corrosion Protection of Buried
or Immersed Steel Pipelines used in Conjunction with Cathodic Protection - Tapes and
Shrinkable Materials" and the requirements of this specification. Unless
modifiedlreplaced by this specification, all requirements of DIN EN 12068 shall remain
fully applicable and complied with.
This specification shall be read in conjunction with the conditions of all specifications
and documents included in the Contract between Company and Contractor. Unless
specified otherwise, all sections of this specification shall apply to all specifications
referred in this specification.
Reference has also been made to the latest edition (edition enforce at the time of issue
of enquiry) of the following standards, codes and specifications:
In case of conflict between the requirements of this specification and that of above
referred documents, the requirements of this specification shall govern.
The CONTRACTOR shall be familiar with the requirements of these documents and shall
make them readily available at the site to all personnel concerned with carrying out the
works specified in this specification.
3.1 Field joint anti-corrosion coating material shall be either heat shrinkable wraparound
sleeve or cold applied tape suitable for a maximum operating temperature of (+) 60°C
(Tmax) and shall conform to designation EN 12068 - C HT 60 UV. In addition, the field
joint anti-corrosion coating shall comply the requirements specified in para 3.2 of this
specification.
The total thickness of heat shrinkable wraparound sleeve in the as applied condition
shall be as follows:
Heat shrinkable wraparound field joint coating system manufactured by M/S Tyco
Adhesives Raychem and M/S Canusa are acceptable for the supply of field joint coating
materials. The Contractor shall propose the specific grade of field joint coating system
meeting the requirements of this specification from these manufacturers. In case the
Contractor proposes to supply heat shrinkable wraparound sleeve from any other
manufacturer, then the Contractor shall propose only those coating systems that have
been previously used for pipelines of size same or higher than the size indicated in
tender, for a length of 50 Km and above in a single project for similar operating
conditions.
Cold applied tape system shall comprise of primer, an inner wrap and an outer wrap.
The inner and outer wraps shall be asymmetric 3-ply tape with co-extruded
polyethylene carrier film and butyl rubber adhesive layers on both sides. The inner layer
of butyl rubber adhesive of inner wrap shall have a thickness of min. 1.0 mm. The inner
and outer wraps are to be spirally wrapped with 55% overlap, equivalent to two layers
each providing a total minimum thickness of 3.0 mm on the pipe body and 2.5 mm on
the weld.
The Contractor shall propose only those cold applied tape coating systems that have
been previously used in pipelines of size 16" and above and a length of 50 km and
above in a single project for similar operating conditions.
As applied field joint coating system shall comply the requirements of DIN EN 12068,
Table 1 and 2 corresponding to designation DIN EN 12068 - C HT 60 W, except as
modified below:
a) Cathodic Disbondment Resistance at Tmax i.e 60°C shall be 20 mm when tested as per
Annexure K of DIN EN 12068. Test shall be carried out at (+) 60°C
Contractor shall obtain prior approval from Company regarding the Manufacturer of the
joint coating material and the specific grade of the joint coating system. Complete
technical details along with test certificates complying with the requirements of clause
3.2.1 and 3.2.2 shall be submitted to Company for this purpose. The Contractor shall
finish test certificates from an independent DIN recognized / approved laboratory for all
the properties required for the specified EN designation of field joint coating and the
requirements of this specification.
3.3 The material shall not be older than their period of validity at the time of application by
the Contractor. Deteriorated/ decomposed material shall be disposed off and replaced
by the contractor at his own expenses.
Contractor shall ensure that the coating materials supplied by him are properly packed
and clearly marked with the following:
- Manufacturer's name
3.4 Contractor shall ensure that the Manufacturer has carried out all quality control tests on
each batch and manufacturer shall provide test certificates to certify that the supplied
materials meet the manufacturer's specifications as indicated in the purchase order and
as approved by COMPANY. Certificates and data sheets certifying the qualities of the
coating materials shall be submitted by Contractor to Company prior to application.
Company reserves the right to have the materials tested by an independent laboratory.
3.5 Materials shall be stored in sheltered storage in the manufacturer's original packing and
away from direct sunlight and in accordance with manufacturer's instructions.
3.6 Contractor shall provide and maintain mobile facilities which contain all necessary
equipment and its spares for cleaning, coating, repairs, inspection and tests.
3.7 Contractor shall furnish sufficient number of the following equipment and the required
spares as a minimum for inspection and test purposes for each crew:
a) Fully automatic full circle adjustable holiday detector with a visible and audible
signal system for inspection of coatings.
4.1 General
4.1.1 The application procedure shall be in accordance with manufacturer's instructions and
the minimum requirements specified below whichever are the most stringent and shall
be demonstrated to and approved by the Company. Manufacturer's expert shall
supervise the application and shall be available at site upon request during qualification
of application procedure and during construction at Contractor's cost.
4.1.2 Operators for coating application shall be given necessary instructions and training
before start of work, by the Contractor. To verify and qualify the application
procedures, all coating applied during the qualification test, shall be removed for
destructive testing as detailed subsequently in this specification. Contractor shall only
4.1.3 Oil, grease and salt shall be removed from steel surface by wiping with rags soaked
with suitable solvents such as naphtha or benzene. Kerosene shall not be used for this
purpose. Solvent cleaning procedure according to SSPC-SP1 shall be followed.
4.1.4 Each field joint shall be blast cleaned using a closed cycle blasting unit or an open
expendable blasting equipment. With the first equipment type, steel or chilled shot and
iron grit shall be used and Garnet material with the second one (in case the authority
having jurisdiction have no objection, the contractor may adopt sand blasting instead of
garnet material). During blast cleaning the pipe surface temperature shall be
simultaneously more than 5 0C and more than 3°C above ambient Dew Point, while the
ambient Relative Humidity shall not be greater than 85 %. Prior to surface cleaning the
surfaces shall be completely dry. The surface shall be cleaned to a grade Sa 2 ½ in
accordance with Swedish Standard SIS-055900 with a roughness profile of 50 - 70
microns. Surface roughness profile shall be measured using an approved profile
comparator in accordance with IS0 8503-1 and shall be calibrated prior to the start of
the work in accordance with IS0 8503-3 or IS0 8503-4. The blast cleanliness shall be
checked on every joint and the roughness profile shall be checked 1 every 10 joints.
Dust, girt or foreign matter shall be removed from the cleaned surface by an industrial
vacuum cleaner. The dust contamination allowed shall be of a rating max 2 as per IS0
8502 -3. The frequency of checking for dust contamination shall be 1 every 10 joints.
Blast cleaned field joint shall be coated within 2 - 4 hours according to the conditions
below:
Pipe delayed beyond this point or pipes showing any visible rust stain, shall be blast
cleaned again.
4.1.5 The field joint surface shall be inspected immediately after blast cleaning and any
feature of the steel surface such as weld spatter, scabs, laminations or other
imperfections considered injurious to the coating integrity, made visible during blast
cleaning, shall be reported to the Company Representative and on permission from
Company Representative, such defects shall be removed by filing or grinding. Pipes
affected in this manner shall be then re-blast cleaned if the defective area is larger than
50 mm in diameter.
4.1.6 The ends of existing pipe protective coating shall be inspected and chamfered.
Unbounded portions of the coating shall be removed and then suitably trimmed.
STANDARD SPECIFICATION FOR FIELD SPECIFICATION REV-0
GAIL (INDIA) LTD JOINT COATING (ONSHORE PIPEINE)
NEW DELHI S-04-02-021 Page 9 of 15
Copyright GAIL – All rights reserved
Portions where parent coating is removed shall be thoroughly cleaned as specified. The
adjacent chamfered areas of the line pipe coating shall be cleaned and abraded, to
expose a clean uniform fresh surface of uncontaminated factory applied coating.
4.1.7 All steel joint surfaces shall be thoroughly examined before the application of the
coating in order to ensure the surfaces are free of oil, grease, rust, mud, earth or any
other foreign matter. All these substances shall be removed before coating, to the
procedures herein described.
4.1.8 Protection coating shall be applied on the joints immediately after the completion of
cleaning operation.
4.2.1 The wrap around sleeve shall be of a size such that a minimum overlap of 50 mm is
ensured (after shrinking) on both sides of the yard applied corrosion coating of pipes.
In the cases where carrier pipe is installed by direct boring/ jacking, the overlap on the
mill coating for the leading edges of the joints shall be minimum 200 mm. When this
extra overlap is achieved by providing an additional patch of heat shrink tape/
wraparound, it shall be applied in such a manner that the square edge of the patch on
the joint coating is in the direction opposite to the direction of boring / jacking.
4.2.2 Before centering the wraparound sleeve, the bare steel surface shall be preheated
either with a torch moved back and forth over the surface or by induction heating. The
minimum pre-heat temperature shall be as recommended by manufacturer and shall be
checked by means of contact type temperature-recording thermometer (Digital
Pyrometer with flat probe type contact). Temperature indicating crayons shall not be
used. Pre-heat temperature shall be checked on every joint. Care shall be taken to
ensure that the entire circumference of the pipe is heated evenly. Temperature
measuring instruments shall be calibrated immediately before the start of the works and
thereafter at intervals recommended by the manufacturer of the instrument.
4.2.3 Upon pre-heating, the pipe surface shall be applied with two pack epoxy primer of wet
film thickness 150 microns or as per manufacturer's recommendation whichever is
higher, to cover the exposed bare metal of the welded field joint and 10 mm min. onto
the adjacent pipe coating if recommended by the manufacturer. The wet film thickness
of the primer shall be checked on every joint with a wet film thickness gauge prior to
installation of sleeve. Thickness gauge shall be calibrated once per shift.
4.2.4 Immediately after application of epoxy primer, the wraparound sleeve shall be entirely
wrapped around the pipe within the stipulated time recommended by the manufacturer.
Sleeve shall be positioned such that the closure patch is located to one side of the pipe
STANDARD SPECIFICATION FOR FIELD SPECIFICATION REV-0
GAIL (INDIA) LTD JOINT COATING (ONSHORE PIPEINE)
NEW DELHI S-04-02-021 Page 10 of 15
Copyright GAIL – All rights reserved
in 10 or 2 O'clock position, with the edge of the undergoing layer facing upward and an
overlap of min. 50 mm. Gently heat by appropriate torch the backing and the adhesive
of the closure and press it firmly into place.
4.2.5 A heat shrinking procedure shall be applied to shrink the sleeve in such a manner to
start shrinkage of the sleeve beginning from the center of the sleeve and heat
circumferentially around the pipe. Continue heating from the center towards one end of
the sleeve until recovery is completed. In a similar manner, heat and shrink the
remaining side. Shrinking has been completed when the adhesive begins to ooze at the
sleeve edges all around the circumference.
The complete shrinking of the entire sleeves shall be obtained without undue heating of
existing pipe coating and providing due bonding between pipe, sleeve and pipe coating.
The installed sleeve shall not be disturbed until the adhesive has solidified.
4.3.1 Cold applied joint protection tape shall be of the type, which can be applied by spiral
wrapping on the pipe.
4.3.2 Immediately after the completion of surface preparation, the approved primer of wet
film thickness 150 microns or as per manufacturer's recommendation whichever is
higher, to cover the exposed bare metal of the welded field joint and 10 mm min. onto
the adjacent pipe coating if recommended by the manufacturer. Any dirt on the primed
surface shall be removed. If the primer is damaged, the damaged area shall be cleaned
and re-primed.
4.3.3 Approximately 100 mm of inner wrap interleaving paper shall be peeled back and inner
wrap shall be applied with the thicker adhesive side to the pipe. Whilst continuously
removing the interleaving paper, the tape shall be spirally applied through a machine to
provide a minimum of 55% overlap. Sufficient tension shall be applied to ensure good
conformity, avoiding air pockets and also continuously smooth out as the wrapping
proceeds. The wrapping shall start and finish to give a minimum 50 mm overlap on to
the adjoining yard applied coating. Outer wrap shall also be applied in similar method.
The field joint coating system materials and the procedures proposed by the Contractor
shall be pre-qualified during the sleeve installation start-up phase. Five joints (5) shall
be coated with the requirements of this specification and then inspected and tested in
accordance with the requirements of this specification with respect to the following:
(vi) Peel test at (+) 23°C & (+) 60°C on pipe surface & factory applied coating and
at overlaps (as applicable). If required to achieve the temperature of (+) 60°C,
suitable thermal blanket may be used.
(vii) Visual appearance and void after installation on the body, area adjoining the
weld and area adjoining the factory applied coating. (To establish voids adjoining
the weld and factory coating, a strip of 50 mm wide and 200 mm long shall be
stripped and examined.)
Company Representative shall witness the tests and inspection. Regular application of
field joint coating shall commence only upon successful completion of the pre-
qualification testing.
After successful completion of the pre-qualification testing as above, the entire field
joint coating shall be removed, the pipe surface re-blasted and field joint coating re-
applied as per the requirements of this specification.
Visual inspection of the as applied coating shall be carried out on every joint, for the
following:
(ii) There shall be no sign of punctures or pinholes or bend failure. The external
appearance of the sleeve shall be smooth, free of dimples, air entrapment or
void formation. All sleeves shall be tested for the presence of voids by knocking
on the sleeves. A hollow sound compared to the remainder of the sleeve may
indicate the presence of voids under the sleeve. Such sleeve shall be tested for
adhesion at the discretion of the Company Representative.
(iv) Visual indicator provided on the backing and the closure patch showing desired
heat is achieved.
The entire surface of each joint shall be inspected by means of a full circle holiday
detector approved by Company, set to a DC voltage applicable as per the requirements
of factory applied mainline coating specification of Company. Inspection of the sleeves
shall be conducted only after the joint has cooled below 50°C. The holiday detector
used shall be checked and calibrated daily with an accurate DC voltmeter. The detector
electrode shall be in direct contact with the surface of coating to be inspected.
No field joint shall be covered or lowered in the trench until it has been approved by the
Company.
Coating thickness shall be checked by non-destructive methods for each field joint.
Average thickness of the as-applied coating on pipe body shall be established based on
measurements at min. eight locations i.e four measurements on either sides of the girth
weld at 3, 6, 9 & 12 O'clock positions. To establish the minimum thickness on the girth
weld, four measurements shall be taken on apex on the weld at 3, 6, 9 & 12 O'clock
positions. All such measurements shall be recorded. Company Representative reserves
the right to ask for additional measurements at any location on the field joint coating,
whenever doubt arises.
5.4.1 One out of every 50 joint coatings or one joint coating out of every day's production,
whichever is stringent, shall be tested to establish the peel strength on steel and factory
applied coating. Contractor shall carry out such testing in the presence of Company
Representative.
5.4.2 From each test sleeve selected as above, one or more strips of size 25rnrn x 200 mm
shall be cut perpendicular to the pipe axis and slowly peeled off.
The required peel strength shall meet the requirements of this specification as
applicable for (+)23 0C or (+) 60 0C whichever is feasible. This test shall be conducted
between wrapping & metal and mill coating & between layers at overlap with joint
coating (wherever applicable). After removal of strip, the bulk of adhesive shall remain
adhered to the pipe showing no bare metal, otherwise, test shall be considered failed.
The adhesive layer that remains on the pipe surface shall generally be free of voids
resulting from air or gas inclusion. In case the peel strength test at a different
temperature than that specified is warranted due to the ambient site conditions, then
the peel strength shall comply the recommendation of the manufacturer. Manufacturer
shall be asked to furnish peel strength values corresponding to various expected
temperatures, prior to start of the works.
5.4.4 Company Representative reserve the right of 100% removal of sleeves if he is not
convinced that the requirements of clause 5.4.2 are achieved.
6.0 REPAIRS
6.1 If a field joint is detected to be unacceptable after testing as per section 5.0 of this
specification the Contractor shall, at his own cost:
(i) Determine the cause of the faulty results of the field coating.
(ii) Mobilise the expert of manufacturer, if required.
(iii) Test to the complete satisfaction of Company, already completed field coatings.
(iv) Stop the field coating works until remedial measures are taken against the
causes of such faults, to the entire satisfaction of the Company.
6.2 Contractor shall replace all joint coating found or expected to be unacceptable as per
section 5.0 of this specification.
6.3 Contractor shall, at his own cost repair all areas where the coating has been removed
for testing by the Company.
6.4 After the coating work on welded joints and repairs to the coating have been completed
the coating as a whole shall be tested with a spark-tester before lowering or jacking the
pipeline.
6.5 Company shall be entitled to check the coating on buried pipelines or parts of pipelines
with equipment such as the "Pearson Meter" and the resistance meter. If coating
defects are established, the Contractor shall be responsible for excavation at such
points, repairing the coating, spark testing and backfilling the excavations without extra
charge.
7.0 DOCUMENTATION
7.1 Prior to procurement of coating materials, Contractor shall furnish the following
information for qualification of the Manufacturer and material:
a. Complete information as per clause 3.2 and DIN EN 12068 along with descriptive
technical catalogues.
STANDARD SPECIFICATION FOR FIELD SPECIFICATION REV-0
GAIL (INDIA) LTD JOINT COATING (ONSHORE PIPEINE)
NEW DELHI S-04-02-021 Page 14 of 15
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b. Test certificates and results of previously conducted tests, for all properties listed
in clause 3.2 of this specification.
c. Reference list of previous supplies, in last 5 years, of the similar material
indicating the project details such as diameter, quantity, operating temperature,
year of supply, project name, contact person and feed back on performance.
Once the Company's approval has been given, any change in material or
Manufacturer shall be notified to Company, whose approval in writing of all
changes shall be obtained before the materials are manufactured.
7.2 Prior to shipment of materials from the Manufacturer's Works, Contractor shall furnish
the following documents:
1.1 This specification covers the minimum requirements for the materials, application,
inspection, handling and other activities for external concrete weight coating of
pipelines.
1.2 This specification shall be read in conjunction with the conditions of all specifications
and documents included in the CONTRACT between Company and Contractor.
1.3 Contractor shall, with care and diligency, execute the work in compliance with all laws,
bylaws, ordinances, regulation, etc. and provide all services and labour, inclusive of
supervision thereof, all materials, excluding the materials indicated as Company
supplied materials in the CONTRACT, equipment, appliances or other things of
whatsoever nature required in or about the execution of the work, whether of
temporary or pemanent nature.
1.4 Unless otherwise specified, all sections of this specification shall apply to all the
specification referred in this specification.
2.1 Reference has been made in this specification to the latest edition (edition enforce at
the time of issue of enquiry) of the following codes and specifications:
ASTM A-1 85 : Specification for Steel Welded Wire Fabric, Plain, for
Concrete Reinforcement
ASTM C-138 : Test Method for Unit weight, Yield and Air Content of
Concrete.
In case of conflict between the requirements of this specification and that of the above
referred codes and standards, the requirements of this specification shall govern. The
Contractor shall be familiar with the requirements of these documents and shall make them
readily available at the coating plant.
2.2 For the purpose of this specification, the following definition shall hold:
3.0 MATERIALS
The Contractor shall supply all the materials necessary for the performance of the work.
Materials for concrete weight coating shall comply with the following requirements. All
the materials supplied by the Contractor, which in the opinion of Company's
Representative / Inspector, do not comply with the appropriate specifications, shall be
rejected and removed from the site.
3.1 Cement
3.2 Aggregates
i) Natural sand;
ii) Crushed stone sand;
iii) Crushed gravel sand.
Sand shall be well graded from fine to coarse in accordance with Table 4 of IS:383.
3.2.4 Aggregates (fine and coarse) shall be clean and free from clay and injurious amounts of
salt, alkali, deleterious substances or organic impurities.
3.3 Water
The water shall be fresh and clean and shall be free from injurious amounts of oils,
acids, alkalis, salts, sugar, organic materials or other substances that may be
deleterious to concrete or steel. It shall not contain chlorides, sulphates, and
magnesium salts. Water from each source shall be tested prior to its use and shall be
approved by Company. Seawater or contaminated water shall not be used. Water from
doubtful sources shall be tested by the Contractor at his expanse and approved by
Company before use.
3.4. Reinforcement
3.4.1 Reinforcement shall consist of welded steel wire fabric manufactured in flat sheets or in
rolls (ribbon mesh) and shall conform ASTM A-185. Wires shall conform to ASTM A-82.
3.4.2 Steel wire shall be galvanised at finished size as per ASTM A-641. The diameter of the
wire and spacing of wires (mesh dimensions) shall be selected according to the
following criteria.
3.4.2.1 Wire fabric manufactured in flat sheets shall be 2 x 4 inches max. Steel wire mesh, 13
gauge U.S. Steel wire (2.4 mm) min. each way.
Pipes shall be concrete coated to a thickness and density as specified in the drawings
and CONTRACT documents. The concrete unit weight shall be minimum 2245 kg/m3
(140 pounds per cubic foot) and the compressive strength shall not be less than 200
kg/cm2 in 28 days and 135 kg/cm2 in 7 days. Concrete coating shape shall be circular
and concentric to pipe outside diameter. Other concrete coating shapes are not
acceptable.
Concrete coating shall be applied either using casting or impingement method. Any
alteration or modifications to the methods described in this specification shall be
submitted to theCompany for approval. The application method shall however ensure
the basic characteristics of concrete coating in compliance with the minimum
requirements of this specification.
Wherever practical, the total thickness of coating shall be applied in a single pass.
6.0 EQUIPMENT
The equipment used for performing the concrete coating shall be capable of doing so
with a required degree of uniformity with respect to thickness, density and strength.
The proportioning equipment and procedure shall be of the type to assure consistently
proportioned material by weight. Concrete shall be mixed in a mechanical mixer, which
shall ensure thorough mixing of all materials. Any equipment that tends to separate the
ingredients shall not be used.
7.1 All measurements as mentioned below shall be taken during the work stages and
clearly logged in a logbook. A special logbook shall be used for recording tests and trial
results. A logbook shall refer to pipe lengths having the same nominal diameter, and
steel wall thickness.
7.2 The following shall be subject to measurement and logging for each pipe length :
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GAIL (INDIA) LTD CONCRETE WEIGHT COATING OF
NEW DELHI ONSHORE PIPELINE S-04-02-022 Page 7 of 15
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a) Line Pipe
b) Corrosion coating
c) Concrete Coating
7.3 No concrete placing shall be allowed before items 1 through 10 listed at clause 7.2,
have been logged.
Before commencement of the work, Contractor shall perform all tests, either in
laboratory or in field and trials necessary to properly select type of mix, which meets
the requirements of this specification.
8.1 The type of mix, i.e. the correct combination of the cement, aggregates and water
which results in the desired properties of concrete shall be at first determined for each
mix and following shall be accurately checked and recorded:
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- proportion and weights of the respective materials used;
- the water / cement ratio;
- the grading of the aggregates.
8.2 Samples shall be prepared and tested in accordance with ASTM C-642 to determine the
dry specific gravity of the concrete. In parallel, test according to ASTM C-138 shall be
performed so as to determine the expected correlation between concrete weight after
placing and dry specific gravity (28 days after placing). Test for concrete specific gravity
at Intermediate time
(7 days after coating) shall be performed.
8.3 When the results of the above tests do not meet the requirements, the mix shall be
modified and concrete samples tested until a proper mix has been determined.
8.4 The mix so determined, shall then be used for sampling of concrete to be submitted to
compressive strength tests as per ASTM C39.
8.5 Frequency of sampling for tests for density and compressive strength of concrete shall
be as follows:
Upto 25 3
26 to 50 4
5 1 and above 4 plus one additional
sample for each
additional 50 m3 or
part thereof.
'Quantity' means the volume of concrete to be used for each qualified mix.
9.1 Two test cubes each per day shall be obtained from batches and tested at the end of 7
days after coating, for compressive strength and specific gravity.
9.2 The moisture content of the aggregates used shall be such as to maintain a satisfactory
control on the water / cement ratio of the concrete mix.
Prior to placing of reinforcement, the anti-corrosion coating of each pipe length shall be
carefully inspected visually and by holiday detectors and, if damages are found, they
shall be repaired in accordance with the relevant specification, before start of the work.
Foreign matters, if any, shall be removed from the surface of the anti-corrosion coating.
9.4.1 Reinforcement shall be placed around the pipe in such a way as to cover the whole pipe
length or sections to be concrete coated. The reinforcement shall not protrude beyond
the concrete coating ends.
9.4.2 Reinforcement shall rest on synthetic resin or concrete/ RCC spacers forming a "Crown"
whose number shall be such as to avoid any contact with the pipe's protective coating.
Spacing between the two consecutive "crown" centres shall be 500 to 1000 mm.
9.4.3 Splices and attachments shall be done by binding with steel wire having 1.5 mm
diameter. Circular and longitudinal joints of wire fabric in sheets shall be lapped at least
for one mesh.
When wire fabric in rolls (ribbon mesh) is used, the spiral lap shall be one mesh while
and spliced lap shall be three meshes.
9.4.4 One layer of reinforcement steel shall be provided for concrete thickness less than 50
mm. The reinforcing steel shall be embedded approximately midway in the concrete
coating thickness.
For concrete thickness 50 mm and above two layers of reinforcing steel shall be
provided. If application method requires more than one pass concrete, one
reinforcement layer for each pass is to be applied independently from concrete coating
thickness.
9.5.1 Concrete shall be placed within a maximum of 30 minutes from the time of mixing (i.e.
after adding water to mix) and shall be handled in such a way so as to prevent
9.5.2 If casting method is used, once reinforcement and mould have been applied around the
pipe, concrete mixture shall be poured through an opening on the upper section of the
same mould. Concrete shall not be deposited from a height greater than 1 metre.
During pouring of concrete, vibrator sets applied inside of pipe or outside the mould
shall vibrate the mix so as to obtain the best possible compactness.
9.5.4 No casting shall be interrupted or passes shall be stopped for more than 30 minutes.
Before placing fresh concrete against the joint, the contact surfaces shall be carefully
cleaned and wetted to obtain a good bond between the fresh material and the
previously placed material.
9.5.5 Suitable means shall be provided to ensure that the temperature of the concrete, when
placed, does not exceed 32°C.
9.5.6 All pipes shall be kept clean and free from cement concrete and grout either inside or
outside of the uncoated sections.
9.5.7 Bevel protectors shall be kept in place throughout the coating application and after.
9.5.8 The coating at each end of the pipe shall be bevelled to a slope of approximately two-
to-one (2: 1). It shall terminate about 50 mm short of the end of the corrosion coating
applied on the pipe surface.
9.6 Curing
9.6.1 Immediately after concreting, the exposed surfaces of the concrete shall be protected
during hardening from the effects of sunshine, drying winds, rain, etc. and then after
the initial set has taken place, the concrete coating shall be properly cured. The coated
pipe sections shall be handled gently by suitable means to prevent undue distortion.
9.6.2 Curing shall be performed by application of an approved curing membrane using sealing
compounds and shall meet the requirements of ASTM C-309. The material shall be
stored, prepared and applied in strict conformity with the instructions of the
Manufacturer. The ingredients of any such compound shall be non-toxic and non-
inflammable and shall not react with any ingredient of the concrete, the reinforcement,
protective coating or pipe. The application of the curing compound shall take place
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NEW DELHI ONSHORE PIPELINE S-04-02-022 Page 11 of 15
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immediately after the coating is completed and preferably before the pipe is removed
from the concrete coating apparatus. The surface of the concrete shall be lightly
sprayed with water before applying the curing compound. The membrane curing period
shall not be less than 4 days, during which period the freshly coated pipes shall not be
disturbed. The pipe surface shall be kept wet during daylight hours for seven days after
application of the concrete coating. The concrete coating shall not be allowed to
dehydrate.
Curing of concrete coating may also be done by using jute bags, provided continuous
wetting is ensured by the Contractor.
9.6.3 Before handling and hauling the concrete coated pipes, a check shall be made to make
sure that the concrete coating is properly cured. Stacking and shipment of the coated
pipe shall be initiated only after seven days provided that the concrete coating suffers
no damage.
10.0 TOLERANCES
10.1 Contractor shall maintain a surface tolerance of 8 mm (5/16") maximum for the radial
distance between high and low areas of the surfaces. The diameter of each coated pipe
shall be obtained at three (3) or more points, spaced at equal intervals between the
end points.
10.2 The acceptable weight tolerance for any single pipe shall be limited to plus five (5) or
minus two (2) percent of the calculated theoretical weight. The theoretical weight shall
be calculated using total weight of the pipe with concrete and corrosion coating.
11.0 WEIGHING
11.1 The test specimen shall be selected at equal intervals during the course of production.
11.2 Contractor shall weigh each pipe when dry prior to shipment and 28 days after placing
of concrete and mark the weight with paint on the inside of the pipe. The weight mark
shall be
followed with letters "DW" meaning Dry Weight.
In case contractor opts not to weigh the pipe, the contractor shall provide 20% extra
concrete coating thickness over the specified concrete thickness at no extra cost and
time to Company.
11.3 The acceptable weight tolerance of any single pipe shall be limited to +5% or -2% of
the calculated weight of concrete. Calculated weight shall consider only the weight of
concrete coating based on approved concrete density and thickness.
12.1 After curing, every length of concrete coated pipe shall be non-destructively tested by
means such as "ringing" to determine if any suspected defects are present. In case this
indicates faulty coating, cores shall be removed form coating and inspected. When
defective coating appears from cores, the concrete costing shall be removed from the
pipe lengths.
12.2 Every length of concrete coated pipe shall be checked to verify insulation between steel
reinforcement and pipe by means of a megger or equivalent device. To this purpose
provisions should be made during placing of concrete such as to leave at least a point
of exposed steel reinforcement whenever the latter shall terminate inside of concrete
coating.
12.3 During the tests as per clause 12.2 above, and before transporting of concrete coated
pipes, every pipe length shall be visually inspected to detect whether any damages and
/ or defects are present. Possible damages and/or defects with their allowable limits are
described at following clause 14.0. Repairable concrete coatings shall be clearly marked
while the non-repairable once shall be removed from the pipe lengths.
13.0 REPAIRS
The following repairs are permitted to coating due to unavoidable damage in handling
and in storage (This applies only to concrete that has hardened).
13.1 Spalling due to compression or shearing caused by impact against other objects.
Spalling is defined as damage, which causes a loss in concrete of more than 25 % of
the total thickness of the coating at the point of damage.
13.2 Damage due to spalling of an area of less than 0.1 m2 (1 square foot) where the
remaining concrete is sound and reinforcement steel is not exposed, will be accepted
without repairs.
13.3 Damage due to spalling of an area of less than 0.1 m2 with reinforcement exposed; and
area more than 0.1 m2 and less than 0.3 m2 shall have the concrete remaining in place
over that area removed as necessary to expose the reinforcing steel throughout the
damaged area. Edges of the spalled area shall be under-cut so as to provide a key lock
for the repair material. A stiff mixture of cement, water and aggregate shall be
trowelled into and through the reinforcement and built up until the surface is level with
the coating around the repair. The pipe shall then be carefully laid with the repaired
13.4 Should the damaged area be more than 0.3 m2, coating shall be removed around the
entire damaged area. A repair shall be made by satisfactorily restoring the
reinforcement, forming the area with a metal form and pouring a complete replacement
of materials similar to that from which the coating was made. The mixture shall be one
(1) part of cement to three (3) parts of aggregate and the necessary water to produce
a slump not to exceed 100 mrn (four inches). The resulting coating shall be equal in
weight, density, uniformity, thickness, strength and characteristics to the originally
applied coating. The pipe shall then be carefully laid in a position where it shall be
allowed to remain for a minimum of 36 hours before furtherhandling.
14.0 MARKING
14.1 Every concrete coated pipe length shall be clearly marked by a suitable type of paint
(i.e. red and/or white lead paint). Markings of concrete coating shall be made inside of
pipe close to bevel end, in such a way that the area involved by welding operations is
not affected by paint.
14.2 For each concrete coated pipe length, at one of the two ends, the field identification
number and the date of concrete placing shall be marked, while the dry as well as the
wet weight along with number of days after coating shall be marked at the other end.
In addition, Contractor shall develop a colour coding (band) system to be marked on
the outside surface for easy identification of the coated pipe for each concrete coating
thickness, concrete density, pipe diameter, pipe thickness and pipe material variation.
15.1 Once the pipe sections have been taken on charge, the Contractor, complying with
provisions of the CONTRACT, shall execute their transport together with other material,
either supplied by him or by the Company, from the site of receipt to the coating yard
and after concrete coating completion and acceptance, to delivery point at laying field
or storage areas as previously established providing each time the necessary storages.
15.2 Materials other than pipes and which are susceptible of deteriorating or suffering from
damages especially due to humidity or other adverse weather conditions, shall be
suitably stored and protected.
15.3 During loading, transport, unloading and hauling of inert aggregates, any contact and
mixing with mud, earth, grease and any other foreign material shall be carefully
avoided. Precautions shall be taken to prevent contamination, to maintain the
cleanliness and against effects of hot or cold weather or other adverse climatological
condition.
15.5 Stacks shall consist of a limited number of layers such that the pressure exercised by
the pipes own weight does not cause damage to coating. Stacking with more number of
layers shall be agreed upon with the Company provided that each pipe section is
separated by means of spacers suitably spaced so as to avoid stresses and compressed
points of contact on the coated surfaces.
This specification covers the minimum requirements for materials and equipment,
application procedure and inspection of repair of damaged Polyethylene coatings on
steel pipes.
The repair shall be carried out using repair patch made of radiation cross-linked
polyolefin backing, coated on the inside with semi-crystalline thermoplastic adhesive
and filler mastic.
The repair patch shall have thermal indicators to ensure correct heat is being applied
during application.
2.2 The repair material shall be certified by DIN to meet the requirements of EN12068
Stress Class CHT 80
2.3 The material shall not be older than their period of validity at the time of application by
the Contractor. Deteriorated / decomposed materials shall not be used.
2.4 Materials shall be stored in sheltered storages in the manufacturer's original packing
away from direct sunlight and in accordance with manufacturer's instructions.
2.5 Contractor shall supply all equipment and manpower required for a skillful application
in the field in accordance with the specification.
3.1 The application procedure to be followed for holiday type of damage shall be in
accordance with manufacturer's instruction and minimum requirement specified below
whichever are the more stringent.
3.1 .1 Preparation
3.1.2 Preheating
Preheat the exposed bare metal surface to approx. 80" C and adjacent pipe coating to
approx. 600 C with a torch moved back and forth over the surface.
Plastic filler shall be cut to size and applied to all exposed metal surface. The mastic
shall be heated and smoothed down with a paint scraper to cover all bare metal in a
manner such that all entrapped air is removed.
A patch shall be cut from the tape in a manner such that it extends 50 mm (2 inch)
beyond the damaged area on all sides. The patch shall be positioned over the damaged
area and heated until the temperature sensitive paint on the outside of the patch
changes colour or dimples on the backing vanish. It shall be smoothed down to confirm
with the contour of lap, and shall be freed of any air bubbles or wrinkles.
3.2 For cosmetic type of defects such as minor gouging, tearing, andlor scratches, which do
not indicate holiday during holiday inspection, following procedure shall be adopted.
3.2.1 The defective area shall be roughened to remove loose polyethylene coating, oil,
grease, dirt, etc.
The entire surface of the repaired section shall be inspected by means of a full circle
holiday detector approved by Owner set to a D.C. Voltage of at least 25 KV. Inspection
of repaired patch shall be conducted only after it has cooled below 500 C.
4.3 Procedure qualification shall be carried out for repair patch. The value for peel strength
to pipe surface and to factory coating carried out as per EN 12068 shall be 0.5 N/mm
minimum at 60°C.
5.0 DOCUMENTATION
5.1 Prior to procurement of coating repair materials, Contractor shall furnish four copies of,
but not limited to, the following for qualification of the Manufacturer and material:
i) Complete descriptive technical catalogs describing the materials offered along with
samples of repair coating materials, its properties and installation instruction as
applicable specifically to the project.
ii) Test certificate and results of previously conducted tests from independent inspection
agency, for properties listed in Para 4.3 of this specification.
iii) Reference list of previous supplies of the similar material indicating the project details
such as diameter, quantity, service conditions, year of supply, project name, contact
person and feed back on performance.
Once the Company's approval has been given, any change in material or Manufacturer shall be
notified to Company, whose approval in writing of all changes shall be obtained before the
materials are manufactured.
5.2 Prior to shipment of materials from the Manufacturer's works, Contractor shall furnish
six copies of the following:
SI.No. Description
1.0 SCOPE
3.0 MATERIALS
8.0 GUARANTEE
9.0 SPARES
10.0 DOCUMENTATION
This specification covers the minimum requirements for design, manufacture, testing and
supply of quick opening end closures to be installed at various blow-down points/ lines
handling non-sour hydro carbons in gaseous phase.
Reference has been made in this specification to the latest edition (edition enforce at the
time of issue of enquiry) of the following codes, standards and specifications:
c) ASME Sec. VIII : Boiler and Pressure Vessels Code- Rules for the
Construction of Pressure vessels
In case of conflict between the requirement of this specification and the requirements of
above referred documents, the requirements of this specification shall govern.
3.0 MATERIALS
3.1 Carbon steel material used in the manufacture of pressure containing parts of quick
opening enclosure shall be fully killed. In addition, the material shall also meet the
requirements specified herein.
The minimum SMYS of the material of pressure containing part of the closure shall be
35,000 psi.
Other components shall be as per Manufacturer’s Standard. However, all the materials
used shall be suitable for the service Conditions indicated in the Data Sheets, which will
be subject to approval by Purchaser.
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3.2 Material of the ends to be field welded by Purchaser shall have carbon equivalent not
more than 0.45 based on check analysis, for each heat of steel used, calculated as per
the following formula:
Mn Cr+Mo+V Ni+Cu
CE = C + ------ + ---------------- + -----------
6 5 15
3.3 For quick opening end closures specified to be used for Gas service and LPG service,
Charpy V-notch test shall be conducted at 00C on each heat of carbon steel material used
in manufacture of quick opening end closures. Test procedure shall conform to ASTM A
370. The average absorbed impact energy values of three full-sized specimens shall be
27 Joules. The minimum impact energy value of any one specimen of the three
specimens analyzed as above, shall not be less than 22 Joules.
When Low Temperature Carbon Steel (LTCS) materials are specified in Data Sheet or
offered by Manufacturer, the Charpy V-notch test requirements of applicable material
standard shall be complied with.
3.4 For quick opening end closures specified to be used for Gas service and LPG service,
hardness test shall be carried out as per ASTM A 370 for each heat of steel used in the
manufacture of pressure containing parts of traps. A full thickness cross section shall be
taken for this purpose and the maximum hardness of base metal, weld metal and HAZ of
all the pressure containing parts shall not exceed 248 HVlo.
4.1 End closure shall be designed in accordance with the provisions of ASME B 31.8 and
ASME Sec. VIII Division 1. Design factor and corrosion factor shall be as indicated in the
data sheet.
4.2 Diameter, thickness, material, ANSI rating of the pipeline with which the end closure to
be welded shall be as indicated in the Data Sheets. End closure supplied shall be suitable
for the same.
4.3 The quick opening end closure shall be of clamp ring/ band lock type or equivalent design
and shall consists of a safety pressure release system allowing the opening only when
there is no pressure in the trap. End closure shall be hand operated by a single lever
operation and operable by one operator. Screwed type or plug -in type of end closures
are not permitted.
4.4 End closure shall be suitable for installation in vertical position at an elevation of 2.0
meters above ground level.
4.5 The handing device shall be attached to the welding end hub, which shall be suitable for
such attachment.
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GAIL (INDIA) LTD OPENING END CLOSURE
NEW DELHI S – 04 – 02 – 024 Page 4 of 8
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4.6 End closure shall be provided with a butt-welding end for direct welding with the pipeline.
The weld end shall be prepared in accordance with ASME B 31.8.
4.7 All welds shall be made by welders and welding procedures qualified in accordance with
the provisions of ASME Sec. IX. The procedure qualification shall also include impact test
and hardness test as per clause 3.3 and 3.4 of this specification and shall meet the
requirements as specified therein.
4.8 Completed assembly shall be stress relieved as per the provisions of the design codes.
4.9 The tolerance on internal diameter end out of roundness shall be as per connected pipe
specifications indicated in the Data Sheet.
4.10 When closed, the closure shall provide a positive seal without any leakage. Gaskets or
seals when provided for this purpose shall be self sealing and suitable for the service
condition indicated in Annexure-I & Data Sheets.
5.1 Manufacturer shall perform all inspection and tests as per the requirements of this
specification and the relevant codes, standards and specifications, prior to shipment at
his Works. Such inspection shall be, but not limited to, the following:
5.1.1 All closures shall be visually inspected. The internal and external surfaces shall be free
from any strikes, gouges and other detrimental defects. The surfaces shall be thoroughly
cleaned and free from dirt, rust and scales.
5.1.7 All finished wrought weld ends shall be ultrasonically inspected for lamination type
defects for a distance of 50 mm from the end. Any lamination larger than 6.35 mm
shall not be acceptable.
a. Test Certificates relevant to chemical and mechanical properties of the material used
as per the relevant standards.
7.1 After all inspection and tests required have been carried out, the exterior surface of
Quick Opening End Closures shall be thoroughly cleaned, freed from rust and grease
and applied with sufficient coats of corrosion resistant paint. Manufacturer shall indicate
the type and corrosion resistant paint used in the drawings submitted for approval.
7.2 Marking shall be done on a stainless steel plate and affixed to the body permanently.
Marking shall include the following:
a. Manufacturer's Name
c. ANSI Rating
d. Tag Number
8.0 GUARANTEE
8.1 Manufacturer shall guarantee that the closure along with the davits is in compliance
with the requirements of this specification for material and workmanship. Manufacturer
shall replace or repair all parts which should result defective due to inadequate
engineering of quality of material or workmanship. In case the defect cannot be
eliminated, Manufacturer shall replace the closure without any delay. Any defects
occurring within the time period specified elsewhere shall be required making all
necessary modifications and repair of defective parts free of charge to the purchaser.
9.0 SPARES
9.1.1 Manufacturer shall furnish list of recommended spares and accessories for Quick
Opening End Closures required during start-up and commissioning and supply of such
spares shall be included in the price quoted by Manufacturer.
9.1.2 Manufacturer shall furnish list of recommended spares and accessories required for two
years of normal operation and maintenance of Quick Opening End Closures and price
for such spares shall be quoted separately.
10.0 DOCUMENTATION
Documentation to be submitted by Manufacturer to Company is summarized below.
Number of Copies (Hard copies / soft copies etc.) shall be as indicated in CONTRACT
document.
10.1 At the time of bidding, Manufacturer shall submit the following documents:
a) General arrangement drawing of end closure with overall dimensions and cross-
sectional drawings.
c) Reference list of similar previous supplies. Reference list of similar supplies of Quick
Opening End Closures shall be furnished including project, Year of supply, Client,
Size, Rating and Service for the last five years.
10.2 Within three weeks of placement of order, the Manufacturer shall submit the following
drawings, documents and specifications for approval:
b. Closure assembly and sectional drawings showing all parts with materials and
dimensions.
Once the above-mentioned documents have been approved by the Company, any
change in design, material and method of manufacture shall be notified to the
Company, whose approval in writing of all changes shall be obtained before the
closures are manufactured.
10.5 Within four weeks from the approval date, Manufacturer shall submit the approved
drawings, documents and specifications listed in Clause 9.2 of above.
1.0 SCOPE
3.0 CONSTRUCTION
4.0 DOCUMENTATION
1.1 This specification covers the minimum requirements for various activities to be
performed by the CONTRACTOR for the engineering and construction of pipeline
river crossings using directional drilling method.
1.2 This specification shall be read in conjunction with the requirements all
specifications and documents included in the CONTRACT between COMPANY and
CONTRACTOR.
1.3 CONTRACTOR shall, execute the work in compliance with laws, by-laws,
ordinances and regulations. CONTRACTOR shall provide all services, labour,
inclusive of supervision thereof, supply of all materials, (excluding "COMPANY
supplied Materials ") equipment, appliances.
1.4 CONTRACTOR shall take full responsibility for the stability and safety of all
operations and methods involved in the work.
1.5 CONTRACTOR shall be deemed to have inspected and examined the work area and
its surroundings and to have satisfied himself as far as practicable with sub-surface
conditions, hydrological and climatic conditions, the extent and nature of the work
and materials necessary for the completion of the work, and the means of access
to the work area.
1.6 CONTRACTOR shall be deemed to have obtained all necessary information with
regard to risks, contingencies and all other circumstances, which may influence the
work.
1.7 CONTRACTOR shall, in connection with the work, provide and maintain at his own
costs all lights, guards, fencing, as necessary or directed by COMPANY.
1.8 For the purpose of this specification, the following definitions shall hold:
2.1 The minimum requirement of limits of each river crossing shall be as defined in the
drawings furnished by COMPANY. CONTRACTOR may change the limits slightly to
suit his equipment and installation technique, with prior written approval from
COMPANY.
2.2 Within the entire limits of crossing, as defined in the CONTRACT drawings, the
cover to top of corrosion coated pipe shall be at least 2.5 meters below the
"specified" minimum scour level profile for the river with normal soil, and at least
1.5 meters below the "specified" minimum scour level profile for the river with rock
sub-strata.
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2.3 The entry and exit points of the pipeline at ground level shall not come within the
limits of crossing as defined for individual river crossings.
2.4 Wherever the drilled length for a river crossing includes the crossings of other
obstacles such as roads, railroads, canals, streams, etc., the following minimum
requirements of cover to the pipe shall be satisfied:
For canal / stream crossing - 1.5 m from lowest bed level to top of
pipe
2.5 CONTRACTOR shall carry out calculations for determining the maximum
permissible overburden on pipe, to check that the empty pipeline is safe from
collapse at any point along the drilled crossing section. CONTRACTOR shall submit
these calculations to COMPANY for approval.
As shown in the reference drawing at each crossing, the plane containing the pipe
axis shall be perpendicular to the horizontal plane. There shall be no bending of
longitudinal pipe axis at depths shallower than two meters below ground level.
Bentonite density
In order to optimize the crossing design in terms of pipeline stresses and pull force
requirements. CONTRACTOR shall indicate what maximum shear stress in the
pipeline coating will result from his choice of above parameters and other design
characteristics described in this section.
CONTRACTOR shall furnish all calculations for COMPANY'S approval. If shear stress
on pipe coatings is, in the opinion of COMPANY, beyond the permissible limits,
CONTRACTOR shall revise his choice of parameters to reduce shear stress on pipe
coating to permissible values.
Total maximum longitudinal stress in the pipeline due to tension and bending at
any location shall not exceed 90 % of the SMYS of the pipe material.
2.8.4 The minimum allowable radius of curvature for the pipeline shall be the highest
value of the minimum pipeline elastic bend radius as computed from the
considerations outlined in clause 2.8.1 thru' 2.8.3 above after correction for drilling
inaccuracies or multiplication by the factor 1.85, whichever result in the highest
permissible value of minimum elastic bend radius.
2.9 Pipeline Configuration Along The Supported String Before Entry Point
For each crossing, CONTRACTOR shall determine the required pipeline
configuration in order to allow smooth pull in the crossing entry point and
admissible stress in the supported pipeline string. Pipeline combined stress shall
not exceed 90 % of the specified minimum yield strength for line pipe material.
CONTRACTOR shall furnish all calculations and specify the number of required
supports, description of the supports, their coordinates and capacity in metric tons.
CONTRACTOR shall also furnish a drawing of the launching ramp indicating the
pipeline configuration.
The distance between each roller shall also be specified and justified.
2.10 CONTRACTOR shall, based on results of design and engineering carried out by him,
prepare construction drawings for each river crossing and shall submit the same
for COMPANY'S approval. Construction drawings shall indicate the pipeline profile
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with levels furnished at sufficient intervals for proper control during construction.
Other relevant details viz. entry and exit angles, radii of bends, etc. shall also be
indicated.
CONTRACTOR shall also calculate the total length of pipeline required as well as
the maximum tension required on the pull head of the rig.
All construction works shall be carried out in accordance with the construction
drawings approved by COMPANY.
2.11 Before commencement of any field work, CONTRACTOR shall furnish for
COMPANY'S approval all design calculations as stipulated in clause Nos. 2.5, 2.7,
2.8, 2.9 and 2.10 above and all construction drawings. COMPANY shall inform
CONTRACTOR within 21 calendar days if any objection against the design requires
resubmission by CONTRACTOR.
3 .O CONSTRUCTION:
CONTRACTOR shall comply with all the conditions and requirements issued by
Authorities having jurisdiction in the area where the work is to be performed.
If no public road exists, CONTRACTOR shall arrange on his own for access to his
work area at no extra cost to COMPANY.
CONTRACTOR shall, before commencing any work at site, submit for COMPANY'S
approval a detailed installation procedure for each river crossing.
c) Details of Equipment
The time schedule shall be in accordance with overall time schedule for the
project.
CONTRACTOR shall clear and grade the length of ROU required for installation of
on land portion and drilled river crossing portion in his scope. CONTRACTOR shall
do such grading on Right of Use to provide access to the pipeline construction and
to ensure safe construction of pipeline.
CONTRACTOR shall ensure that his construction activities shall not cause
inconvenience to public nor there any undue interference with the normal use of
the land and water courses. Minimum necessary trees on ROU to be felled shall be
identified; permissions obtained, recorded and record shall be handed over to
COMPANY.
3.3 Taking-over, Handling, Hauling, Storing and Stringing of pipes and other
materials
3.3.1 CONTRACTOR shall receive and take-over against requisition corrosion coated line
pipe from COMPANY'S designated place(s) of issue. CONTRACTOR shall be fully
responsible for the pipe and pipe identification marking from the time of taking
delivery from the COMPANY, until such time that the pipes are installed in
permanent installation.
The CONTRACTOR shall be entitled for extra compensation for repair and
rectification of defects recorded at the time of taking delivery as per the rates set
forth in the 'Schedule of Rates'. Repair of all damages beyond such record shall be
to the CONTRACTOR'S cost. CONTRACTOR shall be fully responsible for arranging
and paying for storage areas.
3.6 Lining-Up
Each length of pipe shall be thoroughly examined internally and externally to make
sure that it is free from visual defects, damage, severe corrosion, dirt, animals, or
any other foreign objects. Each length of the pipe shall be adequately swabbed,
either by use of canvas belt disc of proper diameter or by other methods approved
by the COMPANY. Damaged / corroded pipes shall be kept separate. Each length of
pipe shall be pulled through just before being welded.
All damaged ends of pipes that are bent, cut or otherwise mutilated such that, in
the opinion of the COMPANY, faulty alignment or unacceptable welding would
result, shall be repaired or cut-off and re-beveled to the correct angle with a
beveling machine of a type approved by COMPANY.
CONTRACTOR shall re-bevel dented bevel ends with a depth of dent between 1
mm and 3mm. Dents over 3mm depth shall be repaired by cutting and re-
beveling.
3.8 Welding
The complete field joint shall be blast cleaned to near white metal finish to
Swedish Standard SIS 055900 Grade SA 2.5. The coating edges shall be suitably
roughed and chamfered to provide smooth transition. The joint coating material
shall be Raychem’s "DIRAX" or other COMPANY approved equivalent. The method
of application shall be strictly as per manufacturer’s recommendations and will be
subject to COMPANY approval prior to use.
Coating of field weld joints shall be carried out after pre-installation hydrostatic
testing.
3.10 Installation
3.10.2 The lateral offset of the actual exit point of the pilot hole from the calculated and
theoretical exit point shall not exceed two percent of the length of the crossing,
however the actual exit point shall not come outside the ROU limits of the pipeline.
The length tolerance shall not exceed one per cent of the crossing length, subject
to the condition that the actual exit point shall not be within the limits of crossing
as defined in the CONTRACT drawings.
3.10.3 Back reaming shall be done separately from the pipeline pulling operation. The
size of the back-reamed hole shall be adequate (approximately 1.5 times the
pipeline diameter) to allow enough clearance for smooth pull-back of the pipeline.
3.10.4 CONTRACTOR shall be responsible for maintaining the drilled hole till such time
the pipeline is pulled in.
3.10.5 During pulling operation, the buoyancy of the pipeline shall be controlled by
suitable approved methods so as to maintain the buoyancy as close as possible to
zero during pullback in order to reduce friction forces of the pipeline in the hole.
Bentonite slurry of specified viscosity shall be pumped into the hole, preventing the
wall from collapsing and protecting the pipeline coating.
3.10.7 CONTRACTOR shall be responsible for the integrity of the corrosion coating and
shall apply any necessary approved protective coatings.
b) Excavating the adjacent portion up to and including the first field joint.
The pipeline and joint coating shall be examined visually and with holiday
detectors for defect. The length to be inspected shall, as a minimum, be one
pipe length and one joint coating. In case damages / holidays are detected
in the first pipe length / joint, the subsequent pipe length / joint shall be
exposed and coating integrity checks shall be made. If found acceptable by
COMPANY, the first pipe length / joint shall be repaired and / or replaced as
directed by COMPANY. If the coating of second pipe length / joint is also
found damaged, CONTRACTOR shall propose further course of action and
COMPANY'S instructions shall be followed. All works shall be done at no
extra cost to COMPANY.
3.10.8 Before final hydrostatic testing, CONTRACTOR shall 'prove' the diameter of the
pipeline by passing a gauging pig through the pipeline. The gauging pig shall
have a diameter equal to 95 % of the nominal internal diameter of the pipe.
CONTRACTOR shall supply and install all temporary scraper launchers / receivers
and other equipment, piping and materials and consumable for the purpose.
CONTRACTOR shall obtain plans and full details of all existing and planned
underground services from the relevant Local Authorities and be responsible for
location and protection of the same.
3.12 Bending
3.12.1 After pulling the pipeline across the drilled crossing, CONTRACTOR shall cut the
extended portion of the pipeline at the entry and exit points. Thereafter, the
drilled portion of the pipeline shall be cut at suitable location / depth and
extended on either bank by installing a cold field bend with minimum bend
radius of 40 times the pipe O.D. and a straight pipe length of 12 meters, such
that at the ends the top of the pipeline is minimum 1.0 meter below the
natural ground level.
The procedure shall include amongst other steps- lengths, maximum degree per
pull and method and accuracy of measurement during pulling of the bend.
Cold field bends made from coated pipes shall be inspected visually and by holiday
detector to locate damages which shall be repaired by CONTRACTOR as per
COMPANY approved procedures.
The ends of each bent pipe length shall be straight and not involved anyway in the
bending. In no event shall the end of the bend be closer than 1.5 meters from the
end of a pipe or within one meter of a girth weld.
The ovality in the bent pipe shall not exceed 2.5% of the nominal diameter at any
point. A check shall be performed on all bends in the presence of COMPANY by
passing a gauge consisting of two discs with a diameter equal to 95 % of the
nominal internal diameter of the pipe connected rigidly together at a distance equal
to 300 mm.
CONTRACTOR shall hydrostatically test the complete pipe string of each river
crossing before installation as per approved procedure. The section of the pipeline
corresponding to the river crossing shall, before installation, be subjected to a
minimum hydrostatic test pressure equal to 1.4 times design pressure for gas
pipeline and 1.25 times design pressure for liquid pipeline. The combined
equivalent stress in the pipeline due to bending and test pressure shall not exceed
90% of the SMYS of the pipe material.
After the temperature has been stabilized, the pressure shall be maintained in the
pipeline for at least twenty four hours and recorded by manothermograph. During
the test CONTRACTOR shall check all welds for leakage. Failure, if any, during the
test shall be rectified by the CONTRACTOR. If the same is due to failure on
account of any cause other than defect in COMPANY supplied material, the repairs
shall be done free of cost, to the satisfaction of COMPANY.
3.13.2 Final Hydrostatic Test
The complete water crossing shall be tested after installation. The test procedure
shall result in a hoop stress in pipe corresponding to 90% SMYS of the pipe
material. After temperature stabilization, pressure shall be retained in the pipeline
for a minimum 4 hours and recorded by manothermograph. The hydrostatic testing
shall be carried out in accordance with approved procedures.
a. For the pipe section to be tested, a diagram indicating all fittings, vents,
valves, temporary connections, relevant elevations and ratings. The diagram
shall also indicate injection locations and intake and discharge lines.
d. The type and sequence of pigs and the pig tracking system for cleaning and
removal of air pockets, pig inspection procedures, including procedure to be
followed in case the gauging pig indicates damage.
e. Procedures for leveling and stabilization after filling and for pressurization
and to allow for temperature stabilization.
3.13.4 CONTRACTOR shall furnish all necessary equipment & instrumentation for
performing the work including all temporary piping and scraper launcher/receiver
etc.
3.13.5 The test medium shall be fresh water to be arranged by the CONTRACTOR. The
water to be used shall be filtered, shall not be contaminated, and free from sand of
silt. CONTRACTOR shall submit laboratory test reports of water used for testing.
CONTRACTOR shall provide COMPANY approved corrosion inhibitors, oxygen
scavengers and bactericides to be added to the test water. CONTRACTOR shall
furnish and install all temporary piping which may be necessary to connect from
source of water to its pumps and manifolds / tankage.
3.13.7 The hydrostatic test shall be considered as positive if pressure has kept a constant
value throughout the test duration, except for changes due to temperature
effects, and there is no abrupt pressure drop throughout the test duration.
If test section fails to maintain the specified test pressure after isolation,
CONTRACTOR shall determine by search the location of leakage or failure. All leaks
and failures within the pipe wall or longitudinal seam shall be repaired by
replacement of entire joint or joints in which leakage or failure occurs. In those
cases where leaks occur in circumferential welds the method of repair shall be
determined by COMPANY. CONTRACTOR shall comply with instructions of the
COMPANY whether to replace a section of the line pipe that includes the line leak
or whether to repair the circumferential weld. This repair should, however, meet
the requirements of welding specification contained herein. Where failures occur in
pipeline field bends, bends shall be replaced with same degree of bends. After
completion of repairs, the hydrostatic test shall be repeated in full, as per the
approved procedures.
All work of reinstating line pipe, to replace failures, shall be done in accordance
with the specifications contained herein.
CONTRACTOR shall haul and stockpile all damaged and defective pipes to storage
locations designated by the COMPANY. All cracks and splits resulting from failures
shall be coated with an application of grease to preserve the characteristics of
failures from corrosion. Joints of failed pipes shall be marked with paint, with a tag
indicating failure details, date and location of failure and pressure at which failure
occurred.
3.13.8 After completion of successful hydro test of the above portion, the pipeline shall
be capped and buried. Pipeline end position on the banks shall be marked on the
ground by installing location markers on both banks approved by COMPANY.
3.15 Fencing
CONTRACTOR shall supply all materials and install G.I. Wire Chain link security
fencing of size 10mx10mx2.5m high with lockable steel gate around the pipe ends
and test stations for temporary C.P. on both sides of each river crossing.
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3.16 Idle Time Preservation of Pipeline
After completion of construction, CONTRACTOR shall clear the sites of all balance
material and debris. All balance pipe lengths supplied by COMPANY shall be
returned to COMPANY'S designated stock yard(s). Site shall be cleared to the
complete satisfaction of COMPANY and authorities having jurisdiction. All such
works shall be done at no extra cost to COMPANY.
4.0 DOCUMENTATION
4.2 During the course of execution of the crossing, CONTRACTOR shall generate /
compile the following data. It shall be obligatory on part of the CONTRACTOR to
furnish this data to COMPANY in the event it is required for.
Detailed drilling log and down hole data, including, but not limited to, the
following:
i. Density
Copies of the permits obtained from authorities having jurisdiction for the
various works.
Plan & profile of the drilled hole along with the water level variations.
4.3 After completion of construction, CONTRACTOR shall prepare and furnish six sets
of copies and two sets of reproducible of As-Built drawings for the crossings. As
built drawings shall, as a minimum include the following information:
True profile of the river bed and banks along the pipeline;
True profile of the pipeline as installed and the depth of cover to top of pipe
at regular intervals
Location of entry and exit points and angles of entry and exit, along with
lateral offset of exit point from the original pipeline alignment
This specification covers the minimum requirements for the various activities to be
carried out by the Contractor for or about the installation of pipelines crossing roads,
railroads, minor watercourses and other services.
The provisions of this specification are not applicable for pipelines crossing water
courses, which are specifically designated as "Major Water Courses" in the CONTRACT.
1.2 This specification shall be read in conjunction with the conditions of all specifications
and documents included in the CONTRACT between Company and Contractor. Unless
specified otherwise, all sections of this specification shall apply to all specifications
referred in this specification.
2.1 Reference has been made in this specification to the latest edition (edition enforce at
the time of floating the enquiry) of the following codes, standards and specifications.
e) Part 192, Title 49 - Transportation of Natural and other Gases by Pipe Line
(US DOT - Pipe Line Safety Standards).
2.2 In case of conflict between the requirements of above mentioned codes, standards,
specifications and practices, the most stringent requirement shall govern. In case of
conflict between the requirements of this specification and that of the above referred
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codes, standards, specifications and practices, the requirements of this specification
shall govern.
2.3 For the purpose of this specification the following definitions shall hold:
3.0 GENERAL
3.1 Crossing of roads, railroads, buried services. canals and minor water courses with
equipment and/or personnel is allowed only after acquiring approval from the
authorities having jurisdiction and after making arrangements for safeguarding the
roads, etc. and the verges and/or banks thereof and the buried services with
appropriate provisions.
Highways, Main-Roads and Railroads and their verges and banks of water crossings are
not allowed to be used for loading, unloading or stacking of materials and/or
equipment. For secondary roads, such loading/unloading is permitted only after prior
approval from the concerned authorities. Contractor is not allowed to close or divert
roads or watercourses without prior approval from the Company and the concerned
authorities. Contractor shall never unnecessarily hamper the users of the roads,
railroads, buried services and/or watercourses. The water flow shall not be obstructed
in any way.
All Civil and Mechanical works associated with or incidental to the installation of pipeline
crossings shall be carried out in accordance with GAIL Specification "Standard
Specification for Pipeline Construction (Onshore)".
3.2 Company reserves the right to demand for individual crossings from the Contractor a
separate detailed report for approval, containing:
- Time Schedule
- Test procedure
- Manpower deployment
3.3 Pipeline crossings for road, railroad, canals and rivers etc., shall be hydrostatically pre-
tested ex-situ, prior to joint coating, whenever,
The section of the pipeline for the crossing shall be tested as a single string. Unless
specified otherwise in the CONTRACT, the test pressure shall be the one resulting in
hoop stress corresponding to 90% of SMYS of pipe material. Test pressure shall be
retained in the pipeline for minimum period of four (4) hours. Test section shall be kept
under surveillance by regular patrols during test and it shall be visually examined for
leaks/defects, etc.
4.1 The work under crossings shall include necessary clearing, grading and trenching to
required depths and widths, welding of casing (when required) and carrier pipes,
lowering-in, back filling, clean-up, restoration to the original condition and further
strengthening and protective works, testing, installation of assemblies, insulators and
end-seals, and temporary works such as sheet piling, bridges, etc.
The work shall be carried out in accordance with the approved drawings and job
standards, as directed by Company and to the satisfaction of Company and the
authorities having jurisdiction over the facility crossed. The work carried out for road
and railroad crossings shall meet the minimum requirements of API RP 1 102.
Before the installation work of crossings is started, the Contractor shall provide suitable
barricades, temporary bridge / bypass work (especially where roads are open-cut) with
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railing, if required by Company for safety of traffic. Adequate traffic warning signals
and/or traffic lights and suitable diversions shall be provided as directed by
Company/Authority having jurisdiction over these areas. Such diversions shall not cross
the pipeline where it has already been installed, unless proper safeguarding at
Company's opinion is ensured.
Prior approval from the statutory authorities shall be obtained to lay the pipeline across
the highway/road either by boring or by open -cut method. Installation of the crossing
shall be by the method (i.e., boring/open-cut) approved by Authorities having
jurisdiction. Railroad crossings shall always be bored/ jacked.
4.2 Boring/ jacking of carrier pipes for crossings is allowed only if the pipes for boring/
jacking are provided with a suitable corrosion coating and Contractor remains liable for
the suitability of the pipe and weld-coating of carrier pipes to be bored and type of
coating and method of application are anyhow to be authorized by Company without
prejudice to Contractor's liability. In all other cases the carrier pipes shall be cased.
Before start of the boring/ jacking operation, Contractor shall execute soil investigations
and determine the ground water table. Based on these investigations, Contractor shall
prepare a construction drawing and submit to Company for approval including time
schedule and soil investigation report.
During the execution of the boring, the ground water table over the length of the
boring shall be lowered up to at least 0.50 m below bottom of the pipeline. This water
table is to be regularly inspected and maintained by Contractor and reported to
Company. To safeguard the stability of the bore pit, contractor shall, if necessary in
Company's opinion, use a closed sheet piling, which shall extend at least over 50% of
the length in undisturbed soil. The length of the boring shall be in accordance with the
width of the ROU of the crossing (road, railroad, etc.), with minimum 0.6 m extra on
either side.
If the soil conditions and ground water for a particular boring give reasons for this,
Contractor is entitled to suggest to Company for a relaxation of one or more of the
following requirements as defined here forth.
Soil investigation
Sheet piling
4.3 The bottom of the trench and/or the pit for at least twelve (12) meters at the approach
to each end of a casing shall be graded and if necessary backfilled with clean sand and
compacted up to atleast 95% Proctor Density to an elevation that will provide sufficient
and continuous support to the pipeline so that the pipeline remains correctly aligned at
casing ends during and after backfilling.
4.4 The diameter of the hole for a bored section shall have a hole diameter as close as
practicable to the outside diameter of the carrier or casing pipe. If excessive void or too
large hole results, or if it is necessary, in the opinion of Company, to abandon the bored
hole, prompt remedial measures such as filling the hole with suitabie material shall be
taken to the entire satisfaction of the company and Authorities having jurisdiction
thereof at no extra cost to Company. Equipment used for installation of casing pipe
shall be of the type approved by Company.
At the front of the pipe there may be a cutting ring, which may be 12 mm large than
the outside diameter of the pipe or casing. A lubricating pipe can also be used in
jacking, the nipples of which shall not protrude from the cutting ring. Said lubricating
pipe shall not be fixed to the pipe or casing. When jacking, only biologically degradable
lubricants shall be used (e.g. WRC Medlube or an emulsion of bentonite).
Removal of soil from the pipeline during jacking shall be done mechanically by means of
a standard, locked auger, which has to be safeguarded against jacking ahead of the
pipe. If, in the opinion of the Company, fluid sand may arise, an inner pipe with funnel
shall be used.
During jacking, the progress of the pipe to be jacked and the cutting capacity of the
auger shall be mutually adjusted, by regulating the speed of auger, to prevent the road
from bulging (rpm too low) or cave-ins (rpm too high). In any case no more soil shall
be removed than the volume of the pipe. The auger drive shall be provided with a
clutch.
The progress in the work, the readings of the gauge pipes, the jacking pressures
observed, etc., shall be recorded in a log book, to be shown to Company upon request.
All information shall be supplied to Company on completion of the work.
Company reserves the right to inspect certain lengths of pipes to assess damages, if
any, to the corrosion coating of the carrier pipe used for boring. Contractor shall weld
additional lengths of pipe and pull the required extra lengths for Company's inspection.
If during inspection any defects are noticed, Contractor, in consultation with Company,
shall carry out the remedial measures, as required.
4.5 While welding of the casing and vent/ drain pipes, internal high or low is not allowed.
Welding of casing and vent/drain pipes need not be radiographed, however, only
normal visual checks shall be carried out. Before welding, the single length of pipe shall
be inspected in order to check that there is no out of roundness and dents. When such
defects are noticed, these must be completely removed before joining the pipes. If
these defects cannot be repaired, the defective section shall be cut out.
4.6 In the case of crossings where excavation has been authorised, the welding for the
casing pipe and for a continuous section of the pipeline corresponding to the expected
length shall be carried out in the proximity of the crossing. Casing must be laid
immediately after the trenching. Casing pipe must be laid with a single gradient in order
to allow for an easy insertion and, if necessary at a future date, to allow for the removal
or replacement of the pipeline, leaving the casing undisturbed. The direction of gradient
shall be marked in the crossing drawings for future reference.
4.7 The installation of assembly of vent pipe units as approved by Company shall be carried
out by direct insertion and welding to the ends of the casing pipe before introducing the
carrier pipe to avoid damage to insulators from welding heat. The operation of
assembling and extending the vent pipe shall be carried out in such a way that there is
no contact with the carrier pipe. The painting/ coating of the vent pipes shall be applied
before backfilling as per relevant specifications.
4.8 The casing pipe shall be considered ready for installation of the carrier pipe, after
careful inspection and internal cleaning with the removal of soil, mud, stones and other
foreign materials.
4.9 Insulators, as approved by Company, shal1 be securely fastened to the pipe with all
bolts and fixtures firmly tightened. The number of insulators and spacing shall be as
shown in the drawings or at 2.5 meters center (whichever is more stringent). At the
end of both sides of the casing, a double set of insulators shall be installed.
4.10 Care must be taken in pushing or pulling carrier pipe into the casing so that the pipe is
aligned correctly in the casing and that the pushing or pulling force is evenly and
constantly applied to avoid damages to the insulators. A nose piece having a diameter
equal to that of the pipe shall be welded on the front and back end of the carrier pipe
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to facilitate installation of the carrier pipe properly in the casing and to keep it dry and
clean.
4.11 After installation of the carrier pipe section, the casing and the appurtenances, but prior
to making tie-in welds and backfilling, an electrical test shall be conducted by the
Contractor in the presence of the Company, to determine the resistance between the
casing and the carrier pipe or the carrier pipe and the soil. These tests shall show at
least a resistance of 100,000 ohm M2 . After backfilling and compaction, additional
tests shall be conducted to determine if the casing is electrically shorted to the pipe. If
the installation is found to be shorted, Contractor shall make the necessary corrections
and repairs at his cost, unless a test to the satisfaction of the Company is obtained.
5.1 The pipeline under construction may pass above or below the existing buried facilities
such as pipelines, cables, etc. Type of crossing shall be such that a minimum depth of
cover as required in the drawings and specifications are guaranteed. The clearance
required between pipeline and the existing facility shall be 500 mm (min.) as indicated
in job standard.
5.2 Whenever buried services in the ROU are to be crossed by Contractor, Contractor shall
safeguard the buried facilities and the required protecting precautions shall be executed
as approved by Owners of the buried services and by Company.
5.3 For buried services to be crossed by boring/ jacking, the relevant provisions of Section
4.0 shall apply.
6.1 Minor water crossings are crossings of (future) ditches, canals, water courses, rivers,
streams etc., whether the bed(s) contain(s) water or not, and such crossings are not
being specified as "Major Water Crossings" in the CONTRACT.
6.2 For minor water crossings a standard drawing or a separate detailed approved drawing
for individual crossing shall be applicable, and all further specifications are applicable.
6.3 Wherever minor water crossings in the ROU are to be crossed, Contractor shall install
bridges and further comply with the provisions as laid down in this specification.
6.5 In case of crossings of water courses for which no special methods of laying are
required, a pipe section of a size as per the approved drawings shall be assembled and
subsequently laid. Bends shall be of cold field type.
The depth of the existing bottom of a minor water course crossing shall be determined
in relation to the adjacent ground level by taking the average of four measurements.
Measurements shall be taken with a gauge rod and with dimensions 60x60 mm and
having a flat bottom. The minimum force to be exerted shall be 360N (36 kgf).
Contractor shall take special care to check with the responsible authorities for special
conditions applying to working on, over, under or thorough minor water crossings and
Contractor shall comply with any such conditions. Written arrangements with authorities
shall be drawn up in cooperation with Company.
6.6 The minimum cover over the pipe shall be as specified in the relevant approved
drawings and job standard.
6.7 For crossing beneath the bed of water courses, the pipe section shall be made in such a
way that it conforms to the existing or future bed as indicated in the approved
drawings. In crossings for which an individual drawing has not been prepared, the
minimum cover of the pipeline shall not be less than that indicated in the standard
drawings for a similar type of crossing.
6.8 Whenever the crossing requires a straight section of pipe between the lower bends
coinciding with the river bed, this section shall be laid at a single horizontal level.
6.9 For crossings of ditches, canals, banked channels, etc. by boring, the pipe section shall
be prepared, laid and tested in accordance with the applicable clauses of Section 4.0 of
this specification.
6.10 The Contractor shall arrange temporary installation of diversions as may be necessary,
to ensure the effective functioning of these watercourses crossed, to the entire
satisfaction of the concerned local Authorities as well as the Company.
6.11 Banks and trenches of minor water crossings shall be backfilled with soil which is to be
approved by Company and shall be thoroughly compacted to prevent soil and bank
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GAIL (INDIA) LTD CNSTRUCTION OF PIPELINES CROSSING
ROADS, RAIL ROADS AND MINOR WATER Page 10 of
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erosion as per the drawings and standards to the satisfaction of authorities having
jurisdiction thereof and the Company. Whenever boulders, rock, gravel and other hard
objects are encountered, they shall not be placed directly on the pipe. Sufficient earth,
sand or selected and approved backfill material shall be backfilled initially around and
over the pipe to provide a protective padding or cushion extending to a minimum
thickness of 300 mm around the pipe before backfilling remainder of the trench with
excavated or other material as per approved drawings and standards.
After the trench has been backfilled and during the clean up works, the minor water
crossing shall be cleaned across the whole width of the ROU.
When specified in the CONTRACT, Contractor shall repair the ditch bank with materials
to be supplied by him as follows:
- The excavation shall be backfilled with well compacted solid soil, followed by a
minimum 0.25 m thick layer of properly shaped boulders (75- 150 mm) encased
in a net of galvanized iron wire of dia 3 mm spaced at a maximum distance of 50
min to be laid over the backfilled, compacted and graded banks.
- The lengths of the above protection shall be equal to the bank excavation and
damage and extending 2 m on either side. The width of this protection on the
slope shall be determined by the following:
6.12 The crossing of any embankments shall be carried out strictly in accordance with
approved drawings.
No drilling work on embankments shall be permitted without prior written approval from
the competent Authorities.
1.1 This specification covers the minimum requirements for the various activities to be
performed by contractor for the construction of pipeline major water crossings by
conventional trenching method. Provisions of this specification are applicable only for
"Major Water Crossing" specifically named as such in the CONTRACT.
1.2 This specification shall be read in conjunction with the conditions of all specifications
and documents included in the CONTRACT between Company and Contractor.
1.3 Contractor shall, with due care and diligence, execute the work in compliance with all
laws, by-laws, ordinances, regulation etc., and provide all services and labor, inclusive
of supervision thereof, all materials, excluding the materials indicated as "Company
Supplied Materials" in the CONTRACT, equipment appliances or other things of
whatsoever nature required in or about the execution of the work, whether of a
temporary of permanent nature.
1.4 Contractor shall take full responsibility for the suitability, stability and safety of all
operations and methods involved in the work.
1.5 Contractor shall be deemed to have inspected and examined the work area and its
surroundings and to have satisfied himself so far as practicable as to the form and
nature thereof, including sub-surface conditions, hydrological and climatic conditions,
the extent and nature of the work and materials necessary for the completion of the
work, and the means of access to the work area.
1.6 Contractor shall be deemed to have obtained all necessary information subject as above
mentioned as to risks, contingencies and all other circumstances, which may influence
the work.
1.7 Contractor shall, in connection with the work, provide and maintain at his own costs all
lights, guards, fencing, watching etc., when and where necessary or required by
Company or by any duly constituted Authority for the protection of the work and
properties or for the safety and the convenience of public and/or others.
2.1 Reference has been made in this specification to the latest edition (edition enforce at
the time of issue of enquiry) of the following codes, standards and specifications:
2.2 In case of conflict between the requirements of above mentioned codes, standards,
specifications and practices, the most stringent requirement shall govern. In case of
conflict between the requirements of this specification and that of the above referred
codes, standards, specifications and practices, the requirements of this specification
shall govern.
2.3 For the purpose of this specification the following definitions shall hold:
3.0 GENERAL
3.1 All works of the pipeline major water crossing shall be performed in accordance with
the approved construction drawings, procedure, and other applicable documents as per
the CONTRACT, good pipeline practices and as directed by Company.
3.2 Before start of the field construction, Contractor shall submit in triplicate to Company,
for approval, for each major water crossing, a complete report containing at least:
i) Installation method.
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ii) Proposed time schedule indicating start and finish dates and detailed break-up of
time period for all critical activities associated with the work.
vi) Proposed sub-contractors and/ or vendors along with their scope of work.
The description of the installation method as a minimum shall include the following:
a) Study of water currents in relation to the method of launching (on bottom and
on surface).
c) Buoyancy Studies.
d) Preparation of fabrication yard and launching areas along with proposed layouts.
f) Pre-test procedure.
h) Dredging, anchoring requirements, spoil deposit and trench survey method and
Contractor's proposed methodology for execution of these activities.
j) Pulling arrangement including launch way and anchoring and braking device.
p) Safety system adopted during rope/ winch capacity test and during construction
including launching.
Company shall inform Contractor within 21 calendar days, if any objection against the
document and procedures described requires resubmission by Contractor.
3.3 Contractor shall comply with all the conditions and requirements issued by Authorities
having jurisdiction in the area where the work is to be performed. Contractor shall, at
his own responsibility, obtain necessary permits from the Authorities having jurisdiction,
for performing its work.
If no public roads exist, Contractor shall arrange at his own for access to work areas at
no extra time and cost to Company.
Prior to start of any work, Contractor shall carry out a survey of the major water
crossings and acquaint himself with site conditions and to collect any data regarding the
water velocity and the tidal variation in the flow pattern and shall verify the suitability of
his equipment and the method of Construction.
4.0 TRENCHING
4.1.1 Contractor shall dredge or excavate the trench for the water crossing in conformity with
the approved drawings. Dredging of the trench shall be executed as accurately as
possible.
4.1.2 The trench shall be excavated to such depth as required to provide the minimum cover
and the pipeline configuration as specified. The pipeline profile of the crossing shall be
followed as accurately as possible. Before laying, the trench shall be cleaned and
leveled. The trench shall be subject to inspection by Company prior to installation of the
pipe.
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4.1.3 Navigational traffic shall not be obstructed, unless permission has been given thereto.
Contractor shall issue all necessary publication according to the local requisitions.
Instructions given by Authorities shall be followed accurately and immediately, so that
traffic encounters no hindrance.
Contractor can not request a compensation if his work is hampered or delayed due to
weather conditions, any obstacles/or any traffic on the spot, where work is executed.
4.1.4 Contractor is fully responsible for the execution of the blasting (wherever permitted),
the dredging and excavation work, hopping of the spoil, transportation, dumping on
land or in water, all to be executed in agreement with Authorities, land owners and
Company.
4.1.5 Contractor may be obliged to dredge or excavate a trench deeper or wider than
indicated in the drawings in order to properly lay the pipeline in unstable (underwater)
areas, or near and adjacent to the banks of water-courses. It shall be understood that
Contractor is aware of such problems at the time of his Bid and that, when such
additional excavation is required, it shall be done by Contractor as part of the work and
that he will install the necessary provisions and/ or temporary works such as sheet-
piling, special filling materials, etc. at no extra cost to Company.
4.1.6 During the execution of dredging work by Contractor, bearings, measurements and
levels shall be taken by or on behalf of Company. Contractor shall render assistance for
this purpose and make available for Company appropriate survey boats, fully manned
and equipped, before the trench excavation work of the water crossing can be started
Contractor, if so desired by Company, shall make cross profiles at intervals of not more
than 10.0 m of the bottom of the watercourse along the surveyed centerline of the
water crossing. In such a case, horizontal measurements shall be taken by triangulation
or tapping between known points and shall be made with such accuracy that the
location of each vertical measurements is known with 1.0 m. Vertical measurements
shall be taken with a sonic recording device, or with line and rod, as directed by
Company and shall be taken with such an accuracy that each depth is known within 0.2
m. Vertical measurements shall be taken at points averaging not more than 5.0 m apart
and no two measurements shall be more than 7.0 m apart. The cross profiles shall
extend at least 10 in on both sides of the top of the trench.
4.1.7 Contractor shall keep the trench in good condition until the pipe is laid, and no claim is
to be made to the Company by reason of its caving either before or after the pipe is
laid. Contractor shall do whatever is required to excavate the trench, install the pipe in
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NEW DELHI (CONVENTIONAL TRENCHING) S – 04 – 02 – 027 Page 8 of 15
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it and backfill the trench in accordance with the specifications at no extra cost to
Company.
4.1.8 Immediately before installation of the water crossing in the excavated trench,
Contractor shall prepare a profile of the trench bottom along the surveyed center line of
the water crossing for comparison with the reference profile. Contractor shall also make
cross sections of the trench at intervals of not more than 50 m. All profiles and cross
section measurements shall be taken as specified and, if required, shall be witnessed by
Company. These data shall be submitted to Company for approval and Company will
approve or reject the trench excavation as completed within 24 hours after receipt of
the profile and cross sections.
4.1.9 Contractor shall grade the trench in such a manner as to give the maximum amount of
uniform support to the pipeline when it is lowered or pulled into place. The maximum
unsupported span shall not exceed 10.0 m.
4.1.10 In submerged sections, where rock or gravel is encountered in the bottom of the
trench, padding is required. The thickness of the padding under the concrete coated
pipe shall at least be 0.5 m and after installation at least 0.5 m around the pipe.
Pumping lines, discharges and siphons shall be installed by Contractor and removed
before the completion of the work. At crossing with existing roads, the pumping lines
shall be led through a casing pipe boredljacket under the road or led through a porch
over the road. A stress calculation must then be handed over to Company. The
necessary provision to embank the dumping area and also the spoil-basins shall be
made by Contractor. Contractor is responsible for transportation of the spoil and
dumping on land and is liable for damage to works of third parties caused by leakage of
pumping lines, etc. Contractor shall at all time prevent overflow of pumping water, spoil
or sand over embankments, parcels or roads. Further more, Contractor shall safeguard
Company from claims of compensation by third parties due to encountered damage.
4.3 Spoil
Spoil which is not dumped on and including spoil acquired after cleaning the water
crossing trench, shall be transported and dumped in places, designated thereto by
agreement between Contractor and authorities and approved by Company. Spoil shall
be transported in (split), barges; only those barges shall be used that avoid spilling
during transportation due to incorrect closing of the flaps, etc. Spoil, which is dumped
Contractor shall install temporary provision in the existing dikes, dams, etc. to prevent
flooding of low areas. Therefore in general, in existing dikes, dams, etc. a double
substituting weir must be installed before start of excavation in the existing dike or
dam. Such a double substituting weir can be a closed wall of sheet piling, supported by
soil. The provisions shall be such that the underwater profile of the dredged trench, the
water movement caused by ships etc. cause no slide/ cave-ins of the dike or dam.
Contractor shall take all necessary precautions not to pollute river water and banks
during entire construction operation. Equipment deployed and construction
methodology adopted shall be such that minimum damage is caused to the existing
environmental conditions. Union and State Government requirements concerning
pollution control and environmental protection shall be fully complied with.
Contractor shall provide concrete coating over the pipeline including the bends in
accordance with the specification issued for the purpose and approved procedure.
Contractor shall coat the weld joints in order to arrive at the continuously concrete
coated pipeline. However the concrete coating shall be applied after the hydrostatic
pretest.
The section of the pipeline corresponding to the major water crossing shall, before
installation, be subjected to hydrostatic pretesting on a combined equivalent stress of
90% of the SMYS of the pipe material. After the temperature has been stabilised, the
pressure shall be maintained in the pipeline for at least twenty-four hours and recorded
by manothermograph. During test, the Contractor shall check all welds for leakage.
Failure, if any, during the test shall be rectified -by the Contractor. If the same is due to
failure on account of any cause other than defect in materials supplied by Company, the
repairs shall be done free of cost, to the satisfaction of Company.
7.0 INSTALLATION
7.2 Contractor shall perform all work required to install the water crossings, including the
possible appurtenances indicated in the drawings. The water crossings shall be installed
in such a manner as to comply with the requirements and conditions stated by the
Authorities issuing the permits. Contractor shall pay special attention to minimise any
damage to embankments and dikes in the vicinity of water crossings.
7.3 The equipment for launching shall be arranged in such a way that the pipeline is laid
without impact or jerking and is not subjected to stresses of any type other than those
which are allowable. Minimum allowed radius of curvature shall be followed, particularly
at the end of the launching way towards the water in the freely suspended section.
During the launching the Pipe shall have a submerged weight of 30 kg/ meter with a
tolerance of & ± l0%.
7.4 After the water-crossing section has been installed in place, Contractor shall fill this
pipeline section including the pertaining land pipeline sections with water for the final
testing.
7.5 Contractor shall check if the position and depth of the water crossing are in accordance
with the approved drawing, by means of a profile of the pipeline, before and after the
water-crossing section is filled with water. Contractor shall lower each pipeline section,
which is not sufficiently deep by dredging or jetting the underlying ground.
7.6 The maxiinuin allowed horizontal deviation from the required center-line shall be limited
by the following:
7.7 Prior to backfill the pipeline shall, when laid in the trench, conform to the bottom
contour of the trench grade, so that it will be firmly, uniformly and continuously
supported within the permissible limits of unsupported spans as specified in Para 4.1.9.
Company may employ a diver or use other suitable methods to inspect the bottom of
the trench and/or after the pipe is installed prior to backfilling of the trench. Contractor
shall facilitate the work of the diver and shall furnish the necessary equipment and
helpers necessary for the diver/ inspector to perform his work.
7.8 If the pipe does not properly fit the trench or does not rest at sufficient depth to satisfy
the minimum requirements of cover as specified in approved drawings, the Contractor
shall make necessary corrections to either trench or to the pipe alignment or to both so
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that the pipe, when finally in position in the trench, shall fully meet the specification,
failing which Contractor may be asked to remove the pipeline. This shall be done at no
extra time and cost to the Company.
When parallel pipelines are required to, be installed across major water crossing,
Contractor shall further comply with the following requirements.
7.9.1 Depending on the diameter of the parallel pipelines, the characteristics of the crossing
and the limitation of Contractor's equipment, Contractor may propose installation of the
parallel pipelines either together in a combined operation or separately in a common
trench.
7.9.2 If the pipelines are installed together, the minimum clear distance between the parallel
pipelines (measured from the outside diameters of the concrete coated pipes) shall be
300 mm. Contractor shall provide spacers (at sufficient intervals along the length of the
pipe sections), securely fixed to the pipes, or shall propose other suitable alternative
methods, so as to ensure that the stipulated minimum clear distance is maintained. The
buoyancy of the combined installation (pipes+spacers) shall be checked before
installation. The spacers may be removed before the trench is backfilled.
Contractor shall furnish detailed drawings/calculations for the pipe assembly, showing
the details of spacers/ other arrangements for Company's approval before start of
construction.
7.9.3 If the parallel pipelines are installed separately in a common trench, the minimum clear
distance between the parallel pipelines in the trench shall be 5000 mm. Contractor shall
ensure that this minimum spacing is maintained till the time the trench is backfilled.
8.1 Backfilling of the water-crossing section shall be performed as described in the following
clauses.
8.1.1 The bottom of the water way shall be reinstated to its original level by backfilling the
trench in a manner and with suitable material and as prescribed and approved by the
Authorities and Company. In case material other than the original spoil is required, this
shall be supplied and applied by Contractor.
Sufficient earth, sand or selected and approved back fill material shall be backfilled
initially around and over the pipe to provide a protective padding or cushion extending
to a minimum thickness of 0.5 m around the pipe before backfilling remainder of the
trench with excavated or other material.
Wherever required by Company, Contractor shall cover the nearly backfilled trench with
a layer of rock boulders to be approved by Company over a width equal to the width of
excavated trench with an extra of 5m on either side at no extra cost to Company.
8.1.2 Backfilling progress of the trench shall be checked continuously and a daily progress
report shall be made in three-fold and handed over to Company.
8.1.3 All embankments and/or dikes, bed and banks shall be reinstated to their original state
and levels, unless otherwise prescribed in the drawings or by the competent Authorities
or Company.
Trenches in banks of major water crossing shall be backfilled with soil approved by
Company. The fill at the banks shall be compacted firmly and reinforced with sacked
earth, rip-rap, or by other means as directed by Company to the satisfaction of
Authorities having jurisdiction thereof. In areas where the backfilled soil is expected to
be of loose type, which is prone to flow, the trench shall be backfilled with crushed rock
of size approved by Company and pipe shall be provided with adequate padding of soil
of a quantity approved by Company. After the trench has been backfilled and during the
clean up works, the water crossing shall be cleaned across the whole width of ROU.
- 5m below Low Water Level or 60m along the slope from Highest Water Level,
whichever is the smaller.
8.3 Before final hydrostatic testing, Contractor shall "prove" the Diameter of the pipeline by
passing a gauging pig through the pipeline. The gauging pig shall be capable of locating
and detecting defects permitted by governing code. Contractor shall supply and install
all temporary scraper launchers receivers and other equipment, piping materials and
other consumables for the purpose.
The complete water crossing must be tested immediately after the approved backfilling
of the trench. The test procedure shall result in a hoop stress in pipe corresponding to
90% SMYS of the pipe material. After temperature stabilisation, pressure shall be
retained in the pipeline for a minimum twenty four (24) hours and recorded by
manothermograph. The hydrostatic testing shall be carried out in accordance with
approved procedures.
After laying of the pipeline, Contractor shalI carry out a post-construction survey jointly
with Company. Any defects brought to the notice of Contractor shall be promptly
corrected by contractor at his own expense to the complete satisfaction of Company.
After completion of construction, Contractor shall clear the site of all balance material
and debris. All balance pipe lengths, in case supplied by company, shall be returned to
Company's designated stock yard(s). Site shall be cleared to the complete satisfaction
of Company and Authorities having jurisdiction. All such works shall be done at no extra
cost to Company.
12.0 DOCUMENTATION
12.1 In addition to the documents specified elsewhere in this specification, Contractor shall
submit to the Company six copies of leach of the following documents/records.
- Copies of the permits obtained from Authorities having jurisdiction for the
various works.
- Clearance certificates from the land owners and Authorities having jurisdiction
regarding satisfactory clean-up and restoration of pipeline RoU and work areas.
12.2 After completion of construction, Contractor shall prepare and furnish six sets of copies
and two sets of reproducible of As-Built drawings for the crossings.
- True profile of the bed and banks of water crossing along the pipeline after
backfilling
- True profile of the pipeline as installed and depth of cover at top of pipe at 10 m
interval.
- Cross section along the pipeline indicating nature and extent of backfill materials,
thickness of concrete coating to pipe etc.
1.1 This specification covers the minimum requirements for the various activities to be carried out
by Contractor for or about the construction of cross-country onshore pipelines.
1.2 The various activities covered in this specification include the following works of pipeline
construction:
- Trenching;
- Pipeline laying;
- Backfilling;
- Tieing-in
1.3 This specification shall be read in conjunction with Scope of Work and requirements indicated in
specifications and documents included in the CONTRACT between Company and Contractor.
1.4 Contractor shall, with due care and diligence, execute the WORK in compliance with all laws, by
laws, ordinances, regulations etc. of the land and provide all services and labour, inclusive of
supervision thereof, all materials, excluding the materials indicated as "Company Supplied
Materials" in the CONTRACT, equipment, appliances or other things of whatsoever nature
required for the execution of the WORK, whether of a temporary or permanent nature.
1.5 Contractor shall take full responsibility for the stability, suitability and safety of all operations
and methods involved in the WORK.
1.7 Contractor shall be deemed to have obtained and understood all necessary information with
respect to risks, contingencies and all other circumstances, which may influence the WORK.
Any neglect/omission/failure on the part of Contractor in obtaining necessary and reliable
information for performance of WORK shall not relieve him from any liabilities or
responsibilities for completion of WORK.
1.8 Contractor shall, in connection with the WORK, provide and maintain at his own costs, all lights,
guards, fencing, watching etc., when and where necessary or required by Company or by any
duly constituted authority and/or by the authorities having jurisdiction thereof for the protection
of the WORK and properties or for the safety and the convenience of public and/or others.
1.9 Unless otherwise specified, all sections of this specification shall apply to all the specifications
referred in this specification.
2.1 Reference has been made in this specification to the latest edition of the following codes,
standards and specifications:
f. Part 192, Title 49 - Transportation of Natural and other Gases by Pipe Line
(US DOT - Pipe Line Safety Standards).
In case of conflict between the requirements of above mentioned codes, standards and practices,
the most stringent requirement shall govern. In case of conflict between the requirements of this
2.2 For the purpose of this specification the following definitions shall hold:
- the words 'Should', 'May' and 'Will' are non-mandatory, advisory or recommended.
Contractor shall, before starting and clearing operations, familiarize himself with all the
requirements of the Authorities having jurisdiction over the Right of Use (ROU) for WORK
along the pipeline route or in connection with the use of other lands or roads for construction
purposes.
Contractor shall notify Company well in advance during WORK progress, the method of
construction for crossing road, railway, pipeline, cable, canal, river and other existing obstacles.
Contractor shall not commence WORK on such crossings before having obtained approval from
the Authorities and landowners concerned to the satisfaction of Company. The crossings shall be
installed to meet at all times, the requirements and conditions of the permit(s) issued by the
Authorities concerned. In the absence of any specific requirements by Authorities, Contractor
shall comply wit11 Company's instructions.
The right of ingress and egress to the ROU shall be limited to points where such RoU intersects
public roads. Arrangements for other access required by the Contractor shall be made by him (at
his own cost and responsibility) and for such accesses the requirements of this specification shall
also apply.
Where the ROU comes within 30 meters of an existing line or facility, Contractor shall propose
and provide methods to safeguard the existing line or facility (e.g. a demarcation fence). No
work is allowed in such areas without Company's prior approval.
Where the ROU comes within the area of influence of high voltage electrical installations, the
following instructions shall be followed:
3.1 Instructions concerning high voltage influencing Safety measures during construction of
pipelines inside the area influenced by high voltage lines.
3.1.1 General
Pipelines, which are constructed inside the area of high voltage lines, may be electrically
influenced by these high voltage lines. The voltage caused by the influence may at times be so
high as to pose a danger to personnel working on the pipeline. It is imperative therefore, that the
instructions given below shall be accurately followed:
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3.1.1.1 It is a prerequisite that all personnel involved in construction of the pipeline, which is being
constructed in the area influenced by the high voltage system, must be given clear instructions on
safety measures to be taken while execution of WORK.
3.1.1.2 Vehicles and equipment must be earth-connected. This may be effected by attaching an
uninsulated cable or chain (which touches the ground) of adequate length to the underside of the
vehicle.
3.1.1.3 If it is not impossible for plant and/or materials to come to within 50m of the centre of the high
voltage system, special measures must be taken to prevent any approach beyond that distance,
unless Clause 3.1.2 is complied with.
3.1.1.5 To prevent electrical voltages in a non-buried section of the pipeline from rising to dangerous
values, the length of the pipeline section which has been welded together before burial must not
exceed the length at which the maximum admissible voltage may be induced. This length shall
be calculated using an approved calculation method.
3.1.1.6 Before a pipeline section is lowered into the trench the structure's earth electrodes indicated in
the drawings or determined with calculation method must have been installed and connected
both to the pipeline section already buried and to the section, which is about to be buried. The
electrical connections, which serve the purpose of preventing dangerous voltages, must have a
min. area of 35 mm2.
Said connections must not be interrupted until after the permanent safety earth connections have
been installed and connected to the entire uninterrupted pipeline.
3.1.1.7 The welded connection between the pipeline section and the section already buried must be
installed at a distance of at least 50m from the nearest point of a pylon base.
3.1.1.8 Personnel doing WORK inside the area influenced by the high voltage system must wear
electrically insulating foot-wear (e.g. rubber knee boots) and wear insulating rubber or plastic
gloves.
3.1.2 Additional measures for WORK to be done at a distance less than 50m from the centre of
the high voltage system.
If WORK is to be done at a distance less than 50m from the centre of the high voltage system,
the measures indicated below must be complied with, in addition to the instructions specified in
clause 3.1.1.
This distance depends on the voltage carried. For individual connections the distance must be:
2. In case the measures recommended in 1. above are not feasible, installation of clearly visible
markers of sufficient height or laying out a 'no passage beyond this point' line of drums painted
bright red and white must prevent any WORK being done inside the danger area. Furthermore,
an inspector must be present all the time.
3.1.2.3 In the event that a vehicle, crane etc. should accidentally come into contact with a live cable of a
high voltage system or flash-over of electrical charge occurs, the driver must not leave his
vehicle because this will pose a serious threat to his life.
The vehicle or crane must break the contact WITHOUT ANY HELP FROM OUTSIDE.
The driver must not leave his vehicle until he has managed to leave the dangerous area, or
alternatively, when the Electricity Authorities have given notice that the cable(s) have been put
out of circuit. In case a serious fire starts in the vehicle, he is permitted to jump from the vehicle,
clearing it as far as possible, while the jump should possibly be to a dry spot.
4.0 RIGHT-OF-USE
The Contractor is required to perform his construction activities within the width of Right-of-
Use (RoU) set aside for construction of pipeline, unless he has made other arrangements with the
land owner and/or tenant for using extra land. Variation in this width caused by local conditions
or installation of associated pipeline facilities or existing pipelines will be identified in the field
or instructed to the Contractor by Company.
The Right-of-Use boundary lines shall be accurately staked by the Contractor, so as to prepare
the strip for laying the pipeline.
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4.1 Stakings
1. Install Bench Marks, Intersection Points and other required survey monuments.
2. Stake markers in the centerline of the pipeline at distances of maximum 100 metres for
straight line sections and maximum 10 metres of horizontal bends. Wherever RoU
centerline has been staked on ground, Contractor shall exercise care in accurately staking
the pipeline centerline, in consultation with Company.
4. Set out a reference line with respect to pipeline centerline at a convenient location.
Markers on reference line shall be at a distance of maximum 100 metres for straight line
sections and maximum 10 metres for horizontal bends.
5. Install distinct markers location and indicating special points, such as but not limited to:
ROU Markers shall be staked out at the boundary limits of Right-of-Use wherever possible.
ROU Markers shall be painted red with numbers painted in white. Number shall be identical to
centerline marker number with letters A (left side) and B(right side) added, (looking to flow
direction). Reference markers shall also carry the same information as its corresponding
centerline markers.
Markers shall be of suitable material so as to serve their purpose and shall be coloured distinctly
for easy identification. Contractor shall be responsible for the maintenance and replacement of
the reference line markers until the permanent pipeline markers are placed and the as-built
drawings are submitted and approved.
Any deviation from the approved alignment shall be executed by Contractor after seeking
Company approval in writing prior to clearing operations.
4.2 Monuments
All shrines, monuments, border stones, stone walls and the like shall be protected and when
required, removed for safe keeping and replaced in original condition after construction as
directed by Company.
4.3 Fencing
Contractor shall install temporary fencing on either side of ROU where in Company's opinion, it
is considered essential to ensure safety and non-interference, especially in areas like grazing
lands, villages etc.
Fencing shall be removable type wherever necessary, to permit crossing of traffic. The type of
fencing must be suitable for the situation in accordance with user. The pole distance shall not be
greater than 6m. The minimum height of the fencing shall be 1.2 in above grade. Fencing can
consist of one or more rows of smooth wire and/or of barbed wire.
Fencing shall be continuously maintained and the through-ways inspected to be shut during the
execution of the WORK.
Any obstacle, which may hinder the construction and laying of the pipeline all along the pipeline
route and for a strip of land of the size provided, shall be removed.
4.4.1 All stumps shall be grubbed on a continuous strip, with a width equal to trench top width plus
two meters on either side centered on the pipeline centerline. Further, all stumps will be grubbed
from areas of the construction Right-of-Use, where Right-of-Use grading will be required.
Outside of these areas to be graded and the mentioned trench strip, and at the option of
Contractor, the stumps may either be grubbed or cut off to ground level. Any stump cut off must
be left in a condition suitable for rubber-tyred pipeline equipment traffic.
4.4.2 All grubbed stumps, timber, bush, undergrowth and roots cut or removed from the Right-of-Use
shall be disposed off in a manner and method satisfactory to Company, land-owner and/or tenant,
and Government Authorities having jurisdiction and as soon as practical after the initial removal.
In no case shall it be left to interfere with the grading and laying operations. Whenever stumps
are grubbed and a hole is left in the ground, Contractor shall back-fill the hole and compact it to
prevent water from gathering in it and malting a big hole.
4.4.3 Contractor shall grade the pipeline Right-of-Use as required for proper installation of the
pipeline, for providing access to the pipeline during construction, and for ensuring that the
pipeline is constructed in accordance with the most up-to-date engineering and construction
practices.
4.4.5 No temporary or permanent deposit of any kind of material resulting from clearing and grading
shall be permitted in the approach to roads, railways, streams, ditches, drainage ditches and any
other position which may hinder the passage and/or the natural water drainage.
4.4.6 The Right-of-Use clearing and grading operations shall in no case involve embankment
structures of any type and class without prior approval of the authorities having jurisdiction over
the same.
4.4.7 In the case of natural or artificial deposits of loose soil, sand, heaps of earth, or other fill
materials, these shall be removed till stable natural ground level is reached so as to ensure the
construction of the pipeline ditch in stable ground.
4.4.8 In the case of Right-of-Use clearing and grading on the hillside or in steep slope areas, proper
barriers or other arrangement/structures shall be provided to prevent the removed materials from
rolling downhill. The Right-of-Use cross fall shall not exceed 10%. Slope of side hill faces shall
be stabilized to prevent landslides.
4.4.9 Wherever the pipeline Right-of-Use runs across, through or alongside farmyards, built-up areas,
groups of trees, forests, groves, horticultural spreads, gardens, grass-fields, ditches, dikes, roads,
paths, railways or any other area with restrictions of some kind, Contractor shall grade only the
width of the Right-of-Use necessary for digging the pipeline trench and constructing the pipeline.
In the said places Contractor shall carry out the works in such a way that damage resulting from
the pipeline construction is kept to a minimum.
Contractor shall do all necessary grading and bridging at road, water and other crossings and at
other locations where needed, to permit the passage of its men and equipment. It is understood
that the Contractor has recognized such restrictive features of the Right-of-Use and shall provide
the necessary detours and execute the works without any extra cost to Company. Public travel
shall not be inconvenienced nor shall it be wholly obstructed at any point.
Contractor at his own cost shall furnish and maintain watchman detours, lanterns, traffic lights,
barricades, signs, wherever necessary to fully protect the public.
Contractor shall be responsible for moving its equipment and men across or around
watercourses. This may require the construction of temporary bridges or culverts. Temporary
bridging required for Right-of-Use crossing water courses shall be constructed in consultation
with concerned Authorities. Contractor shall ensure that such temporary works shall not interfere
with normal water flow, avoid overflows, keep the existing morphology unchanged and shall not
unduly damage the banks of water courses. No public ditches or drains shall be filled or bridged
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for passage of equipment until Contractor has secured written approval of the Authorities having
jurisdiction over the same. Contractor shall furnish Company a copy of such approval.
Grading operations could normally be carried out along the Right-of-Use with mechanical
excavators or manually. In certain areas, grading may have to be resorted to exclusively by
blasting.
In rough or steep terrain, Contractor may have to grade access roads and temporary bypass roads
for its own use. Where such access roads do not fall on the Right-of-Use, Contractor shall obtain
necessary written permission from land owners and tenants and be responsible for all damages
caused by the construction and use of such roads, and at no extra cost to Company.
Wherever rocky terrain is encountered, grading shall be carried out in all types of solid rocks
which cannot be removed until loosened by blasting, drilling, wedging or by other recognized
methods of querrying solid rocks.
Where use of explosives is required in connection with Right-of-Use grading and trenching,
Contractor shall comply fully with requirements of the use of explosives as provided under
clause 6.3 of this Specification and as provided under "Rules for Blasting", as per “Specification
for Blasting” issued for this purpose.
Contractor shall confine all its operations within limits of the Right-of-Use. Any damage to
property outside RoU shall be restored or settled to the Contractor's account.
Contractor shall promptly settle all off Right-of-Use damage claims. Should Contractor fail to do
so, Company shall give written notice to Contractor that if Contractor does not settle such claims
within seven days after such notice, Company shall have the authority to settle claims from the
account of Contractor.
5.1 General
The Contractor shall exercise utmost care in handling line pipe and other materials. Contractor
shall be fully responsible for all materials and their identification until such time that the pipes
and other materials are installed in permanent installation. Contractor shall be fully responsible
for arranging and paying for temporary storage areas for the pipeline materials, however, method
of storage shall be approved by Company.
Contractor shall reimburse the Company for the cost of replacement of all Company supplied
materials damaged during the period in which such materials are in the custody of the
Contractor. It shall be Contractor's responsibility to unpack any packings for the materials
supplied by Company.
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Pipe bevel protectors shall always be kept in position during all handling, transportation and
stringing operations and shall be removed only prior to fit-up for welding. After fabrication and
welding, the Contractor shall arrange to return all such bevel protectors at Company's designated
storage yard and as instructed by Company.
The following stipulations shall apply in case CONTRACT provides for supply of line pipe, bare
and/or corrosion coated, by Company.
Contractor shall receive and 'take over' against requisition, line pipe from the Company’s
designated place(s) of delivery as defined in the CONTRACT. Contractor shall perform visual
inspection of the bare pipes and coating of the corrosion coated pipes, as the case may be, in the
presence of Company and all damages shall be recorded. In the case of corrosion coated pipes
Contractor at his option may carry out holiday detection at a prescribed set voltage and record
such holidays, in the presence of Company, at the time of 'taking over'. HOWEVER, if
Contractor proposes to perform only visual inspection of coating, then repair of all holidays
found at the time of laying the pipeline shall be carried out by the Contractor at no extra cost to
Company. The Contractor shall be entitled to extra compensation for repair and rectification of
defects recorded at the time of 'taking over' as per the rate set fort11 in the "CONTRACT".
Repair of all damages occurring after taking over the delivery of the materials shall be to the
Contractor's cost. In case of delays in handing over of Company supplied materials, Contractor
shall be fully responsible for stopping and rearranging means of transportation at no extra cost to
Company.
Contractor shall unload, load, stockpile and transport the bare pipes using suitable means and in
a manner to avoid denting, flattening, or other damages to pipes. Pipe shall not be allowed to
drop or strike objects, which will damage the pipe but shall be lifted or lowered from one level to
another by suitable equipment. Lifting hooks when used, shall be equipped wit11 a plate curved
to fit the curvature of the pipe. In loading pipe on trucks each length shall be lowered to position
without dropping and each succeeding length shall rest on special supports on the truck and shall
be separated from the adjacent pipes. After loading, suitable chains and padding shall be used to
tie the load securely to each bolster. Pipe, when stock piled, shall be placed on suitable skid to
keep it clear of the ground and flood water. Care shall be exercised in handling or stock-piling
pipes in order to avoid distortion, flattening, denting or other damages. The Contractor shall
provide all necessary timber or other materials required for the stock-piling. While stacking, the
number of allowable layers of bare pipes shall be calculated as per API RP 5L1 and shall be
agreed with Company. The stacks must be properly secured against sliding and shall consist of
pipes of the same diameter and wall thickness. Adjacent stacks of pipes having different
dimensional characteristics shall be clearly separated.
The Contractor shall load, unload, transport and stockpile the coated pipes using approved
suitable means and in a manner to avoid damage to the pipe and coating. Contractor shall submit
to Company a complete procedure indicating the manner and arrangement used for handling and
stacking of coated pipes for Company approval prior to commencement of handling operations.
Use of vacuum lifting equipments is preferred. Hooks may also be used for handling the pipes
provided they have sufficient width and depth to fit the inside of the pipe and covered with soft
material like rubber, Teflon or equivalent, so as not to cause damages to bevel or pipe ends.
During hoisting cables/wire ropes shall have sufficient inclination compared to pipe axis so that
they do not come into contact with external coating.
Coated pipes may be handled by means of slings and belts of proper width (minimum 60 mm)
made of non-metallic/non-abrasive materials. In this case, pipes to be stacked shall be separated
row by row to avoid damages by rubbing the coated surface in the process of taking off the
slings. Use of round sectional slings is prohibited.
During handling, suitable handling equipments with proper length of booms shall be used.
Forklifts may be used provided that the arms of the forklifts are covered by suitable pads
preferably rubber. Before lifting operations, it is essential to ensure that the pipe surface is free
from foreign materials with sharp edges. Belts/slings when used shall be cleaned to remove hard
materials such as stone, gravel etc. Coated pipes shall not be bumped against any other pipe or
any other objects. Rolling, skidding or dragging shall be strictly forbidden.
Coated pipes at all times shall be stacked completely clear from the ground so that the bottom
row of pipes remain free from any surface water. The pipes shall be stacked at a slope so that
driving rain does not collect inside the pipe.
The coated pipes may be stacked by placing them on ridges of sand free from stones and covered
with a plastic film or on wooden supports provided with suitable cover. This cover can, for
example, consist of dry, germ free straw with a plastic film, otherwise foam rubber may be used.
The supports shall be spaced in such a manner as to avoid permanent bending of the pipes,
particularly in case of small diameter pipes with low wall thickness. The pipes shall be stacked
so that the uncoated bevelled ends are in line at one end, thus making differences in lengths
clearly noticeable.
Stacks shall consist of limited number of layers so that the pressure exercised by the pipes own
weight does not cause damages to the coating. Each pipe section shall be separated by means of
spacers suitably spaced for this purpose. Stacks shall be suitably secured against falling down
and shall consist of pipe sections having the same diameter and wall thickness. The weld bead of
pipes shall be positioned in such a manner so as not to touch the adjacent pipes.
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Coated Pipes stacked in open storage yards/dump yards shall be suitably covered on top to
decrease direct exposure to sunlight.
The ends of the pipes during handling and stacking shall always be protected with bevel
protectors.
The trailers/rail wagons shall be equipped with adequate pipe supports having as many round
hollow beds as the number of pipes to be placed on the bottom of the trailer bed. Supports shall
be provided for at least 10% of the pipe length. These supports shall be lined with a rubber
protection and shall be spaced in a manner as to support equal load from the pipes. The rubber
protection shall be free from all nails and staples where pipes are in contact. The second layer
and all subsequent layers shall be separated from each other with adequate number of separating
layers of protective material such as straw in plastic covers or mineral wool strips or equivalent,
to avoid direct touch between the coated pipes.
All stanchions of trailers/rail wagons used for transportation shall be covered by non-abrasive
material like rubber belts or equivalent. Care shall be exercised to properly cover the top of the
stanchions and convex portions such as reinforcement of the truck/rail wagon body, rivets etc. to
prevent damage to the coated surface.
Pipes shall be unloaded from the stringing trucks and lowered to the ground by means of Side
boom/Hydra crane tractor or swinging crane or other suitable equipment using lifting devices as
mentioned earlier. Dragging or sliding of pipe shall not be permitted. Special precaution shall be
taken during stringing of corrosion coated pipes as per the special requirements of previous Para.
Stringing of pipe shall only be carried out in daylight and after clearing and grading operations
have been completed. Pipe shall not be strung on the Right-of-Use in rocky areas where blasting
may be required, until all blasting is complete and the area cleared of all debris.
The stringing of the pipe on the Right-of-Use shall be done in such a manner as to cause the least
interference with the normal use of the land crossed and to avoid damage to or interference with
the pipes. The sequence of pipes must be interrupted at suitable intervals, spaced to coincide with
passages, roads, railways and water-courses crossings as well as at other places if requested by
land Owner or tenants to permit use of the land. Also care shall be taken to provide safe working
space between trench edge and the pipe. Pipe shall be strung on approved soft earth/sand filled
bags and wedge. Bottom of pipe shall in no way touch the ground. There shall be sufficient
clearance from bottom of pipe & the ground level. The pipe shall be supported at minimum two
locations.
In case line pipe supply is by different Manufacturers, Contractor shall string all line pipe of one
Manufacturer before commencing the stringing of the line pipe of another Manufacturer.
When parallel pipelines are being constructed, bumping against and contact with the strung
sections of pipe shall be avoided, whether the stringing of the pipes for the individual lines is
The pipe lengths must be properly spaced in order to make easier the handling during the
welding phase.
It shall be the responsibility of the Contractor to see that pipe is strung in accordance with the
approved drawings for the proper placement of pipe by size, thickness, grade and other
specifications. Any additional handling of pipes resulting from failure to, comply with these
requirements shall be at the Contractor's expense.
After the pipe has been strung on the Right-of-Use, it shall be inspected by the Contractor and
the Company and all defective pipe ends repaired. Defective pipes shall be repaired or rejected as
the Company may direct as per the requirements of clause 5.2 of this Specification.
Contractor shall receive and take over against requisition all Company supplied materials from
Company's designated place(s) of delivery as defined in the CONTRACT. Contractor shall
perform visual inspection and defects, if any noted, shall be recorded separately. The Contractor
shall be entitled to extra compensation for repair and rectification of such defects at the rates set
forth in the 'CONTRACT".
The Contractor shall perform the necessary loading, unloading, hauling from points designated
by the Company and storing, if necessary, of all materials. The Contractor shall exercise care in
handling, hauling, storing and distribution of materials in order to avoid damage and
deterioration of these materials and prevent their theft or loss.
Materials excluding line pipe shall be stored in sheltered storage. Such materials shall not be
strung on the Right-of-Use but shall be transported in covered conveyances for use only at the
time of installation.
Contractor shall ensure that all valves and whenever applicable, other materials are fitted with
suitable end covers of the type approved by Company. Materials with worked surfaces such as /
flanges, pipe fittings, etc. must be stacked and handled so as to avoid contact with the ground or
with substances that could damage them.
The Manufacturer's instructions regarding temperature and procedure for storing materials,
which are subject to alteration of the original properties and characteristics due to unsuitable
storage, must be strictly complied with and, if required, an adequate heat conditioning shall be
provided for these materials.
When material is supplied in containers and packages, it must not be thrown or dropped, nor
handled using hooks which could damage the container or the materials, either during
loading/unloading or during successive handling, until their final use.
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Coating materials, which are susceptible of deteriorating or suffering from damages especially
due to humidity, exposure to high thermal excursions or other adverse weather conditions, shall
be suitably stored and protected. These materials shall be kept permanently in store, supported
above the ground in a dry place protected against the weather and transported for use only at the
time and in the quantities necessary for immediate application. Deteriorated materials shall not
be used and replaced with no extra cost to Company.
5.7 Identification
Contractor shall provide all pipes, bends etc. greater than 50mm NB with serial numbers as soon
as possible upon the receipt of such materials at site and measure their length and state it on the
pipes, etc. Pipes to be bent shall be measured prior to bending. Identification (i.e. letter, number
and length) shall be indelible.
All serial numbers shall be recorded in a list, which shall also state appurtenant pipe numbers.
Beside recording the stamped pipe numbers, length of pipe and painted-on serial numbers, the
stamped-in numbers of T-pieces, bends, valves, etc. and the batch numbers of bends, T-pieces,
valves, etc and the make of valves, shall also be recorded in said list.
Before a pipe length, pipe end, etc is cut, the painted serial number and stamped-in pipe number
shall be transferred by Contractor in the presence of Company to either side of the joint, which is
to be made by cutting, and the changes shall be recorded in the above mentioned list stating the
(new) length. The result shall be such that all pipes, pups, etc. of diameter greater than 501mm
NB bear clear marks painted on.
Contractor shall explicitly instruct his staff that parts which cannot be identified must not be
removed, except after permission by Company.
As a general rule parts shall be marked as described above before being moved. In no conditions
may unmarked parts be incorporated into the WORK.
6.0 TRENCHING
6.1 Location
Contractor shall excavate and maintain the pipeline trench on the staked centerline of the
pipeline taking into account the curves of the pipeline.
In case of common ROU, the centerline of the trench shall be established from the location of
existing pipeline. In case of independent ROU, the centerline of the trench shall be established
from the edge of ROU.
6.2 Excavation
Suitable crossings shall be provided and maintained over the open RoU, where necessary, to
permit general public, property owners or his tenants to cross or move stock or equipment from
one side of the trench to the other.
Care shall be exercised to see that fresh soil recovered from trenching operation, intended to be
used for backfilling over the laid pipe in the trench, is not mixed with loose debris or foreign
material. The excavated material shall never be deposited over or against the strung pipe.
6.2.2 In steep slope areas or on the hillside, before commencing the works, proper barriers or other
protection shall be provided to prevent the removed materials from rolling downhill.
6.2.3 On slopes wherever there is danger of landslide, the pipeline trench shall be maintained open
only for the time strictly necessary. Moreover, the Company may require manual excavation of
trench, local route detouring and limiting the period of execution of the works. The Contractor
shall make adequate arrangements for safe working of the personnel involved in manual
excavation of trench.
6.2.4 In certain sloppy sections, before the trench cuts through the water table, proper drainage shall be
ensured both near the ditch and the Right-of-Use in order to guarantee soil stability.
6.2.5 All sewers, drain ditches and other natural waterways involved in the execution of the works
shall be maintained open and functional. The same applies to canals, irrigation canals, and
pipelines and buried facilities crossed by the ditch for which temporary pipelines shall be laid, if
required, and proper temporary installations provided.
6.3 Blasting
Blasting for trenching and the related removal of scattered rock and debris caused by the blasting
from the Right-of-Use and/or adjacent property, shall be performed by Contractor as part of his
WORK.
Every possible precaution shall be taken to prevent injuries and damages to persons and
properties during blasting operations, which shall be performed in accordance with Rules for
Blasting in Standard Blasting Specification issued for the purpose.
6.3.1 All necessary precautions shall be taken to prevent stones from falling outside the Right-of-Use
and in cultivated areas and to avoid any damage to the installations and properties existing
nearby.
6.3.2 Blasting and removal of debris shall be carried out prior to stringing the pipes.
The trench shall be excavated to a minimum width so as to provide, on both sides of the installed
pipeline, a clearance as indicated in the job standards/drawings and to a depth sufficient to
provide the minimum cover as indicated below. The dimensions in the table below shall govern
except as noted herein or as shown on the job standards or detailed construction
document/drawings or as required by authorities having jurisdiction, whichever is greatest.
Minimum depth of cover shall be measured from the top of pipe corrosion/concrete weight
coating (as applicable) to the top of undisturbed surface of the soil or top of graded working strip
or top of road or top of rail whichever is lower. Fill material in working strip shall not be
considered to add to the depth of cover. However, surface of fill material placed to fill hollows
may be used to determine the depth of cover subject to prior approval by Company.
f) Other River crossings (Bank width > 5011-1) 2.5 (for normal soil)
(below lowest bed level) 1.5 (for rocky strata)
Notes:
Whenever it is permitted by Authorities and/or Company to open cut a paved road crossing, or
where the line is routed within the road pavement, Contractor shall remove the paving in
accordance wit11 the restrictions and requirements of the Authorities having jurisdiction thereof
or as directed by Company. The open cut for the road crossing shall be carried out only when the
section of pipeline to be laid is complete. After laying the pipeline, backfilling shall be
immediately performed and all the area connected with the works shall be temporarily restored.
Throughout the period of execution of such works, Contractor shall provide and use warning
signs, traffic lights or lanterns, barricades, fencing, watchman, etc. as required by the local
authorities having jurisdiction and/or Company.
For all roads, paths, walkways etc., which are open-cut, Contractor shall provide temporary
diversions properly constructed to allow the passage of normal traffic with the minimum of
inconvenience and interruptions.
The paving shall be restored to its original condition after the pipeline is installed.
At points where the contour of the earth may require extra depth to fit the minimum radius of the
bend as specified or to eliminate unnecessary bending of the pipe according to customary good
pipeline practice, or where a deep trench is required at the approaches to crossings of roadways,
railroads, rivers, streams, drainage ditches, and the like, Contractor shall excavate such
additional depth as may be necessary at no extra cost to the Company.
Contractor shall excavate to additional depth where the pipeline approaches and crosses other
pipelines, sewers, drain pipes, water mains, telephone conduits, and other underground
structures, so that the pipeline may be laid with at least 50 centimeters free clearance from the
obstacle or as specified in the drawings, or such greater minimum distances as may be required
by authorities having jurisdiction.
Where the pipeline crosses areas, whose easements specifically require greater than normal
depths of cover, the trench shall be excavated to extra depth in accordance with the Right-of-Use
Agreements or as required.
Contractor shall excavate all such additional depths as may be necessary at no extra cost to the
Company.
The trench is to be cut to a grade that will provide a firm, uniform and continuous support for the
pipe. Bends shall be made in the pipe at significant changes in grade of the trench. Company
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reserves the right to set the grade of the trench and locate the bends if so desired, in which case
Contractor shall excavate, at no extra cost, the trench and bend the pipe to such a grade.
Company desires reduce to a minimum the required number of cold field bends to lay the pipe to
conform to the general contour of the ground and maintain a normal cover. This can be
accomplished by cutting the trench slightly deeper at the crest of ridges and by gradually
deepening the trench in approaches to crossings. Such trenching WORK shall be done by
Contractor at no extra cost to the Company.
Company intends that there will be a minimum of hand grading of the trench bottom. However,
to achieve this, Contractor will have to dig as square a bottom of the trench as possible with the
equipment. This in part can be obtained by adjusting and adopting the crumbing shoe and
digging teeth of the trenching machines and by use of a drag behind the trenching machines or
manually dressing-up the same. Contractor shall do such hand WORK in the trench as is
necessary to free the bottom of the trench from loose rock and hard clay and to trim protruding
roots from the bottom and side walls of the trench.
6.8 Padding
In all cases where rock or gravel or murum/hard soil is encountered in the bottom of the trench,
Company will decide the exact extent of trench padding, that will be required. The thickness of
the compacted padding shall not be less than 150mm. In those areas that are to be padded, the
trench shall be at least 150snm deeper than otherwise required, and evenly and sufficiently
padded to keep the pipe, when in place, at least 150mm above bottom of excavated trench.
Acceptable padding shall be placed under the pipeline before its installation, and around after
installation to establish at both sides and on top of the pipe a permanent layer of padding. The
thickness of compacted padding on top of pipe corrosion coating shall be at least 150mm.
Padding materials that are approved by Company shall be graded soil/sand and/or other materials
containing no gravel, rock, or lumps of hard soil. Sand used for padding shall pass through sieve
size ASTM C33 No. 16.
Contractor shall keep the trench in good condition until the pipe is laid, and no claim is to be
made to the Company by reason of its caving either before or after pipe is laid.
All lumber, sheet-piling jacks or other materials that may be necessary to shore the trench, in
order to prevent caving are to be furnished and removed by Contractor.
Contractor shall dewater if necessary, using well point system/concrete grouting for stabilization
of trench wall or other suitable systems, shore or do what else might be required to excavate the
trench, install the pipe in it and backfill the trench in accordance with the specifications at no
extra cost to Company.
Where the pipeline crosses other underground utilities/structures, the Contractor shall first
manually excavate to a depth and in such a manner that the utilities/structures are located.
Temporary under pinning or any other type of supports and other protective devices necessary to
keep the interfering structure intact shall be provided by the Contractor at his own cost and shall
be of such design as to ensure stability & safety against their possible failure.
Despite all precautions, should any damage to any structure/utility etc., occur, the
Owner/Authority concerned shall be contacted by the Contractor and repair shall forthwith be
carried out by the Contractor at his expense under the direction and to the satisfaction of
Company and the concerned Owner/Authority. If Contractor fails to repair in reasonable time,
Company reserves the right to have the repair executed at the cost of the Contractor.
In locations, where pipeline has to be laid in the body of a road, canal, dyke or other locations
under jurisdiction of Government/Public Bodies, the Contractor shall perform such WORK
without extra compensation, according to the requirement of concerned Authorities. When it
becomes necessary that Contractor has to resort to hand digging, well point, erection of sheet
piling or any other special construction method in these areas, no extra compensation shall be
paid. Contractor shall contact the Authorities concerned in order to become familiar with their
requirements. The facilities damaged during construction shall be restored to their original
condition to the satisfaction of Company/Authority.
In locations, where the pipeline has to be laid more or less parallel to an existing pipeline, cable
and/or other utilities in the Right-of-Use, Contractor shall perform the WORK to the satisfaction
of the Owner/Authority of the existing pipeline/cable/utility. In such locations Contractor shall
perform WORK in such a way that even under the worst weather and flooding conditions, the
existing pipeline/utilities remain stable and shall neither become undermined nor have the
tendency to slide towards the trench.
Contractor shall be liable for any damage occurring to, or resulting from damage to other
pipelines, underground structures/utilities, as laid down in clause 6.10 of this specification.
Contractor shall check if up-floating danger is present in open trench and then shall take
appropriate measures to prevent up-floating such as applying soil dams and dewatering of trench
or temporary filling of water into the line (in exceptional cases).
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In the case of water on the ditch bottom when the pipeline is being laid, the ditch shall be drained
to the extent and for the time required to make a visual inspection of the ditch bottom. After this
inspection, the presence of water will be allowed provided its level does not cause sliding of the
ditch sides and pipe floating before backfilling when no concrete weighing is provided.
The water pumped out of the ditch shall be discharged into a natural water course.
The above provisions shall be in accordance with the relevant specifications and/or job
standards/drawings.
Contractor shall indicate the option(s) selected to Company for review and approval along with
calculations, wherever applicable.
7.0 BENDING
Contractor shall preferably provide for changes of vertical and horizontal alignment in pipeline
by malting elastic bends. Contractor may provide cold field bends, at its option for change of
direction and change of slope. Company at its option, may authorise fabricated bends for
installation at points where in Company's judgment the use of such bends is unavoidable.
Overbends shall be made in such a manner that the centre of the bend clears the high points of
the trench bottom. Sag bends shall fit the bottom of the trench and side bends shall conform and
leave specified clearance to the outside wall of the trench.
The minimum allowable radius for elastic bends in the buried pipeline including that for
continuous concrete weight coated pipe shall be in accordance with relevant job standards. The
elastic bend shall be continuously supported over its full length. A radius smaller than permitted
in elastic bending shall require a cold bend.
7.2.1 The radius of cold field bends shall not be less than 40 times the pipe specified diameter for pipe
diameters 18 inch and above and shall not be less than 30 times the pipe specified diameter for
pipe diameter less than 18 inch.
7.2.2 Contractor shall use a pipe bending machine of adequate capacity and employ recognized and
accepted methods of bending of coated pipe in accordance wit11 good pipeline construction
practice. However, bending machines shall be capable of making bends without wrinkles,
buckles, stretching and with minimum damage to the coating.
7.2.3 Contractor shall, before the start of the WORK, submit and demonstrate to Company a bending
procedure, which shall conform to the recommendations of the manufacturer of the bending
machine. The procedure shall include amongst other steps- lengths, maximum degree per pull
and method and accuracy of measurement during pulling of the bend. The bending procedure
and the equipment used shall be subject to Company's approval.
7.2.4 Pipes with longitudinal welds shall be bent in such a way that the weld lies in the plane passing
through the neutral axis of the bend, which shall be installed positioning the longitudinal weld in
the upper quadrants. If horizontal deviations are to be achieved by joining more adjacent bends,
the bending of the pipe lengths shall be made by positioning the longitudinal welds alternatively
70mm above and below the plane passing through the neutral axis in such a way that the bends
are welded with the longitudinal welds displaced by about 150 mm and situated in the upper
quadrants. In case of vertical bends formed from a number of pipe lengths, the longitudinal
welds shall be positioned on the plane passing through the neutral axis of the bend to the right
and left alternatively.
7.2.5 The pads, dies and rolls of the bending equipment shall have relatively soft surfaces to avoid
damage to the pipe coating. Where applicable, fully retaining bending shoes shall be used. Roller
type bending machines are preferred.
7.2.6 The ends of each bent length shall be straight and not involved anyway in the bending. The
length of the straight section shall permit easy joining. In no event shall the end of the bend be
closer than 1.5 m from the end of a pipe or within one meter of a girth weld.
7.2.7 The ovalization caused on each pipe by bending shall be less than 2.5% of the specified diameter
at any point. Ovalization is defined as the reduction or increase in the internal diameter of the
pipe compared with the nominal internal diameter. A check shall be performed on all bends in
the presence of Company Representative by passing a gauge consisting of two metallic discs
with a diameter equal to 95% of the nominal internal diameter of the pipe connected rigidly
together at a distance equal to 300 mm.
7.2.8 The wall thickness of finished bends, taking into account wall thinning at the outer radius, should
not be less than the design thickness. An indication of wall thinning as a percentage is given by
the following empirical formula:
Where 'n' is the inner bend radius divided by pipe diameter. Pipes with measured wall thickness
greater than the nominal wall thickness (i.e. with +ve tolerance) shall normally be used for
making cold field bends.
7.2.9 Cold bend pipes on site shall have the corrosion coating carefully checked with the aid of a
holiday detector for cracks in the coating down to the pipe wall. It must also be checked whether
the coating has disbonded from the pipe wall during bending by beating with a wooden mallet
along the outer radius. Any defects or disbonding of the coating caused during bending (also
forced ridges in the coating) shall be repaired at the Contractor's expense in accordance with
Company approved procedures.
7.2.9 When pipelines are laid in parallel, the horizontal bends shall be concentric.
All bends showing buckling, wrinkles, cracks or other visible defects or which are in any way in
disagreement, in whole or in part, with this specification shall be rejected.
No miter bends shall be permitted in the construction of the pipe line. Contractor shall cut out
and remove any bend or bends, which do not meet the specifications and shall replace the same
with bends complying with specification at no additional cost to the Company. In the event the
CONTRACT provides for supply of line pipe by Company, the pipes required for replacement
will be furnished by Company, but the cost of replacement of such pipes shall be borne by
Contractor.
Cutting of factory made bends and cold field bends for any purpose are not permitted.
Each length of pipe shall be thoroughly examined internally and externally to make sure that it is
free from visual defects, damage, sever corrosion (sea water pitting), dirt, animals or any other
foreign objects. Each length of the pipe shall be adequately swabbed, either by use of canvas belt
disc of proper diameter, or compressed air blowing or by other methods approved by the
Company. Damaged/corroded pipes shall be kept separate. Each length of pipe shall be pulled
through just before being welded.
All rust and foreign matters shall be removed from the beveled ends by power operated brush.
This shall be affected inside & out side and for a minimum distance of 25 mm from edge of
bevel. The bevel shall be thoroughly inspected at this stage. Should laminations, spilt ends or
manufacturing defects in the pipe observed, the length of the pipe containing such defects shall
be removed from the line in accordance with relevant specification.
8.1.1 Acceptability of defects in the pipe detected during inspection at the WORK site shall be
determined in accordance with latest edition of Company's own material specification or code
ASME B31.8 / B 31.4 whichever is more stringent.
8.1.2 The maximum permissible depth of dents in pipes shall be as per applicable linepipe
specification issued by Company.
8.1.3 Dents, which contain a stress concentrator such as scratch, gauge, arc burn or groove, and dents
located at the longitudinal, spiral or circumferential weld shall be removed by cutting out the
damaged portion of pipe as a cylinder.
8.1.4 Repair on line pipe shall be executed as specified in Company's material specification or Code
ASME B 31.8 / B 31.4, whichever is more stringent. A record of all repairs shall be maintained
by Contractor. This record, provided with the pipe identification number shall be submitted to
the Company.
8.1.5 If due to cutting or repairs, the pipe identification number is removed, it shall be reprinted
immediately by Contractor in the presence of Company. In the event, the CONTRACT provides
for supply of line pipe by Company, Contractor shall be charged for any pipe length due to loss
of identification number. No pipe without identification number shall be transported and/or
welded into the pipeline.
8.1.6 Repair of damaged pipe ends by hammering and/or heating is not allowed. If the dented area is
minor and at least 200 mm away from the pipe end, and the steel is not stretched, severed, or
split in the Company's opinion, the pipe may be straightened with a proper jack.
8.2.1 When lifting pipe, care must be taken not to kink or overstress it. Proper pipe slings approved by
Company shall be used. Contractor shall submit his method of skidding and skid spacing for
Company's approval. A strip of soft material shall be placed in between skid and pipe to protect
the external coating of the pipe. The material shall be approved by the Company.
8.2.2 The maximum skid spacing is not allowed before the stringer 'bead and the top and bottom
reinforcements are completed, provided that the distance between the incomplete weld and the
skid shall not exceed 9 (nine) percent of the skid spacing.
8.2.3 Skids shall be at least 1.20 meter long. For pipe with an O.D. of 324 mm and larger the skids in
contact with the pipe shall have a width of at least 200 mm. For pipe with an O.D. of less than
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324 mm the skids in contact with the pipe shall have a width of at least 150 mm. Pipe supports
shall be stable, so that pipe movement will not cause the supports to move. Skids shall not be
removed under a string before lowering in. The welded pipe shall be maintained on skids at the
minimum distance of 500 mm above ground. Crotches shall be installed at frequent intervals (at
least every l0th support) with a greater number required at bends and undulating grounds.
At the end of each day's WORK or every time when joining and welding operations are
interrupted, the open ends on the welded strings of pipes shall be capped with a securely closed
metal cap or plug as approved by Company so as to prevent the entry of dirt, water, or any
foreign matter into the pipeline. These covers shall not be removed until the WORK is to be
resumed. The caps/plugs used shall be mechanical type and shall not be attached to pipe by
welding or by any other means, which may dent, scratch or scar the pipe.
Whenever the welded strings of pipes are left open at intervals to be tied in later after an
appreciable time lag, under roads, railroads, rivers, marshy crossings, etc., temporary caps
approved by Company shall be welded to the ends of the pipe.
9.0 LAYING
9.1.1 Lowering can start after removal from ditch bottom of all off cuts, pipe supports, stones, roots,
debris, stakes, rock projections up to 15 cm below underside of pipe and any other rigid materials
which could lead to perforation or tearing of the coating. Sand padding, graded soil and/or other
materials containing no gravel, rock shall be provided as required in accordance with clause 6.8
of this specification in such a way to get an even surface for pipe laying.
9.1.2 Lowering shall follow as soon as possible, after the completion of the joint coating of the welded
pipe string In the case of parallel pipelines, laying shall be carried out by means of successive
operations, if possible without interruption.
9.1.3 Before lowering in, a complete check by a full circle holiday detector for pipe coating and for
field joint coating shall be carried out and all damages repaired at Contractor's cost. All points on
the pipeline where the coating has been in contact with either the skids or with the lifting
equipment during laying, shall be carefully inspected for damages, denting or other defects and
shall be completely repaired. If, after checking, it becomes necessary to place the pipeline again
on supports at the bottom of the trench, these must be padded in such a way as to prevent damage
to the coating, thus avoiding necessity for further repairs when the pipe is finally raised and laid.
Before the last operation, a check must be made of the coating at points of contact with the
supports.
9.1.4 Before lowering in, short completed sections of the pipeline shall be cleaned with compressed air
driven cup Pig or Foam pig in order to remove all dirt, etc. from the inside of pipe sections. In
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case such cleaning is proposed by Contractor after lowering, the Contractor shall obtain approval
from the Company.
9.1.5 The pipeline shall be lifted and laid using, for all movements necessary, suitable equipment of
non-abrasive material having adequate width for the fragility 'of the coating. Care shall be
exercised while removing the slings from around the coated pipe after it has been lowered into
the trench. Any damage caused to the coating shall be promptly repaired. Lowering-in utilizing
standard pipe cradles shall be permitted if Contractor demonstrates that pipe coating is not
damaged. No sling shall be put around field joint coating.
9.1.6 Wherever the pipeline is laid under tension, as a result of an assembly error (for example,
incorrect positioning of bends, either horizontal or vertical), the trench shall be rectified or in
exceptional cases a new assembly shall be carried out, to be approved by Company, so that it fits
the excavation and the laying bed.
9.1.7 Laying shall be carried out under safe conditions so as to avoid stresses and temporary
deformations of the equipments, which may cause damage to the pipeline itself and to the
coating. In case of localised points where the right-of-use is restricted to the minimum necessary
for the transit of mechanical equipment, the laying shall be carried out using other suitable
means. The pipe shall be placed on the floor of the excavation, without jerking, falling, impact or
other similar stresses. In particular, care must be taken that the deformation caused during the
raising of the pipe from the supports, does not exceed the values for the minimum allowable
radius of elastic curvature, so as to keep the stresses on the steel and on the coating within safe
limits. The portion of the pipeline between trench and bank shall be supported by as many side-
booms as required and approved by Company for holding the line in gentle S-curve maintaining
minimum elastic bend radius as specified in job standard. Lowering in and backfilling shall
preferably be carried out at the highest ambient temperature.
9.1.8 The pipeline must be laid without interruption for the whole or the length of section available.
Where water is present, no laying shall be permitted until the ditch has been drained to the extent
and for the time necessary to make visual inspection possible of the bed on which the pipe is to
be laid. Following such inspections, the presence of water will be permitted, provided that it is
not so high as to cause cave-in of the walls of the trench or floating of the pipeline before
backfilling, when weighing is not provided for the pipe.
9.1.9 Contractor shall take precautions immediately after lowering in to prevent the movement of the
pipe in trench.
9.1.10 Contractor shall close the two ends of the lowered section with night caps against ingress of
Water/mud or any foreign material in the section.
9.1.11 In laying parallel pipelines in the same trench, the minimum distances between the pipelines
indicated in the approved drawings shall be observed. Once the first pipeline has been
positioned, it shall in no way be disturbed by laying of the subsequent pipelines.
9.2.1 The following works shall be completed before proceeding with the assembly and laying of
overhead pipelines:
- Paints and/or coating of the pipe WORK, as indicated in the engineering specification.
9.2.2 The erection of the supports shall be carried out taking care that the elevation and alignment is in
accordance with the drawings.
In the case of metal work supports, pre-fabrication and/or assembly shall take into account the
maximum allowed free span and the supports shall not interfere with the pipeline welds.
9.2.3 In case roller supports are used, the rollers shall be lubricated, then checked for smooth rotation
and, in case of seizure, the defect shall be repaired or roller shall be replaced. In the case of
overhead section where the pipeline is slanting, the alignment of the end supports shall be made
after placing the pipeline in position. Before installation of the pipe section, all the rollers shall
be perfectly centered acting on the seat of the supports plates.
The above alignment operations shall be carried out before connecting the overhead section with
the end of the buried section.
9.2.4 Lifting, moving and laying of the pipeline shall be carried out in accordance with the provisions
of clause 9.1.5.
An insulation sheet shall be installed to isolate the pipe from the support or support from the
earth. The sheet shall be hard polyethylene at least 5mm thick. It shall extend at least to 1 cm
outside the saddles or clamps.
9.2.5 Moving supports, if any, shall be centered on their support and allow for a movement of at least
300mm in both directions.
9.2.6 A comprehensive report/method statement on the laying operation to be used shall be submitted
to the Company well in advance for approval. The report as a minimum shall include, but not
limited to the following:
b. Pulling method and related calculations, whenever lifting method cannot be used.
10.0 BACK-FILLING
10.1 Backfilling shall not be done until the pipe and appurtenances have the proper fit and the pipe is
following the ditch profile at the required depth that will provide the required cover and has a
bed which is free of extraneous material and which allows the pipe to rest smoothly and evenly.
Before any such WORK is done, it shall be Contractor's responsibility to first secure the
approval of Company. If any backfilling is done without Company's approval, Company will
have the right to require removal of the backfill for examination, and the cost of such uncovering
and refilling shall be borne by Contractor. Backfilling of trench in water courses shall be carried
out as per the relevant specifications issued for the purpose.
10.2 Backfilling shall be carried out immediately after the pipeline has been laid in the trench,
inspected and approved by the Company, so as to provide a natural anchorage for the pipeline,
thus avoiding long exposure of coating to high temperature, damaging actions of adverse weather
conditions, sliding down of trench sides and pipe movement in the trench. If immediate back
filling is not possible, a covering of at least 200mm of earth, free of rock and hard lumps shall be
placed over and around the pipe and coating. On no account the top soil from the ROU be used
for this purpose. In general, the trench shall be dry during backfilling. Deviations thereof must
have prior approval of the Company. The backfill material shall contain no extraneous material
and/or hard lumps of soil, which could damage the pipe and/or coating or leave voids in the
backfield trench. After the initial backfill has been placed into the trench to a level slightly above
the surrounding ground, Contractor shall compact the backfill material. The surplus material
shall be neatly crowned directly over the trench and the adjacent excavated areas on both sides of
the trench as per clause 6.2.1, to such a height, which will, in Company's opinion, provide
adequately for future settlement of the trench backfill during the maintenance period and
thereafter. The crown shall be high enough to prevent the formation of a depression in the soil
when backfill has settled into its permanent position. Should depression occur after backfill,
Contractor shall be responsible for remedial WORK at no extra cost to Company. Surplus
material, including rock, left from this operation shall be disposed of to the satisfaction of land
owner or authority having jurisdiction at no extra cost to the Company.
For Further requirements reference shall be made to section 14.0 "Clean-up and Restoration of
Right-of-Use" of this specification.
10.3 Rock, gravel, lumps of hard, soil or like materials shall not be backfield directly onto the pipe
unless padding and/or rock-shield has been provided as per Section 6.8 of this specification.
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When "Padding" as described in Section 6.8 of this specification is to be used, the following
shall be applicable.
Where rock, gravel, lumps of hard soil or like materials are encountered at the time of trench
excavation, sufficient earth, sand or select backfill materials shall be placed around and over the
pipe to form a protective cushion extending at least to a compacted height of 150111m above the
top of the pipe. Select backfill materials for padding that are acceptable to Company shall be soil,
sand, clay or other material containing no gravel, rock or lumps of hard soil. Whether such
padding material would be taken from the adjacent spoil bank or imported from elsewhere shall
be directed by Company. All these works shall be carried out by Contractor at no extra cost to
Company. Loose rock may be returned to the trench after the required selected backfill material
has been placed, provided the rock placed in the ditch will not interfere with the use of the land
by landowner, or tenant.
10.4 When the trench has been dug through drive ways or roads, all backfills shall be executed with
sand or a suitable material as approved by Company and shall be thoroughly compacted. In
certain cases, special compaction methods, such as moistening or ramming of the backfill in
layers may be required by Company. Company and any public or private authority having
jurisdiction over a road, street or drive way may require that the surface of the backfill be
gravelled with crushed rock or some other purchased material and the road shall be repaved. In
such instances, Contractor shall comply with said requirements at no extra cost to Company.
10.5 Trenches excavated in dikes which are the property of railways or which are parts of main roads
shall be graded and backfiled in their original profile and condition. If necessary, new and/or
special backfill materials shall be supplied and worked-up. The materials required may include
gravel, special stabilization materials or stabilized mixtures. Moreover, special processing and/or
compacting methods shall require the approval of Company and/or competent authorities.
10.6 The trench in irrigated and paddy fields shall be backfield to within 300mm of the top, then
rammed and further backfield until the trench is completely backfield. Surplus material
remaining after the operation shall be spread over the RoU as specified in Section 14.0 "Cleanup
and Restoration of Right-of- Use", of this specification.
10.7 At the end of each day's WORK, backfilling shall not be more than 500 meters behind the head
end of lowered-in pipe, which has been padded and approved for backfill. The backfill shall be
maintained by Contractor against washouts and spreading etc., until the completion and final
acceptance of the WORK by Company.
10.8 Contractor shall furnish materials and install breakers in the trench in steep areas (slope generally
10% and more) for the purpose of preventing erosion of the back fill. The type of breakers
installed shall be as per the approved drawings. Breakers shall be constructed of grout bags filled
with a mixture of 4: 1 Sand : Portland cement at Company's direction. Contractor may propose
other methods such as foam dams etc. which shall be subject to approval by Company. Such
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works shall be at no extra cost to Company. Contractor shall pay attention to the direction of
backfilling in such steep areas.
10.9 When backfilling the trenches in sloping terrains or steep areas, where in the opinion of the
Company the backfill may be washed out of the trench, sheet piling or other effective water
breakers across the trench shall be provided by Contractor. This is to divert the flow of water
away from the trench into normal drainage followed before laying of the line. In no case, the
water is to be drained via the trench or via channels other than those followed before the line was
laid.
10.10 Contractor shall leave the pipe uncovered at certain locations to allow Company to survey the
top of the pipe and the level of the pipeline in the backfield trench. Within 48 hours after
backfilling, Company shall have carried out such survey and informed Contractor of any
realigning, if required. Thereafter Contractor shall compact the backfill.
The maximum allowable deviation from the centerline for land sections as staked out by
Company and as referenced by Contractor after backfilling is limited to following:
10.11 Before backfilling of the trench, Contractor shall comply with the requirements of Clause 6.12 of
this specification.
10.12 Stabilization of backfill shall be carried out by the Contractor in sandy areas and other such
places, as directed by the Company. Contractor shall carry out the stabilization to have a
consolidated cover over the pipeline at no extra cost to Company.
The backfill shall be stabilized preferably with 150 mm layer of marl, mattresses of gatch other
than straw or other stable materials. The width of stablisation shall be at least 3.0 meters on
either side of the pipeline, plus one meter for every 10 meters height of dune (where the line
passes through the dune areas).
10.13 Temporary markers shall be installed during backfilling and the survey as per clause 10.10 to
locate the pipeline axis. These markers shall then be replaced with permanent pipeline markers.
10.14 Backfilling shall be preferably carried out at the highest ambient temperature.
10.15 In certain areas like U/G pipeline crossings, overhead power cable crossings etc, special care to
be taken by putting concrete slab/plastic grating before backfilling. Size and thickness of
concrete slab/plastic grating shall comply applicable job standard and approved by Company.
11.0 TIEING-IN
11.2 Tie-in shall preferably be carried out at ambient temperatures corresponding to the average
operating temperature in the case of a pipeline conveying fluids at normal temperatures and at
the maximum ambient temperature in the case where the pipeline is carrying fluids at high
temperature.
11.3 Contractor shall carry out tie-in-welding (including necessary cutting, bevelling, grinding of pipe
weld seams and line-up etc.) cleaning, priming, coating and backfilling for the tie-in portion as
per relevant specifications. Contractor shall also excavate the required bell-holes for the welding.
Bell holes made to facilitate welding shall provide adequate clearance to enable the welders to
exercise normal welding ability and skill. All tie-in welds shall be radiographically examined.
11.4 The tie-in should be done in such a way as to leave a minimum of strain in the pipe. If necessary,
with respect to the trench, realigning of the pipe shall be done to eliminate force or strain in the
pipe by the Contractor at no extra cost to Company.
11.5 If a pup end cannot be avoided for tie-in, the minimum length that shall be added is 1.0 meter
and two or more such pups shall not be welded together. All cut-off lengths greater than 1.0
meter shall be moved ahead in order to be welded into the pipeline at a suitable location. Tie-in
with two or more pups may be used provided that they each have minimum length of 1.0 meter
and are separated by an entire length of pipe. In no case more than three (3) welds shall be
permitted on a 10 meter length of pipeline.
11.6 In connecting pipes, special items, fittings and equipment where different wall thicknesses are to
be welded, Contractor shall follow the procedures indicated in ASME B3 1 .WASME B3 1.4, as
applicable. The required tapering shall be done by Contractor at no extra cost to Company.
11.7 For tie-in of adjacent sections of pipeline already pressure tested, the pup used for tie-in shall be
of single length or off-cuts of pipe, which have already been hydrostatically tested. Contractor
shall take care that sufficient number of pretested pipes with different wall thicknesses are
readily available.
12.1 General
12.1.1 In addition to constructing the pipeline, Contractor shall also install certain other auxiliary
facilities and appurtenances.
Contractor shall do all WORK necessary at each of the installations to provide facilities, which
are complete in all respects and ready for operations.
On completion, all elements of each entire installation shall be checked out and tested for full
and correct operation in the presence of, and to the satisfaction of Company. All WORK shall be
carried out strictly in accordance with the appropriate codes, the approved drawings, and this and
other related specifications.
Contractor shall fabricate all piping and install valves and fittings as required by the detailed
engineering fabrication drawings prepared by him and approved by Company. Piping fabrication
drawings shall be prepared by Contractor based on AFC drawings and approved by Engineer In
charge at site.
Stainless steel lines will he "swaged" using permanent fittings installed with a hydraulic device.
Cold bending for the fitting of 12 mm NB and 6 mm NB pipes is allowed when special bending
tools are used with guides to prevent flattening. The minimum radius allowed shall not be less
than R=10 D, where D = outside diameter of pipe.
Contractor shall ensure that the piping assemblies are not in a strain prior to the final bolting or
welding. Contractor shall also ensure that all equipment and piping are thoroughly swabbed
clean of all dust, refuse, welding-spatter, scale, or any potentially detachable matter prior to the
tie-in or final bolting.
These tolerances apply to inline items and corrections for other lines. These tolerances can be
exceeded on items such as vents, drains, dummy supports, field supports, temperature and
pressure connections, where the deviation will not affect another spool.
a. General dimensions such as face to face, face or end to end, face or end to centre, and
center to centre: + 3 mm.
b. Inclination of flange face from true in any direction: 4mm per meter.
Contractor shall ensure that prior to final bolting, all flange faces are parallel and centered,
according to standard practice. Contractor shall not use bolting forces as a means for attaining
alignment. A gasket of required size and quality shall be installed between the flanges at each
joint.
Bolts shall be tightened in diagonal sequence and shall be centered with equal amounts of thread
visible on both sides. Bolts shall be uniformly tightened to produce a leak-proof joint. Bolts that
yield during tightening shall be removed and discarded. It is mandatory that a torque wrench is
used for bolt tightening.
Damaged threads shall be cut from the end of a run and the pipe shall be rethreaded.
Contractor shall properly align all threaded joints. Pipe entering unions shall be true to centerline
so the union will not be forced during make-up. The threaded pipe shall not project through
fittings to cause interference with valves or other operating mechanisms.
Except for the threaded connections of instruments, which will require periodic testing and
maintenance, all threaded joints shall be seal welded. The latter joints shall be made up without
pipe joint compound and with a minimum of oil from the thread cutter. Seal welds should taper
into the pipe with as little discontinuity as possible, and should cover all threads. All seal welds
shall be tested with DP, MP testing.
Where the ends of the piping components being welded have an internal surface misalignment
exceeding 1.6mn-1, the wall of the component extending internally shall be trimmed by
machining so that the adjoining internal surfaces will be approximately flush. All welding shall
be performed in accordance with GAIL Specification of “Welding Specification for Onshore
pipeline for Transportation of Gas” and other applicable Jobs Specifications and Welding
Specification Chart.
Civil work shall be performed in accordance with Specifications issued for the purpose.
12.1.7 Painting
All exposed surfaces like piping, valves, structures, and miscellaneous appurtenances shall be
painted in accordance with the specifications issued for this purpose. The corrosion coating on
pipe surface will end approximately 300 mm above the finish grade and it will be necessary for
Contractor to provide a clean interface at the junction of the protective coating and the paint.
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12.1.8 Coating of buried Installations, etc.
All buried valves, insulating joints, flow tees, bends, other in-line fittings and appurtenances
shall be coated with 100 % solid high build epoxy (minimum 500 micron thk.) or any other
equivalent suitable Company approved coating at no extra cost to Company. For buried pipes
and LR bends, heat shrink sleeves / cold applied tapes conforming to Company's specification
for Field Joint Coating shall be used. Contractor shall submit to Company a report regarding the
method of application and the materials used along with all test certificates. Only after obtaining
written approval from the Company, Contractor shall commence the work of coating.
12.1.9 Clean-up
After all required tests have been concluded satisfactorily, Contractor shall clean up the Site as
laid down in the specifications issued for the purpose. The Site shall be graded in accordance
with the approved drawings.
12.2.1 Block and sectionalizing valve stations shall be installed as shown on the approved drawings. It
is Contractor's responsibility to have the units completely assembled, tested and made fully
functional including all related instruments etc.
12.2.2 The civil and structural work shall be carried out in accordance with the relevant specifications
issued for the purpose and in accordance with the approved drawings as directed by Company.
This work as a minimum shall include clearing, grading, fencing, foundations etc. as required.
All above ground structures shall be painted as per the specification and color code given by the
Company.
12.2.3 Suitable concrete foundation as directed by Company shall be constructed on which the valve
shall be firmly installed, after embedding an insulating sheet of hard polyethylene with a
thickness of at least 5min or equivalent. Such insulating sheet is also to be installed under pipe
clamps, etc.
12.2.4 Valves with flow arrows shall be installed according to the normal flow in the pipeline. During
welding, the valves shall be in fully open position. In addition, all manufacturer's instructions
shall be followed.
Care shall be taken to avoid entry of sand particles etc. to valve body, seals etc. during
transportation, storage, assembly and installation.
12.2.5 For valves and piping installed below ground and/or above ground the anti-corrosion
Coating/painting shall be as per the requirements of the relevant specifications issued for the
purpose. The anti-corrosion below ground coating shall extend upto 300mm above grade at the
lowest point.
12.2.7 All valves shall always be handled using appropriate equipment and methods so as to avoid
impact, shaking and other stresses. In particular, the equipment and tools used for lifting and
handling shall never be hooked through hand wheel, valve stem, flange joints and other parts,
which may suffer damage/misalignment.
12.2.8 All sectionalising valve and any other inline assemblies shall be prefabricated and tested
hydrostatically ex-situ as per applicable specification. All such assemblies shall be installed at
the locations shown in the drawings only after successful completion of the hydrostatic test and
dewatering. Thereafter the ends of the assembly shall be closed off, Contractor shall carry out
necessary excavation, cutting, beveling of pipe ends and welding of the tie-ins required for the
installation of such assembly. The tie-in joints shall be radiographically examined over 100%
length and also 100% ultrasonically examined prior to backfilling. All works shall be executed in
accordance with the relevant specifications issued for the purpose.
12.3.1 Scraper stations shall be fabricated and installed as per the approved drawings and whenever
applicable as per the requirements of clause 12.2 of this specification. It is Contractor's
responsibility to have the units completely assembled tested and made fully functional including
all instruments and related piping.
12.3.2 The Civil and structural works for the scraper stations shall be carried out as per the relevant
specifications, in accordance with the drawings and as directed by the Company. The WORK as
a minimum shall include site survey, site preparation, clearing, grading, fencing, foundations,
etc. as required.
12.3.3 It shall be Contractor's responsibility to maintain elevations shown on the approved drawings and
to carry out any pipe work adjustments, necessary for this purpose. Field cuts shall be square and
accurate and field welds shall not be performed under stress of pipe ends.
12.3.4 The painting for the scraper stations shall be carried out as per "Specifications for Painting". The
underground sections shall be coated as specified for the pipeline upto at least 300mm above
grade.
12.3.5 The hydrostatic testing of the scraper stations shall be executed after installation in accordance
with the relevant specifications issued for the purpose.
12.4.1 Insulating joints shall be installed at the locations shown in the drawings. Contractor shall obtain
approval from the Company before installation of the insulating joints.
12.4.3 The insulating joints and the welded joints shall be protected by external coating as per relevant
specifications issued for the purpose.
12.4.4 When the in-line inserting is made on the buried pipeline, care shall be taken to weld at an
external temperature as close as possible to the pipeline operating temperature.
The joint shall be inserted on straight sections and laid on a fine sand bed.
12.4.5 During the execution of the in-line connection welding, the propagation of heat shall be avoided.
To achieve this, the joint shall be kept cold by means of rags continuously wetted.
12.4.6 Insulating joints shall be e1ectrically tested before welding into the pipeline. The electrical
resistance/conductance test shall be carried out using a Megger. Measurement of the insulation
resistance across the joint shall be approx. one (1) Mega Ohm. The tests shall be repeated after
installation and welding of the joint into the pipeline to verify that the assembly is undamaged.
Contractor shall, in general, observe the following maximum distances between the working
mainline spread:
The spread limitations do not apply to point spreads such as rock blasting, river crossing and
bored crossings of roads, railways and canals and HDD crossings.
Any deviations from the above shall meet prior approval of Company. Company reserves the
right to stop the WORK, in case the approved spread limitations are exceeded and Contractor
shall not be paid any compensation for stoppage of WORK.
14.1 Contractor shall restore the RoU and all sites used for the construction of pipelines, water
crossings and other structures in accordance with Company's instructions, and deliver them to
the satisfaction of Company.
For Company supplied materials, after completion of WORK, the Contractor shall return all
surplus materials at Company's designated areas.
14.3 Disposal
14.3.1 All surplus and defective materials supplied by Contractor and all trash, refuse and spoiled
materials shall be collected and disposed off by Contractor.
14.3.2 The ROU shall be cleared of all rubbish, broken skids, empty cans, card board, sacks, stumps,
trash, and leftover construction material. All burnable matter shall be burned, but only after
obtaining appropriate permits for such burning. If burning is not allowed, Contractor shall haul
the clean-up material to an approved dumping area. All scrap metal and unburnable material
shall be disposed of, in an appropriate manner, but never be buried in the ROU.
14.3.3 Surplus soil can only be removed from the Owner's plot after authorisation by Company.
14.3.4 All dumping fees connected with the disposal of materials shall be to the account of Contractor.
14.3.5 All loose stones and rock exposed by the construction operations and scattered over the ROU or
adjacent grounds shall be removed by Contractor and be transported to a location considered
suitable by the land-owner and/or tenant, or by authorities have jurisdiction, for satisfactory
disposal. For stones, gravel or other hard material, which may be buried in the trench the
provisions of the specifications shall apply with the understanding that the use of the land by the
land-owner and/or tenant will not be interfered with.
All auxiliary structures such as bridges, culverts, sheet piling, posts, signs, etc., which were
erected or installed by Contractor as temporary measure, shall be removed. However, it may be
necessary to remove the fence of ROU during the maintenance period.
Damages to roads, bridges, and private property shall be repaired by Contractor. All fences and
other structures, which are damaged during construction, shall be restored to original.
Slopes, water course sides or banks which have been partially or totally demolished during the
execution of the works shall be properly consolidated and restored (without waiting for their -
natural consolidation and settling) complying to requirement of the concerned Authorities. The
bed of water-courses shall be restored to the original level. The banks and any excavated areas
shall be restored to the original levels and contours. The banks shall also be stabilized.
All boundary stones, which have been moved or removed during the WORK must be reset in
their original location to the satisfaction of the landowner concerned.
14.6 On completion of clean-up, the ROU shall be restored to such stable and usable condition as may
be reasonably consistent with the condition of the RoU prior to laying the pipeline. The
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Company shall be completely indemnified and held harmless by Contractor from any and against
all claims, demands, losses, expenses etc. that may arise in this behalf or the Company may
anyway suffer or sustain, relative to, arising out of, or in connection with same. The Company
may require from the Contractor signed Releases from landowners regarding satisfactory
indemnification and restoration of their lands.
14.7 Special precautions shall be taken near steep slopes prone to erosions and landslides. All
necessary steps shall be taken to ensure the rapid growth of grass by providing wicker barriers
and by regulating the drainage of surface waters.
14.8 All cadastral or geodetic markers, which may have been removed during the execution of the
WORKS, shall be restored in their exact position.
14.9 Ditches for which no instructions for their restoration have been issued, or restoration cannot be
done due to absence of banks, shall be restored as instructed by Company. The bed of ditches
crossed by the pipeline shall be cleaned over the full width of the ROU, also outside the ROU if
necessary. This restoration might contain but is not limited to the supply and installation of
proper materials for backfill and protection, the sodding or other precautions to prevent erosion
or guarantee the stability. All work has to be done after deliberation and acceptance of the
authorities and Company. Other field drains have to be restored over full width of ROU and if
necessary also outside the ROU by hand and/or special equipment as soon as possible.
14.10 Any subsidence, cave-ins, wash-outs, which have been caused during the pipeline construction
and maintenance, caused by whatever reason within the edge of ditches and open drains, shall be
repaired by Contractor immediately or at first notice given by Company.
14.11 After the clean-up, the ROU of pastures has to remain fenced considered suitable by the tenant
and to be removed during the maintenance period. When agricultural and other traffic (requested
by tenant) have to cross the ROU the cross-overs have to be fenced with the same material as the
ROU. If necessary, special materials have to be used to allow traffic on the cross-over. Fencing
of the right-of-use as specified shall not be removed until Contractor has obtained written
permission by Company. In general this has to be done during the maintenance period.
14.12 All openings in or damage to the fences or enclosures shall be repaired by installing new fencing
of a quality, which shall be at least equal to the parts damaged or removed. Provisional gates
shall be removed and replaced with new fencing. All repairs to fences and enclosures shall be
carried out by Contractor to the complete satisfaction of Company, landowner and/or tenant.
14.13 If, in the opinion of Company, the sod in pasture land has been damaged by vehicles and wheel
tracks are visible, the ROU shall be tilled with a disc-harrow or rotary cultivator several times.
The damaged sod shall be firmly cut up and thoroughly mixed through the top-soil. In general,
the ROU has also to be ripped. After this procedure no closed-in layers must be found and
sufficiently loose top-soil 25 to 30 cm thick must be present. The whole procedure must be
approved by Company. Subsequently, the entire ROU, which is part of pasture land, shall be
prepared for seeding and fertilized by Contractor according to the instructions of Company.
14.15 Adequate numbers of saplings of any plant/tree uprooted or cut during construction shall be
planted along the route as per the direction of the Company and in accordance with the
requirement of Authorities. The cost of sapling and its plantation shall be to Contractor's
account.
14.16 The ROU and the backfilled trench in particular has to be finished in such a way that after
settlement of the soil the fields are at their original level.
If during the maintenance period certain parts of the ROU are lower than the original level,
Company can order Contractor to bring these parts to the original level.
In cases where heavy damage has occurred to the structure of the subsoil as a result of adverse
circumstances, Company reserves the right to order Contractor to carry out special restoration
work. Said special work can include:
- fertilizing;
If during clean-up operations soil shortages become apparent outside the trench, Contractor shall
supplement said soil shortage using suitable materials, approved by Company.
If site and/or climatic conditions should render this necessary, Company shall have the right to
order Contractor to suspend certain parts of the work related to the clean-up and postpone it to a
later date.
If on site, as a result of the WORK and after careful backfilling and compacting, a sub-soil
surplus exists, this shall be worked up by grading and compacting below the sub-soil top layer
and as a rule this shall be done in the same plot of land. It shall not be permitted to remove the
surplus from the plot concerned, unless it concerns rejected soil, which has to be removed.
Working up surplus soil or removal of rejected soil shall be considered to pertain to the WORK.
To work a soil surplus into the ground, Contractor shall remove an additional strip of top soil
beside the trench. Next, the upper layer of sub-soil shall also be removed. Both soil types shall be
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stored separately across a width depending on the size of the soil surplus. The soil surplus shall
then be distributed across the trench thus widened, after which it shall be graded and compacted
and subsequently the top layer of sub-soil and the top-soil shall be replaced in the correct order,
in accordance with the Specifications.
In case Company has given prior permission for mixed excavation of the sub-soil as well as in
cases where Company deems mixed excavation permissible, the above provision of separate
storage of the upper layer of sub- soil shall not apply to the working up to the soil surplus.
In cases where the soil surplus can be worked up in others plots where soil shortages have arisen
due to the WORK, this shall only be done after prior permission by land-owner, land-user and
Company.
If due to unforeseen circumstances during backfilling and compacting there should not be
enough soil to fill the trench properly, or to install the crown height as stipulated, Contractor
shall supply the necessary backfill material.
Soil shortages shall be supplemented and applied before the top-soil is replaced.
The soil to be supplied shall be worked up in those locations and into those layers where a soil
shortage has been established. The quality of the supplemented soil shall be equal to that of the
shortage.
Defects Liability Period (defined as period of liability in the CONTRACT) means the period
calculated from the date certified in the Completion Certificate.
Company reserves the right to carry out instrumented pigging survey of the completed pipeline.
Contractor shall be responsible for making good with all possible speed at his expense any defect
in or damage to any portion of the Work which may appear or occur during the Defects Liability
Period and which arises either:
a. From any defective material (other than supplied by Company), Workmanship or design
(other than a design made, furnished or specified by Company and for which Contractor
has disclaimed responsibility in writing), or
b. from any act or omission of Contractor done or omitted during the said period.
If such defect shall appear or damage occur, Company shall forthwith inform Contractor thereof
stating in writing the nature of the defect or damage.
- Short-circuit in casings
- Construction defects such as dents, ovality, welding offsets/defects, etc. detected during
intelligent pigging survey, etc.
Company reserves the right to have the required Computerised Potential Logging Test executed
during the DEFECTS LIABILITY PERIOD and whenever weather conditions are more
favorable for this job. The work shall (at or as soon as practicable after the expiration of the
Defects Liability Period) be delivered to Company in the conditions required by the
CONTRACT, fair wear and tear excepted, to the satisfaction of Company. Contractor shall finish
the work, if any outstanding, at the date of completion as soon as possible after such date and
shall execute all such work.
1.1 This specification covers the minimum requirements of supply, work and operation to be
performed by Contractor for hydrostatic testing of cross-country steel pipelines transporting
hydrocarbons in liquid or gaseous phase under high pressure.
This specification does not cover the requirements of caliper pigging, drying/ pre-commissioning
of the tested pipelines.
1.2 This specification shall be read in conjunction with the conditions of all specifications and
documents included in the CONTRACT between Company and Contractor. Unless specified
otherwise, all sections of this specification shall apply to all specifications referred in this
specification.
.
2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS
2.1 Reference has been made in this specification to the latest edition (edition enforce at the time of
floating the enquiry) of the following codes, standards and specifications.
2.2 In case of conflict between the requirements of above mentioned codes, standards, specifications,
practices, the most stringent requirement shall govern.
2.3 For the purpose of this specification the following definitions shall hold:
3.0 GENERAL
3.1 Hydrostatic test shall be performed on the entire length of the pipeline. Hydrostatic test shall be
performed in accordance with approved Hydrostatic Test Diagrams clearly indicating the number
of test sections and minimum and maximum test pressures in each test sections. The maximum
length of each test section shall not exceed 50 Kms.
3.2 For pipeline sections which in Company's opinion, once installed would require an inordinate
amount of effort for repair in case of a leak, a provisional pre-test shall be conducted. However,
after installation, such pre-tested sections shall be tested again along with the entire pipeline.
3.3 Hydrostatic test shall commence only after mechanical and civil works completion, i.e., all welds
have been accepted and the pipeline has been laid and backfilled. Hydrostatic test shall include
those sections which have been previously tested viz. Rail/ road crossings, major water crossings
including test on banks and in place after installation, and scraper traps at the terminals.
Contractor shall perform all works required for hydrostatic testing after obtaining prior written
approval from the Company.
Contractor shall prepare for Company's approval a hydrostatic test procedure manual. The
procedure shall strictly comply with the requirements of this specification and shall be submitted
to Company for approval well in advance. The procedure manual shall include all temporary
materials and equipment, but not be limited to the following items:
a) A diagram for the system to be tested, indicating all fittings, vents, valves, temporary
connection, relevant elevations and ratings. The diagram shall also indicate injection
locations and intake and discharge lines.
d) The type and number of pigs to be used, gauging plate parameters, sequence of pigs to be
launched during pig tracking system for cleaning and removal of air pockets. Pig
inspection procedures, including procedure to be followed in case the caliper pig
indicates damage to pipeline in access of the values specified in governing codes.
e) Procedure for levelling and stabilization after filling and for pressurization and to allow
for temperature stabilization.
h) Procedure for dewatering the pipeline sections(s) after testing, including a complete
description of all proposed equipment and instruments (including spares), their location
and set-up, the type and sequence of pigs and the pig tracking system along with the pig
specification.
5.1 The duration of hydrostatic test shall be minimum 24 hours after thermal stabilization.
5.2 Unless specified otherwise in the Contract, the hydrostatic test pressure shall be as follows:
a) 1.25 times the design pressure for pipeline located in Class-1 and Class-2 locations as
per ASME B 3 1.8.
b) 1.4 times the design pressure for pipeline located in Class-3 and Class-4 locations as per
ASME B 31.8.
a) 1.25 times the design pressure for pipeline handling liquids including Liquefied
Petroleum Gas (LPG).
The test pressure, as calculated above, shall be generated at the highest point in the section under
test. At any point in the test section hoop-stress due to test pressure and static head shall not
exceed 95% of the SMYS of pipe material.
The Contractor shall furnish all necessary equipment for performing the work as stated in
cleaning, flushing, filling, stabilising, testing and dewatering procedures.
This shall include, but not be limited to the following equipment and instruments:
- Cleaning pigs with spring loaded steel wire brushes. For internally coated pipes, the pigs
shall be provided with nylon/ polyurethane brushes.
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- Four cup batching pigs.
b) Fill pumps:
The Contractor shall determine the type and number of fill pumps in order to guarantee the
following:
c) Variable speed positive displacement pumps equipped with a stroke counter to pressurize the
pipeline. The pump shall be capable of exceeding the maximum test pressure by at least 20 bar.
d) Two positive displacement meters to measure the volume of water used for filling the line. These
meters shall be provided with a calibration certificate not older than one month.
e) Portable tanks of sufficient size to provide a continuous supply of water to the pump during
filling and pressurizing.
g) Dead weight testers with an accuracy of 0.01 bar measuring in increment of 0.05 bar provided
with a calibration certificate not older than one month at the time of the first hydrostatic test in
the pipeline.
h) Two 48 hours recording pressure gauges complete with pressure recording charts and ink, duly
tested with dead weight tester prior to use. These shall be installed at the test head.
l) Two laboratory thermometers of range 00C to 600C and with accuracy of ± 0.10C to be used in
thermowells.
m) Means to measure the volume of water necessary to drop the line pressure by 0.5 bar (container
on scales or graduated cylinder)
o) Communication equipment suitable for a continuous connection between the beginning and the
end of the test section and with the inspection team along the line, in accordance with the
requirements of Local Authorities.
p) The temporary scraper traps shall be installed according to the test section fixed in the test
procedure manual. Proper piping and valving arrangements shall be available to allow lunching
and receiving of each pig independently.
The test heads shall be sized in conformity with ASME specification Section VIII, Division 2
with particular reference to Appendices 4 and 5.
q) Thermocouples for measuring the temperature of the pipe wall shall be installed on the pipeline
to be tested:
- One (1) thermocouple at about 500 m distance from the pumping head.
- One (1) thermocouple every 2500 m of the pipe. The spacing may be increased to
maximum 5000 m depending on the terrain and nature of sub soil along the alignment of
test section.
- One (1) thermocouple at about 500 m distance from the terminal head.
Thermocouples shall be attached on the external surface of the pipe after removal of external
coating and shall be adequately protected and Company's coating instructions shall be followed.
After successful testing, the thermocouples shall be removed and damaged coating shall be
repaired as per applicable coating repair procedure, approved by Company.
7.0 PROCEDURES
7.1 Equipment andlor parts which need not or must not be subjected to the test pressures or which
must not be tested with water, must be disconnected or separated from the pipeline to be tested.
7.2 If the difference of minimum and maximum atmospheric temperature should cause thermal
instability on the pipe section directly exposed to atmospheric condition, the scraper traps and
above ground pipeline shall be properly protected.
The pipeline test shall exclude long segments of line exposed to atmospheric conditions, viz.
aerial lengths on piers, suspension bridges, etc. Such sections shall be tested separately.
7.3 The test medium shall be soft non-aggressive water furnished by the Contractor. The water to be
used shall be filtered, shall not be contaminated and free from sand of silt. Contractor shall
submit laboratory test reports of water used for testing. The possible use of sea water shall be
subjected to its degree of cleanness, the possibility of obtaining a pre-determined salinity
neutralisation and the use of corrosion inhibitors, this at the sole discretion of Company.
Contractor shall provide Company approved corrosion inhibitors, oxygen scavengers and
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bactericides to be added to the test water. The Contractor shall furnish and install all temporary
piping, which may be necessary to connect from source of water to its pump and manifolds/
tankages.
The following products are acceptable for corrosion inhibition of the water used for hydro
testing:
a. All chemicals for hydrotesting shall be procured from approved vendors. Chemicals older than
three months shall not be used.
b. Company representative shall inspect the chemical containers and take random samples prior to
its use. Contractor shall get the samples tested in an GAIL nominated Govt./PSU/other
competent laboratories. Testing shall be carried out for accelerated % corrosion inhibition
efficiency, % SRB and TBC killing efficiency test. Company reserves the right to witness the
testing. The test report shall be submitted to Company for approval prior to undertaking hydro
testing works.
c. Only those chemicals which have passed the above tests shall be used for hydrotesting.
7.4 Before filling operation, the Contractor shall clean the pipeline by air driven pigs provided with
spring loaded brushes and chisels to remove all mill scale, rust, sand, etc. from the internal of
pipe section. For this purpose, temporary headers for air cleaning shall be attached to the
pipeline. The number of pig runs is depending upon the cleaning results and shall be determined
by the Company at site.
7.5 After cleaning the pipeline by using air and acceptance by Company, gauging shall be carried out
by using gauging pig. The gauge plate diameter shall be equal to 95% of inside diameter of the
heaviest all pipe in the test section. While computing the ID of heaviest wall pipe, pipe
manufacturing tolerances shall not be considered. A 10 mm thick aluminium plate shall be used
for making gauge plate.
After acceptance of gauging operation, air header shall be cut and removed. Pre-tested test
headers loaded with three numbers of four cup batching pig shall be welded to test section.
Joints between test header and pipeline shall be radiographed. Un-inhibited water equal to 10%
of the volume of test section shall be introduced in front of the first pig. The first pig shall be
launched by introducing about 1.5 km un-inhibited water. Then the second pig shall be launched
by pumping the inhibited water till the second pig is received at the other end. Subsequent to
receipt of second pig, the pressurization and thermal stabilization operation can commence.
After a check has been made to confirm if the pressure has attained at least 1 bar (g) on the
highest section, the thermal stabilization can be started.
Thermal equilibrium between the pipeline and environment shall be checked through the
Thermocouples installed on the pipeline.
7.7 Pressurisation
7.7.1 The pressurization shall be performed in the presence of Company at a moderate and constant
rate not exceeding 2 bars/ min. One pressure recording gauge shall be installed in parallel with
the dead weight tester. Volume required to reach the test pressure shall be recorded periodically
throughout the pressurization as follows:
a) each 5 bar increments up to 80% of test pressure as recorded by the dead weight tester;
b) each 2 bar increments between 80% to 90% of test pressure as recorded by the dead
weight tester;
C) each 0.5 bar increments between 90% of the test pressure to full test pressure as recorded
by the dead weight tester.
During the pressurisation to each test pressure, two tests shall be carried out for the calculation of
air volume in the pipeline under test.
In case, during the hold pressure periods indicated above, a decrease in pressure in observed, the
above operations shall not be repeated more than twice, after which the line shall not be
considered capable of test, until the Contractor has isolated and eliminated the cause for the lack
of water tightness.
In order to check the presence of air in the pipeline, two separate consecutive pressure lowering
of 0.5 bar shall be carried out after pressurizing to test pressure.
For calculation of air in the pipeline the second pressure lowering shall be used, and the relevant
drained water shall be accurately measured (V1). This amount measured shall be compared to
the theoretical amount (Vp) corresponding to the pressure lowering that has been carried out, by
using the procedure outlined in clause 12.1 of this specification.
In order that the above ratio is acceptable, it shall not differ from 1 by more than 6% (i.e.1.06). If
the air found in the pipeline is within the above established tolerance, then the pressurising can
continue. If the ratio VINP exceeds 1.06, the hydrostatic testing cannot go on and additional pig
passages shall be performed to remove the air pockets.
The test shall be repeated as per the above procedure until above estimated tolerances are
satisfied. The pressurising can then continue, to reach the value of the test pressure.
7.10 Testing
After the section has been pressurised and the air volume test has given acceptable results the test
pressure shall be held for a minimum of 24 hours after stabilisation. After temperature and
pressure has stabilished, the injection pump shall be disconnected and all connections at the test
heads shall be checked for leakage. The pressure recorders shall then be started with the charts in
a real time orientation for continuous recording throughout the test.
During the testing period the following measurements shall be recorded/ reported
- every two hour the ambient temperature and the pipe temperature at the thermocouples.
All data shall be recorded on appropriate forms attached to the hydrostatic test procedure
manual. Care shall be taken that the maximum test pressures are not exceeded. Bleed-off water
shall be accurately measured and recorded.
8.0 ACCEPTANCE
8.1 The hydrostatic test shall be considered as positive if pressure has kept a constant value
throughout the test duration, except for change due to temperature effects. Such changes shall be
evaluated as described under clause 12.2 of this specification.
The pressure change value as a function of temperature change shall be algebraically added to
the pressure value as read on the meters. The pressure value thus adjusted shall be compared
with the initial value and the test shall be considered as acceptable if the difference is less than or
equal to 0.3 bar. Incase of doubt the testing period shall be extended by 24 hours.
8.2 If test section fails to maintain the specified test pressure after isolation, Contractor shall
determine the location of leakage or failure by suitable means. All leaks and failures within the
pipe wall or weld seams shall be repaired by replacement of entire joint or joints in which
leakage or failure occurs. In those cases where leaks occur in circumferential welds the method
of repair shall be determined by the Company. Contractor shall comply with instructions of the
Company whether to replace a section of the line pipe that includes the line leak or whether to
repair the circumferential weld. This repair should, however, meet the requirements of applicable
welding specification enclosed with the Contract. Where failures occur in pipeline field bends,
bends shall be replaced with same degree of bends. After completion of repairs, the hydrostatic
test shall be repeated in full, as per this specification.
8.3 The cost of repairs or replacements, followed by refilling and repressurising the line, due to poor
workmanship, shall be borne by the Contractor. In the event of leaks or failures resulting from
faulty Company furnished materials, Contractor shall be reimbursed as per the provisions of
Contract. All work of reinstalling line pipe, to replace failures, shall be done in accordance with
the relevant specifications included in the CONTRACT.
8.4 Contractor shall haul and stockpile all damaged and defective pipes to storage location
designated by the Company. All cracks and splits resulting from failure shall be coated with an
application of grease to preserve the characteristics of failures from corrosion. Joint of failed
pipes shall be marked with paint, with a tag indicating failure details, date and location of failure
and pressure at which failure occurred.
9.0 TERMINATION
After the positive result of testing and all the data have been gathered, the test shall be terminated
upon written approval given by the Company. The pipeline shall be slowly depressurised at a
moderate and constant rate as instructed by Company. Subsequent operations such as caliper
9.1 Contractor shall dewater the tested line as per the following requirement after test acceptance.
The dewatering shall be carried out by using four cup pigs and foam pigs driven by compressed
air. The detailed dewatering procedure shall be deployed by the Contractor in such a way as to
provide adequate control of pigs during dewatering. Pigs and equipment required for dewatering
the line shall be furnished by Contractor and shall be approved in advance by the Company. Four
cup pigs shall first be passed through the line to displace the water. Foam pigs shall then be
passed in order to complete the line dewatering. Contractor shall use a number of foam pigs each
in different colours/numbered for this purpose. The line shall be considered dewatered when a
negligible amount of water is flushed out by the last foam pig and approval is given by the
Company.
9.2 During dewatering, care shall be taken to properly dispose the discharging water in order to
avoid pollution, damages to fields under cultivation and/ or existing structures and interference
with the traffic. Before the start of dewatering and disposal of hydrotest water, a procedure for
treatment of inhibited water to prevent pollution shall be submitted by Contractor to Company
for review and approval.
9.3 Upon completion of the testing and dewatering operation, any provisional traps for pigs and all
other temporary installation relating to the test shall be removed. Subsequently, the individual
sections of the line already tested shall be joined in accordance with the requirements of relevant
specifications issued for the purpose.
A complete report signed by Contractor and the Company shall be submitted upon completion of the
hydrostatic test for each test section.
11.0 MEASUREMENTS
The water volume added to the section to be tested shall be measured during the filling stage
through a positive displacement meter (a turbine meter may also be used).
In the calculation, as per clause 12.1 of this specification, use shall be made of the geometrical
volume of the section in question. The water amount that has been let into the section shall be
measured during the pressurisation stages thorough positive displacement meters or turbine
meters.
Pressure shall be measured with a dead weight tester that shall permit readings of at least 0.05
bar.
During the test, the pressure shall be recorded by means of a recording pressure gauge featuring
the following specifications:
a) Water temperature shall be taken at every 2 hours through the thermocouples that have been
installed along the section under test on the pipe wall.
The thermocouples' sensitivity shall enable temperature readings with the accuracy of ±0.20C.
c) Ground temperature shall be taken by measuring pipe temperature at the thermocouples prior to
starting the filling operation.
d) Environmental temperature shall be recorded from the beginning of pressurization to the end of
the test by means of a recording thermometer featuring the following characteristics:
12.0 CALCULATIONS
12.1 The theoretical water amount that is necessary for filling the section to be tested shall be
obtained from the geometrical volume of the section considering the pipe tolerances.
The theoretical water amount that is necessary for pressurizing the section shall be calculated by
means of the following formula:
Where
Where
In addition to all that has been expressly described in the procedures for carrying out the tests,
the following additional requirements shall be complied with:
13.1 Provision shall be made for the installation of no-admittance signs to unauthorised personnel
from the roads to the R.O.U.
13.2 Signs stating 'PIPE UNDER TEST-KEEP OFF" with local language translation shall be placed
where the pipeline is uncovered, and particularly where the provisional traps and stations are
located. Such areas shall be suitably fenced in such a way as to prevent access of unauthorised
personnel. No unauthorised personnel shall be closer than 40M to the pipeline or equipment
under test.
13.3 Provisional scraper traps shall be installed in compliance with methods and suitable location so
that their rupture cannot cause any injuries to the personnel or third parties.
13.4 The test station shall be placed in such a location as to prevent it from being affected by a
catastrophic failure in the test head.
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NEW DELHI PIPELINES S – 04 – 02 – 029 Page 16 of 22
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13.5 Once dewatering is over the sectionalising valves and other valve assemblies tested previously,
shall be installed at locations shown in the drawings and in accordance with the procedures
contained in the relevant specifications. All thermocouples installed in the pipeline shall be
removed and damage corrosion coating shall be repaired using Company approved materials and
procedure.
When so stated in the CONTRACT, to preserve/conserve the pipeline for a specified duration,
Contractor shall completely fill the pipeline with water, with sufficient quantity of corrosion
inhibitors depending upon quality of water and the period of conservation, at a pressure to be
agreed upon with the Company at a later stage. Contractor shall obtain necessary approval from
the Company of the procedure, type and quality and quantity of inhibitors used before
commencement of the works.
3.0 GENERAL
REFERENCE DRAWINGS
1.1 This specification covers the minimum requirements for supply, fabrication and
erection of pipeline markers to be installed by CONTRACTOR at various locations
along the route of a cross-country pipeline.
1.2 This specification shall be read in conjunction with the conditions of all
specifications and documents included in the CONTRACT between COMPANY and
CONTRACTOR.
Reference has been made in this specification to the latest edition of the following code:
3.0 GENERAL:
3.1 CONTRACTOR shall supply, fabricate and install the Pipeline Markers along the
pipeline route. The location of markers as indicated in the approved drawings shall
be treated for guidance purpose only and the exact location of the markers shall be
based on AS BUILT drawings and as directed by COMPANY.
3.2 The pipeline markers shall be fabricated and installed in accordance with the GAIL
standard drawings included herein. Before start of fabrication of the markers, the
CONTRACTOR shall prepare and submit for COMPANY'S approval, the detailed
scheme for the marker plates as applicable for the project. All the markers shall be
painted in accordance with the requirements of Standard Specification for Shop
and Field Painting (Specification No. S-05-02-014). The painting scheme shall be
suitable for Normal Corrosive Environment.
3.3 The pipeline markers shall be installed, as far as possible, at locations such that
they do not cause any hindrance to the regular use of the land or to the traffic.
Aerial Markers shall in general be installed along the pipeline at every five (5) kilometers
intervals and at places specified by COMPANY. Refer GAIL Standard Drawing No. S-04-01-
016 for details.
Kilometer Markers shall in general be installed along the pipeline at every one (1)
kilometer interval. Markers shall indicate cumulative distance in kilometers from the
reference station, as directed by COMPANY. A kilometer marker is not required, if the
relative distance between its location and any pipeline warning sign is less than 200
meters. Refer GAIL Standard Drawing No. S-04-01-014 for details.
DOCUMENT NO. REV-0
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NEW DELHI S-04-02-030
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6.0 PIPELINE WARNING SIGN:
Pipeline Warning Sign shall identify the existence of the pipeline and display the name of
the COMPANY, with an emergency telephone number, as shown in GAIL Standard
Drawing No. S-04-01-018.
Right-of-Use boundary markers shall be fabricated as per the drawings and shall be
installed at every 250 meters interval along the entire pipeline route. These shall be
installed on either side of the pipeline alignment to define the ROW boundary limits.
These shall also be installed at pipeline turning points to maintain the continuity of the
ROW limits. Refer GAIL Standard Drawing No. S-04-01-015 for details.
Direction Markers as shown in GAIL Standard Drawing No. S-04-01-017 shall be installed
to identify the significant Turning Points of the pipeline during serial traverse. One
direction marker shall be installed at each Turning Point, two more direction markers shall
be installed along the pipeline alignment, one on either side of the Turning Point at 200 m
from the Turning Point.
The Navigable Waterway Pipeline Crossing Warning Sign shall be fabricated in accordance
with GAIL Standard Drawing No. S-04-01-019. Such Warning Sign shall be installed one
on each bank of navigable water courses at the pipeline crossing location, in lieu of the
Pipeline Warning Sign described in Clause 6.0 of this specification.
DOCUMENT NO. REV-0
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NEW DELHI S-04-02-030
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10.0 SPECIAL MARKERS:
Change in class / zone locations for pipelines conveying gas and HVP
products.
The above data may be provided on other types of marker (except ROU boundary
marker), if the relative distance between the two does not exceed 100m.
1.0 SCOPE
2.0 RECORDS
1.1 This specification covers the minimum requirements of various records, reports and
drawings for all aspects of pipeline construction to be prepared by the
CONTRACTOR and submitted to the COMPANY at intervals as described in this
specification and as directed by the COMPANY.
1.2 All documents required to be prepared and submitted by the CONTRACTOR as per
this specification shall be in addition to the various reports, records, methodology
statements, calculations, drawings etc. to be submitted by the CONTRACTOR for
COMPANY'S record, review or approval as per the requirements of all other
specifications included in the CONTRACT between the COMPANY and the
CONTRACTOR.
1.3 This specification shall be read in conjunction with the conditions of all
specifications and documents included in the CONTRACT between COMPANY and
CONTRACTOR.
2.0 RECORDS:
The CONTRACTOR shall submit daily, weekly, monthly and after completion, to the
COMAPANY, various records and reports for COMPANY'S documentation purpose during
and immediately after the construction. This shall as a minimum include, but not limited
to the following:
2.1 Daily
Accidents
Damages
Materials Receipts
Progress planned
Reports of accidents
Reports of damages
Prices variations
2.3 Monthly
2.4 Further, CONTRACTOR shall supply for approval, if required, to the COMPANY with
document such as but not limited to:
Time schedule
Vendor drawings.
Coating procedure.
Installation of crossings.
Hydrostatic testing
Blasting
Water samples
Hydrostatic test
Calibration test
Blasting trials
Manuals
Waste disposal
2.5 The CONTRACTOR shall submit to COMPANY, colour photographs (hard copy as
well as digital format) taken through digital camera (having resolution > 1 million
pixels) of various construction activities/operations at regular intervals. Size,
number and frequency of the photographs shall be mutually agreed upon between
the CONTRACTOR and the COMPANY. The CONTRACTOR shall make video
recordings of all operations right from the start of construction till the completion
of the work, covering to the extent as instructed by COMPANY and submit to
COMPANY. Upon completion of the work, the CONTRACTOR shall submit edited
master tape plus six copies of video recording in VCD / DVD formats or any other
format ordered by the COMPANY. The duration of video recording shall be of ½
hour and shall cover all aspects of the job.
3.1 General
Route maps
Alignment sheets
Detail drawings (road, railway, minor water crossings, major water crossing,
valley crossings)
Special installation.
If required by the COMPANY, the CONTRACTOR shall update the diskettes for
drawings issued for construction of the job. -
The CONTRACTOR shall prepare a complete set of "As-built" drawings. From the
start of construction, the CONTRACTOR shall, on daily basis, process any changes
in two sets of drawings. Deleted parts shall be indicated in red, new parts in blue,
remarks in green and unchanged parts in yellow. Said drawings shall be kept at
site and shall be available to COMPANY at all times. The CONTRACTOR shall
prepare "As-built" drawings based on these data. On completion of the work, one
revised film transparency of all drawings made "As-built" by CONTRACTOR
containing the "As-built" information as well as one complete set of CD ROM
containing "As-built" drawings shall be handed over to COMPANY.
The CONTRACTOR shall prepare and submit a specimen of the layout of the
drawings for COMPANY'S approval.
The surveyors shall daily take care of all measurements required such as but not
limited to:
Vertical level with regard to Mean Sea Level of pipeline and grade.
Location and type of bends, fittings etc. and grades, points of intersection.
Type of soil.
Type of rock.
STANDARD SPECIFICATION FOR DOCUMENT NO. REV-0
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NEW DELHI CONSTRUCTION S-04-02-031
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Type of blasting and ripping
Sand Padding
Sequential number
Alignment sheet number and at least the location thereon of two welds on
every page of the Pipe Book.
Further,
Diameter of pipeline
Wall thickness
Pipe number
Coating
Data of welding
Direction of working
Weld number
Welder number
Type of welding, electrodes, diameter of electrodes etc.
Heat treatment
In order to achieve this, the CONTRACTOR shall identify all pipe elements. Sample
format of Pipe Book shall be submitted for COMPANY approval.
1.1 This specification covers the minimum requirements for materials, personnel,
transportation, storage and use of explosives for grading of Right of Use (ROU) and
excavation of trenches for the burial of pipelines in rocky terrain.
1.2 This specification does not cover the construction or operation of permanent
magazines.
2.1 The following National and International regulations and codes shall be used:
3.0 GENERAL
3.1 The CONTRACTOR shall acquaint himself and comply with all the applicable local laws
and regulations concerning storing, handling and the use of explosives. All such laws,
regulations and rules etc., as enforced from time to time shall be binding upon the
CONTRACTOR. National/Local Laws and Regulations shall take precedence over this
specification in the event of conflict. All conflicts shall be brought to the notice of the
COMPANY.
3.2 The requirements stated herein however in no way relieve the CONTRACTOR of this
responsibility of carrying out safe blasting operations and shall be solely responsible for
damages and claims thereof.
3.3 The use of explosives requires an approval from the Chief Inspector of Explosives
and/or his authorized Inspector. It shall be the responsibility of the CONTRACTOR
to obtain all such permits and observe all requirements regarding the safe storage,
handling and use of explosives. All expenses incurred in this regard shall be to
CONTRACTOR'S account.
STANDARD SPECIFICATION FOR SPECIFICATION REV-0
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NEW DELHI S – 04 – 02 – 032 Page 3 of 11
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3.4 Contractor shall inform the COMPANY in writing at least four(4) weeks prior to planned
use of explosives.
3.5 Contractor shall notify the COMPANY prior to any blasting in the proximity of overhead
power lines, roads, communication lines, pipelines, utility services or other services and
structures above and below ground. Before, starting blasting operations, local
authorities and owners of utilities shall be consulted to check on the presence of
services which could be damaged and their approval obtained to undertake blasting
operations. The distances to nearest structures(houses, offices, factories) or service
shall also be taken into consideration when planning blasts so that ground vibration and
air-over pressure is kept within acceptable levels as given in section 11.0 of this
specification.
3.6 CONTRACTOR shall prepare an Explosives Handling and usage Procedure for the
information of the COMPANY which shall incorporate the following:
- Rock characteristics
- Type of explosives
4.0 MATERIALS
4.1 All materials such as explosives, detonators, fuses, tamping materials etc. that are
proposed to be used by the CONTRACTOR in blasting operations, shall be as Approved
for use in the Country.
4.2 All electric detonators used in the blast shall be of the same electrical sensitivity and
be produced/procured from the same manufacturer.
4.3 The detonators used shall be capable of giving effective blasting of the explosives.
Damaged explosive materials shall be destroyed by a responsible person as per
manufacturer's instructions or returned to the manufacturer.
4.5 All blasting materials and testing equipment shall be regularly tested for correct
performance. The intervals between test shall be decided after consideration of the
local factors, but tests shall always be carried out if the blasting materials and/or test
equipment have been subjected to abnormal conditions, or following misfires.
Guidelines/recornrnendations of the manufacturer shall be adhered to.
4.6 All packaging and.other waste materials gathered together during blasting operation
shall be burnt after the blast has been fired.
The burning site shall be chosen at a safe distance with due respect to prevailing wind
strength and direction, at least 100 meters from explosives stores and other premises. A
minimum of two fire extinguishers shall be on hand during burning activities.
5.0 PERSONNEL
5.1 Excavation by blasting will be permitted only under personal supervision of competent
and licensed persons and by trained workmen.
5.2 The storage of explosives shall be in the charge of a person approved by the COMPANY.
COMPANY may, if necessary, ask police inquiries being made as to his reliability,
antecedents etc.
6.1 The CONTRACTOR shall build a magazine for storing the explosives. The site of the
magazine, its capacity and design shall be subject to approval by the COMPANY and the
inspector of Explosives before the fabrication is taken up. As a rule the explosives
should be stored in a clean, dry, well ventilated, bullet proof and fire proof building, at
an isolated site. Adequate security shall be provided to ensure no unauthorized entry
into the magazine. A notice shall be hung next to magazine entrance prohibiting entry
of unauthorized persons.
6.2 CONTRACTOR shall comply with National/Local Regulations and specifications for
truck mounted mobile explosives store. Mobile stores shall only carry ONE DAY'S
Explosives requirements and shall be parked overnight inside the compound at the
authorized magazine.
6.3 All safety precautions and necessary equipment for maintenance, operation of mobile
stores, as required by local authorities or regulatory bodies shall also be
installed/provided on the Mobile Store.
6.4 A careful and day-to-day account of all explosives shall be kept by the CONTRACTOR in
a register and in an approved manner. The register shall be produced by the
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NEW DELHI S – 04 – 02 – 032 Page 5 of 11
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CONTRACTOR, for the inspection of the COMPANY/Inspectorof Explosives when so
required by the later.
Any loss, damage or theft shall be reported immediately to the necessary local authorities and
to the COMPANY.
6.6 Magazine-shoes without nails shall, at all times, be kept in the magazine, and a wood-
tub or cement trough, filled with water shall be fixed near the door of the magazine.
1) not to put their feet on the clean floor unless they have magazine-shoes on.
11) not to allow the magazine-shoes to touch the ground outside the clean floor.
111) not to allow any dirt or grit to fall on the clean floor.
6.8 No matches or inflammable material shall be allowed in the magazine. Light shall
be obtained from an electric storage battery lamp.
6.9 No person having articles of steel or iron on him shall be allowed to enter the magazine.
No tools or implements other than those of copper, brass, gun metal or wood shall be
allowed inside the magazine.
Oily cotton, rags, waste and articles liable to spontaneous ignition, shall not be allowed inside
the magazine.
6.10 Boxes of explosives shall not be thrown down or dragged along the floor and shall be
stacked on wooden trestles. Open boxes of explosives shall never be expcsed to the
direct rays of the sun. Empty boxes or loose packing materials shall not be kept inside
the magazine.
6.11 The magazine shall have a lightning conductor, which shall be got tested at least
periodically, by an officer authorized by the COMPANY, the testing fee shall be to the
CONTRACTOR'S account.
6.12 The magazine shall be inspected periodically by an officer representing the COMPANY,
who will see that all the rules are strictly complied with. He will notify all omissions etc.
to the CONTRACTOR, who shall rectify the defects within a period of 3 days from the
7 .O PREPARATION OF EXPLOSIVES
7.1 CONTRACTOR shall submit the following procedure for INFORMATION of the
COMPANY as a minimum.
- Loading of explosives
- Initiation of blasting
- Safety of personnel
- Vibration control
- Misfires
- Emergency procedures
7.2 Trial blasts in conjunction with vibration recording shall be carried out for each rock and
trench type, in order to assess rock breakability and vibration levels. These trial blasts
shall be carried out prior to actual trench blasting of the pipeline route.CONTRACTOR
shall conduct trial digs as directed by COMPANY in order to check suitability of the
lasting pattern and to measure vibration levels to ensure vibration levels are below the
allowable maximum.
7.3 "Weight per Distance Tables" shall be drawn up from these trials.
7.4 The detonators shall never be forced into the primer cartridge. It shall be inserted in a
hole made by a wooden, copper, brass or aluminum pricker. The detonator shall be
firmly embedded in the primer so that it is not pulled out of place during loading.
7.5 Detonators shall be activated electrically. In proximity of electric over-head power lines,
CONTRACTOR may use non-electric system with the approval of COMPANY. Fly rock
7.7 Explosive and detonators shall be carried in separate boxes, tightly closed, and
transported separately. For the conveyance of primers special containers shall be used.
7.8 Explosives shall be stored and used chronologically to ensure that the ones received
earlier are being used first.
7.9 A make-up house shall be provided at each working place in which cartridges shall be
made up by experienced men as required. The make-up house shall be separated from
other buildings. Only electric storage battery lamps shall be used in this house.
The primers shall not be prepared near open flames or fires. The work of preparation of
primers shall always be entrusted to the qualified and approved personnel. Primers shall
be used as soon as possible after they are ready.
9.1 The work of charging shall not commence before all the drilling work at the site is
completed and the COMPANY has satisfied itself to that effect by actual inspection.
9.2 The lead wires shall be kept away from conductors or sources of stray current While
charging, open lampslflames shall be kept away.
9.3 Only wooden tamping rods without any kind of metal on them shall be used.
9.4 Only one cartridge shall be inserted at a time and gently inserted to the required depth
with the tamping rod. The sand, clay or other tamping material used for filling the hole
completely shall not be tamped too hard.
9.5 Blasting shall not take place after sunset or before sunrise unless specific approval is
first obtained by CONTRACTOR from local authorities and the COMPANY.
9.6 The site of blasting operations shall be prominently demarcated by red danger flags.
The order of fire shall be given only by the supervisor-in-charge of the work and this
order shall be given only after giving the warning signal three times, so as to enable all
the labor, watchmen etc. to reach safe shelter and after having ascertained that nobody
is within the danger zone.
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9.7 A buegle with a distinctive note shall be used to give the warning signals. The buegle
shall not be used for any other purpose. All the labor shall be made acquainted with the
sound of the buegle and shall be strictly warned to leave their work immediately at the
first warning signal and to take safe shelters, and not to leave the shelters until the all
clear signals have been given.
9.8 All the roads and foot-paths leading to the blasting area shall be watched
10.1 Only the Supervisor-in-charge shall keep the key of the firing apparatus and shall keep
it always with himself.
10.2 Special apparatus shall be used as source of current for the firing operations. Power
lines shall not be tapped for the purpose.
10.3 The firing cable shall have a proper insulating cover so as to avoid short circuiting due
to contact with water, metallic parts or rock.
10.5 The firing cable shall be connected to the source of current only after ascertaining that
nobody is in the area of blasting
10.7 After firing, whether with or without an actual blast, the contact between the firing
cable and the source of current shall be cut off before any person is allowed to leave
the shelter.
10.8 During storms, charging with electrical detonators shall be suspended. The charges
already placed into the holes shall be blasted as quickly as possible after taking all the
safety precautions and giving necessary warning signals. If this is not possible, the site
shall be abandoned till the storm has passed.
11.1 CONTRACTOR shall use COMPANY approved vibration recording system capable of
measurement in three axes (tri-axial). The device shall have an accuracy of 0.0025 mm
and a resonance of 2 Hz.
11.3.2 Areas with existing buried or above ground facilities within 500 m.
- 20 mm/sec. At a surface measured distance from the trench center line towards
the nearest existing facilities.
11.4 The particle velocity levels are provided for the guidance only, CONTRACTOR
shall be responsible and liable for any injury to life or damage to property/facilities.
12.0 MISFIRES
12.1 If it is suspected that part of the blast has failed to fire, or is delayed, sufficient time
shall be allowed to lapse before entering the danger zone. When fuse and blasting caps
are used, a safe time should be allowed and then the Supervisor alone shall leave the
shelter to see the misfire.
12.2 Drilling near the hole that has misfired shall not be permitted until one of the two
following operations have been carried out by the Supervisor:
I) The Supervisor should very carefully (when the tamping is of damp clay) extract
the tamping with a wooden scraper or jet of water or compressed air (using a
pipe of soft material) and withdraw the fuse with the primer and detonator
attached. A fresh primer and detonator with fuse shall then be placed in this hole
and fired.
II) The Supervisor shall get one foot of the tamping cleaned off and indicate the
direction by placing a stick in the hole. Another hole may then be drilled at least
9" away and parallel to it, this hole should then be charged and fired. The
balance of the cartridges and detonators found in the muck shall be removed.
12.3 The Supervisor shall at once report to the office all cases of misfire, the cause of the
misfire and the steps taken in connection therewith.
12.4 If a misfire has been found to be due to defective detonator, or explosive, the whole
quantity from the box from which the defective articles were taken must be returned to
12.5 Re-drilling the holes that have misfired either wholly or partly shall not be permitted.
2.0 REQUIREMENTS
5.0 CROSSINGS
7.0 CHAINAGE
9.0 PROFILES
2. ALIGNMENT SHEET
This specification covers the minimum requirements of topographical survey along the
pipeline route including locating the centre-line of pipeline alignment on the ground,
constructing survey monuments, field measurements for planimetry and profiles and
preparation of drawings and documents.
This specification also covers the minimum requirements for soil investigation for the
purpose of visual engineering classification of soil along the pipeline route.
2.0 REQUIREMENTS:
2.1 All survey works shall be performed by or under the supervision of a qualified land
surveyor.
2.3 The readings and noting shall be neat, legible and scorings and over-writing shall
be duly initialed by the Surveyor.
The Surveyor is expected to make himself aware of the general conditions of the
terrain before starting detailed survey.
3.1.1 Surveyor shall make a preliminary survey along the route of the proposed pipeline
to establish and flag control points.
3.1.2 Surveyor shall locate and identify the existing features or obstructions along the
route that are not shown in available maps or drawings.
3.1.3 Where it becomes apparent that a better route could be followed, the Surveyor
shall consult the COMPANY / ENGINEER for authorization to make a change.
To check from construction point of view and avoid objects like power, telephone
and telegraph poles, walls, tube wells or such other structures falling in the strip of
land, 25M on either side of pipeline alignment.
3.2.1 The pipeline defining trench centre line shall be staked by placing suitably painted
marker stakes at Turning Points (TPs) and at Intermediate Points (IPS) between
consecutive TPs.
All Turning Points (TPs) and intermediate points are referred as Intersection Points.
First, the Turning Points (TPs) shall be staked on the ground. After locating and
marking the TPs, the intermediate points shall be staked while measuring slack
distance. The staking shall normally be done at intervals of 500 M along the centre
line of the pipeline.
3.2.2 The Intersection Points shall be serially numbered form the starting point. The
serial number of each Intersection Point shall be boldly inscribed on the marker
stake. In addition, the Turning Point (TP) marker stake shall identify the Turning
Point reference number from the starting point.
3.2.3 For Intermediate Points (IPS) letter "P" shall precede the serial number of the
intersection Point marker. For Turning Points, the letters "TP" shall precede the
Turning Point reference number, and the letter "P" shall precede the serial number
of the Intersection Point.
3.2.4 The marker stakes at Turning Points (TPs) shall be referred with three reference
stakes around the TP. The reference stakes shall carry the Turning Point reference
number and their respective distance from the TP marker stake.
3.2.5 Change in direction of line shall be marked on the TP marker stakes. In addition,
direction markers near TPS and other locations shall be placed wherever
necessary.
3.3.1 All marker stakes shall be pre-cast reinforced concrete blocks having dimensions
150 x 200 x 800 MM deep, and shall be buried to a depth of 500 MM.
The exposed surface of the blocks shall have a smooth finish and shall be painted
with 'Post Office' red paint. All letters and figures shall be paint marked on the
surface of the blocks in white.
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3.3.2 On the top surface of the reinforced concrete blocks, a cross inside a circle shall be
engraved at the centre or a nail shall be put centrally inside an engraved circle, to
indicate the exact position of the Intersection Point. The circle shall be of
approximately 50MM diameter.
3.3.3 Surveyor can, however, propose to the COMPANYIENGINEER other types of stakes
/ markers which are better suited to site conditions.
4.1 Permanent Bench Marks (BM) approx. every 5 KMs or permanent structures on or
off the Right-of-Use (ROU) shall be established and described.
4.2 Additional permanent bench marks shall be established near the major pipeline
crossing sites.
4.3 Location of Bench Marks shall be established in the field by using reinforced
concrete blocks similar to pipeline marker stakes described in clause 3.3.1 of this
specification. Exact position of BM shall be marked by a cross inside a circle or a
nail put centrally inside an engraved circle on the top surface of the concrete block.
The reduced level of the BM shall be paint marked on the concrete block. Letters
"BM" shall precede the reduced level of bench mark recorded to the second place
of decimal.
4.4 Accuracy of the reduced levels of the Bench Marks shall be verified wherever
possible by checking levels with the nearest permanent Bench Mark established by
Survey of India.
5.0 CROSSINGS:
5.1 General
As far as possible, crossings shall be made at right angles. The Surveyor shall
record the angles of crossing for all fences, property lines, utilities, roads, railways,
canals, streams, etc. that are crossed. In addition, the true bearings of the
centerline of the road, railway, canal, as well as that of the pipe centre-line shall be
recorded. Turning Points (TPs) provided near crossings shall be located, at least
50m from the crossing's boundaries, in stable and firm ground.
The angles for all railway crossings shall be as close to 90 degrees as possible, but
in no case less than 85 degrees to the centre-line of the railway.
Primary roads are the National & State Highways, all-weather roads (paved /
unpaved) and roads providing access to major installations. The angle of crossings
Utilities crossed shall be located at their centerlines with stakes containing station
numbers in the survey. The angle or crossings shall be measured and locations
established relative to their above-ground facilities. The names and sizes of all
utility lines shall be included in the survey notes. In the cases of overhead power
and telephone lines, the distance to the poles and towers on each side of the
survey line shall be measured, and the numbers of poles or towers noted. Line
voltage shall also be recorded. Where possible, the survey shall be established so
that there is a minimum distance of 50 meters from the survey line to the nearest
High Tension pole or tower.
Underground utilities shall be located as far as possible and staked for a minimum
distance of 25 meters on each side of the survey line.
6.1 Surveyor shall incorporate corrections to the linear ground measurement due to
standard errors, variations from standard temperature and pull.
6.2 The error for angular closure for the work shall not exceed one minute per station
and for linear measurements it shall be read to the nearest 0.005 M.
6.3 The error on closure for measurements on vertical distance to establish bench
marks shall not be more that 24K millimeters (where 'K' is the linear distance in
KM). The observations for measurement of vertical distances on bench marks shall
STANDARD SPECIFICATION FOR DOCUMENT NO. REV-0
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be read to accuracy to the nearest 5 MM and for Inter section Points and other
points along the pipeline route and at crossings to the nearest 10 MM. The error of
misclosure in vertical distance shall be distributed linearly.
6.4 Azimuth checks shall be made by observations of the sun or Polaris at intervals of
15-20 Km. These observations of bearings together with deflection angles shall be
recorded in survey notes.
Azimuth misclosure based on bearings with observed angles at Turning Points shall
be equally distributed over the number of stations observed in between. Accuracy
of azimuth observations shall be acceptable if the three deductions agree within
one minute.
7.0 CHAINAGE:
7.1 Slack distance measurement will be made using 50 M steel tape or 30 M chain.
However, in case of abrupt slope change the tape / chain is straightened parallel to
the probable grading.
7.2 Distance between Intersection Points staked along the pipeline route shall be
measured and recorded. In addition, distance between level points shall also be
measured and recorded.
7.3 Chaining will be continuous in the direction of survey.
7.4 The true bearing of all straights shall be observed and recorded.
7.5 Data on nature of terrain, viz. sandy, stony, vegetation, etc. and type of ground
will also be recorded along with chainages of change points.
7.6 Check on distance measurements will be by stadia method at the time of levelling.
7.7 Standard chain survey format will be used for record keeping.
8.1 Theodolite, reading direct to 10 seconds or better, shall preferably be used. Angles
shall be measured clockwise from back station to fore-station. Mean of two
readings-one on face left and other on face right shall be taken as the horizontal
angle.
8.2 The line at both ends shall be tied to the grid control system being used for end
facilities. True bearing at the beginning, end and every 15-20 KM shall be observed
to keep a check on errors in angular measurements.
9.0 PROFILE:
iv) At all points on the pipeline route where there is a change in slope.
9.2 When the terrain is flat, reduced level shall be additionally recorded along the
pipeline route at 100m interval.
9.3 When the terrain is undulating observation of reduced level shall be made at a
sufficient number of points so as to give an accurate plotting of the ground profile
along the route.
9.4 For road and railway crossings, the reduced levels shall be recorded at all points
along the pipeline alignment wherever there is a change in slope within the entire
width of the Right of-Use of the road/ railway. CONTRACTOR shall prepare a
detailed drawing for the crossing in scale 1:100 (in both horizontal and vertical
directions) which shall be truly representative of the crossing profile.
9.5 For river / stream/ nalla / canal crossings, levels shall be taken at intervals of 5M
up to 30M beyond the highest banks on both sides. Levels shall be taken at
closer intervals, if there is a change in slope. CONTRACTOR shall prepare a
detailed drawing for the crossing in scale 1 : 100 (in both Horizontal and Vertical
directions) which shall be truly representative of the crossing profile.
9.6 In right-of-use having slope across the pipeline alignment, as encountered in hilly
areas, Ghat regions, ravines and other similar areas as directed by COMPANY,
cross-sections at 50 M interval and for a length of 25 M on either side of the
pipeline alignment shall be observed and recorded.
9.7 For major water crossing sites, cross section as above shall be observed at both
banks.
9.8 Method of RISE and FALL shall be used to compute reduced levels of various
points. Check on computation shall be made by using the following formula:
Back site - Fore Site = Σ Rise - Σ Fall = First R.L. - Last R.L
9.9 Maximum misclosure shall not exceed 24K MM where 'K' is the distance in KMs.
Maximum length of line of sight shall not exceed 100 M.
9.10 All levels shall be with respect to Mean Sea Level (MSL).
The pipeline alignment shall run clear of the existing monuments, properties and
structures etc., as indicated in Pipeline Route Survey Data Sheet (Annexure-IV).
For congested areas, closer distance may be adopted; however, location shall be
approved by COMPANY / ENGINEER.
Unless otherwise stated, when the pipeline alignment runs generally parallel to a
road or railway it shall be kept sufficiently clear of the Right of Way limits of the
facility.
12.1 The procedures followed both for field and office calculations shall be such that the
results obtained shall be readily understood and retraceable.
12.2 All up-to-date notes and observations related to the basis for determination of
boundary lines and corners shall be maintained by surveyor.
12.4 Geo-graphical and UTM co-ordinates of all Turning Points and starting / end points
of the pipeline shall be computed and furnished to the COMPANY / ENGINEER.
13.1 All maps and drawings shall be made on standard format furnished by the
COMPANY. Surveyor shall perform mapping and drawing work so as to contain all
relevant data consistent with the survey notes and observations. The drawings
shall also contain details of roads, streets, highways, structures, all types of
crossings, terrain, surface vegetation and all other details which will be required for
the purpose of engineering design.
Pipeline route map shall show all features including, but not limited to roads and
railroads, canals, streams, lakes, rivers, villages, towns, and cities that are located
within a distance of 5 Krn from the pipeline centre-line on either side of it. For the
entire region, contours shall be plotted on the route map at 20 M contour interval.
Additional information like cultivated areas, barren land, areas prone to flooding,
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rocky areas and forests including access paths / roads to Right-of-Use shall also be
shown on the route maps.
Additionally for areas which are undulating such as hilly areas, Ghat regions,
ravines, and other areas as directed by COMPANY, Pipeline route map to a scale 1:
15,000 shall be drawn over a distance of 1.0 Km from the pipeline centre-line on
either side of it. For such areas, contours shall be plotted at 10m contour interval.
14.2 Right-of-Use Planimetry drawings shall show all objects within 50 meters on either
side of the Pipeline in Plan.
14.3 In case of all rail, road, river, stream, canal and utility crossings, the angle of
crossing shall be mentioned.
14.4 In case or rail, road, river, stream and canal crossings wider than 10m, the
distances at the start and at the end of the crossing from the nearest IP shall also
be mentioned. For crossings less than 10m, the distance of the centre line of
crossing from the nearest IP shall be given.
14.5 For all river, stream and nalla crossings, the level of water at the time of survey
and the approximate surface velocity of the flowing stream shall be observed and
recorded and reported in the survey drawings. Also, the general nature of the
surface soil (soft / hard, normal soil or rock/boulders) at the bed and banks of the
river / stream / nalla shall be observed and mentioned in the drawings.
2.0 SCOPE:
The scope of soil investigation includes boring, collection of disturbed samples from
boreholes and visual engineering classification of soil along the pipeline route, and
submission of detailed report to COMPANY. Visual classification of soil shall be in
accordance with IS-1498; "IS Classification and Identification of Soils for General
Engineering Purposes".
3.0 BORING:
3.1 Boreholes shall be made at intervals of 500 M along the pipeline route, at all
intermediate points where there is apparently a change in the type of soil and at
any other place as directed by COMPANY.
3.2 For canal, stream and river crossings, boreholes shall be made one on either bank
and one on the bed.
3.3 Minimum diameter of borehole shall be 150 MM. Auger boring shall be resorted to
above the water table, whereas below water table the boreholes shall be advanced
by shell and auger.
3.4 The boring shall be either terminated at a depth of 3 M below NGL or on top of
bed rock if rock is encountered at a depth of less than 3 M.
4.0 SAMPLING:
5.1 The report shall include proper visual engineering classification of soils
encountered along the pipeline route in bore log form. Depth of Ground Water
Table (GWT) below NGL shall also be mentioned if encountered.
5.2 Soil profiles along the pipeline route shall also be prepared and attached with the
report.
1.0 When survey is performed for gas pipelines, the class locations based on
population density index as per code ANSI B3l.8 "Gas Transmission and
Distribution Piping Systems" shall be recorded along with chainages at change
points of each class location.
2.0 Population density index along the pipeline route shall be determined as follows:
As zone, 400 M (one quarter mile) wide, shall be considered along the pipeline
route with the pipeline in the centre-line of this zone. Then the entire route of the
pipeline shall be divided into lengths of 1600 M (one mile) such that the individual
lengths will include the maximum number of dwellings intended for human
occupancy. The number of such dwellings which are intended of human occupancy
within each 1600 M (one mile) zone shall be counted and reported along with
other survey data.
A Class 1 location is any 1600 M (one mile) section that has 10 or fewer dwellings
intended for human occupancy
Class 2 Location
A Class 2 Location is any 1600 M (one mile) section that has more than 10 but less
than 46 dwellings intended for human occupancy.
Class 3 Location
A Class 3 Location is any 1600 M (one mile) section that has 46 or more dwellings
intended for human occupancy except when a Class 4 Location prevails.
Class 4 Location
A class 4 Location includes areas where multi-storey buildings are prevalent, and
where traffic is heavy or dense and where there may be numerous other utilities
under ground.
3.2 In addition to the criteria contained in Clause 3.1 above, while classifying areas,
additional consideration must be given to possibilities of increase in concentration
of population along the pipeline route such as may be caused by the presence of
schools, hospitals, recreational areas of an organized character, places of
assembly, places of worship, etc. If one or more of these facilities are present, the
area shall be classified as a Class 3 Location.
1.0 When survey is performed for High Vapour pressure (HVP) liquid petroleum
pipelines, zone location shall be recorded along the pipeline route along with
chainages at change points of each zone location. (For definitions refer Oil Industry
Safety Directorate (OISD) Standard 141 Design and Construction Requirements by
Cross Country Hydrocarbon Pipelines)
2.0 A zone, 200M wide on either side of the centre-line of the pipeline route, shall be
considered. Then the entire route of the pipeline shall be divided into lengths of 1
Km such that the individual lengths will include the maximum number of dwellings
intended for human occupancy within each 1 Km zone shall be counted and
reported along with other survey data.
3.1 A zone 1 Location is an area extending 200 meters on either side of the centre-line
of any continuous 1 KM length of pipeline that contains 5 or fewer dwelling units
intended for human occupancy.
3.2 A Zone 2 Location is an area as defined in clause 3.1 above that contains more
than 5 dwelling units intended for human occupancy, or a facility that contains 20
or more persons during normal use.
3.3 Each dwelling unit in a multiple dwelling unit building shall be counted as a
separate unit.
3.4 When a facility creates Zone-2 location requirements, the Zone 2 area shall extend
at least 200 meters from that facility.
4.0 Notwithstanding the provisions of clause 3.0 above, while determining zone
location of an area due consideration shall be given to the possibility of future
development of the area during the design life of the pipeline. If it appears likely
that future development may cause a change in the zone location, this shall be
taken into consideration while determining the zone location of the area.
Pipeline size : MM OD
Bend radius :
Note: Number of TPs / Bends in the pipeline, whether in horizontal or in vertical direction
shall be kept to a minimum
FORMATS EXHIBIT A
TO
EXHIBIT H
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.
a) All pipe joints, longitudinal butt welds, circumferential butt welds and socket
welds.
f) The attachments of smaller connections for vents, drain drips and other
instrument tapings.
This specification shall not be applicable for welding of pipelines for transportation
of liquid petroleum and other similar products.
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.
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.
3.1 In general, use of carbon steel, alloy steel and stainless steel is envisaged. The
details of the material specifications are given in the Welding Specification Chart.
3.2 The Contractor shall provide the manufacturer's test certificates for every heat of
the materials supplied by him.
4.1 The Contractor shall provide, at his own expense, all the welding consumables
necessary for the execution of the job such as electrodes, filler wires, argon etc.
and these should bear the approval of the Engineer-in-Charge.
4.2 The welding electrodes and filler wires supplied by the Contractor shall conform to
the class specified in the Welding Specification Chart. The materials shall be of the
make approved by the Engineer-in-Charge.
4.3 Electrode qualification test records should be submitted as per the Exhibit-A
(attached) in respect of the electrodes tested by the Contractor, for obtaining the
approval of the Engineer-in-Charge.
4.4 The Contractor shall submit batch test certificates, from the electrode
manufacturers, giving details of physical and chemical tests carried out by them,
for each batch of electrodes to be used.
4.5 All electrodes shall be purchased in sealed containers and stored properly to
prevent deterioration. The electrodes removed from the containers shall be kept in
holding ovens at temperatures recommended by the electrode manufacturer. "Out
of the oven time" or electrodes, before they are consumed, shall not exceed the
limits recommended by the electrode manufacturer. The electrodes shall be
handled with care to avoid any damage to the flux covering.
4.6 All low hydrogen type of electrodes shall be rebaked at 350°C for 1 hour minimum
and stored in ovens kept at 80-100°C before use. Recommendations of the
electrode manufacturer shall I be followed if available.
4.7 The electrodes, filler wires and flux used shall be free from rust, oil, grease. earth
and other foreign matter which affect the quality of welding.
5.1 Argon gas used in GTA welding for shielding purposes shall be 99.995% pure. The
purity of the gas shall be certified by the manufacturer. The rate of flow for
shielding purposes shall be established through procedure qualification tests.
Normally this rate may be 12-20 CFH.
5.2 Argon gas with a purity level of 99.995% shall be used for purging.
5.3 When GTAW process alone or a combination of GTAW and SMAW processes is
recommended for the production of a particular joint, the purging shall be
maintained during the root pass and for the first filling pass to minimize oxidation
on the inner side of the pipe, unless otherwise specified in Welding Specification
Chart.
5.4 Initial purging shall be maintained for sufficient period of time so that at least 4-5
times the volume between the dams is displaced, in order to completely remove
the entrapped air. In no case should the initial purging period be less than 10
minutes. High gas pressure should be avoided.
5.5 After initial purging, the flow of the backing gas should be reduced to a point
where only a slight positive pressure prevails. For systems, which have a small
volume (up to ½ cubic foot) to be purged, a gas flow rate of 6-CFH is usually
adequate. Systems of larger volume may require higher flow rates and these
should be established during procedure qualification tests.
5.6 Gas backing (purging) is not required for socket type of welded joints.
5.7 Dams, used for conserving inert gas during purging, shall be removed after
completion of the welding, and shall be accounted for. Wherever, removal of dams
is not possible after welding, use of water-soluble dams should be made.
6.1 The Contractor should have the arrangement of sufficient number of welding and
cutting equipments, auxiliaries, and accessories of sufficient capacities so as to
meet the target / schedule.
6.2 All the equipments for performing the heat treatment, including transformers,
thermocouples, pyro-meters, automatic temperature recorders (with suitable
calibration arrangement etc.) shall be provided by the Contractor at his own
expenses and these should bear the approval of the Engineer-in-Charge.
6.3 Contractor shall make necessary arrangements at his own expense, for providing
the radiographic equipments, radiographic films, processing equipment all other
darkroom facilities and all the equipments/materials required for cawing out the
6.4 Redoing of any work, necessitated by faulty equipments or operation used by the
Contractor, will be done at his own expense.
7.1 Welding of various materials under this specification shall be carried out using one
or more of the processes with the approval of the Engineer-in-Charge.
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.
8.1 General
The edges to be welded shall be prepared to meet the joint design requirements
by any of the following methods recommended:
Gas cutting, machining or grinding methods shall be used. After gas cutting,
oxides shall be removed by chipping or grinding.
Gas cutting, machining or grinding methods shall be used. After gas cutting,
machining or grinding shall be carried out on the cut surface.
(c0 High alloy steel (> 5% Chromium) and stainless steels, nickel alloys:
(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.
9.1 Components to be welded shall be aligned and spaced as per the requirements laid
down in applicable code. Special care must be taken to ensure proper fitting and
alignment when the welding is performed by GTAW process. Flame heating for
adjustment and correction of ends is not permitted unless specifically approved by
the Engineer-in-Charge.
9.2 A wire spacer of suitable diameter may be used for maintaining the weld root
opening while tacking, but it must be removed after tack welding and before laying
the root bead.
9.3 For pipes of wall thickness 5 mm and above, the ends to be welded shall be
secured in position with the aid of couplers, yokes and 'C' clamps, to maintain
perfect alignment. Yokes shall be detached after the completion of weld, without
causing any surface irregularity. Any irregularity caused on the pipe surface must
be suitably repaired to the satisfaction of the Engineer-in-Charge.
9.4 Tack welds, for maintaining the alignment, of pipe joints shall be made only by
qualified welders using approved W S . Since the tack welds become part of the
final weldment they shall be executed carefully and shall be free from defects.
Defective tack welds must be removed prior to the actual welding of the joints.
9.5 Tacks should be equally spaced. Minimum number of tacks shall be:
9.6 Welding shall commence only after approval of fit-up by the Engineer-In-Charge.
(a) Root pass shall be made with electrodes/filler wires recommended in the
welding specification chart. For fillet welding, root welding shall be done
with consumables recommended for filler passes. The preferred size of the
electrodes is 2.5 mm diameter (12 SWG) but in any case not greater than
3.25 mm (10 SWG).
(b) Upward technique shall be adopted for welding pipe held fixed with its
axis horizontal.
(c) The root pass of butt joints should be executed so as to achieve full
penetration with complete fusion of the root edges. Weld projection
inside the pipe shall be as per applicable code. It shall be limited 3mm
map, when the applicable code does not place any restriction.
(d) Any deviation desired from the recommended welding technique and
electrodes indicated in the welding specification chart should be adopted
only after obtaining express approval of the Engineer-in-Charge.
(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.
(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.
(e) Rust preventive / protective painting shall be done after the weld joint
has been approved.
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.
12.1 Preheating
(a) No welding shall be performed without preheating the joint to 10°C (50°F)
when the ambient temperature is below 10°C.
(b) Preheating requirements for the various materials shall be as per the
Welding Specification Chart attached.
(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.
In case of alloy steel materials such as Cr-Mo steels, if the post weld heat
treatment is not performed immediately after welding, the weld joint and adjacent
portion of pipe, at least 50 mm on either side of weld, shall be uniformly heated to
300°C. This temperature shall be maintained for half an hour minimum, and then
DOCUMENT NO. REV-0
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Copyright GAIL – All rights reserved
wrapped in asbestos or insulation before allowing it to cool to room temperature. If
the Post Heating temperature specified in the Welding Specification Charts exceeds
300°C, the same shall be followed. Similarly, if the welding specification chart
specifies post-heat time, the same shall be applicable. Post weld heat treatment as
specified in the Welding Specification Chart shall be carried out later on.
(a) Post weld heat treatment, wherever required for joints between pipes, pipes
and fittings, pipe body and supports shall be carried out as per the welding
specification chart, applicable codes standards and the instructions of the
Engineer-in-Charge.
(b) The Contractor shall submit for the approval of the Engineer-in-Charge, well
before carrying out actual heat treatment, the details of the post weld heat
treatment procedure as per Exhibit - B attached, that he proposes to adopt
for each of the materials / assembly /parts involved.
(d) While caving out local post weld heat treatment, technique of application of
heat must ensure uniform temperature attainment at all points of the
portion being heat treated. Care shall be taken to ensure that width of
heated band over which specified post weld heat treatment temperature
attained is at least that specified in relevant applicable codes /standards.
(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.
(i) Immediately on completion of the Heat Treatment, the Post Weld Heat
Treatment charts/records along with the hardness test results on the weld
points, wherever required as per the Welding Specification Chart, shall be
submitted to Engineer-in-Charge for his approval.
(j) Each joint shall bear an identification number, which shall be maintained in
the piping sketch to be prepared by the Contractor. The joint identification
number should appear on the corresponding post weld heat treatment
charts. The chart containing the identification numbers and piping sketch
shall be submitted to Engineer-in-Charge in suitable folders.
All weld joints shall be free from adherent weld spatters slag, sward, dirt or foreign
matter. This can be achieved by brushing. For stainless steels, brushes with only
stainless steel bristles should be used.
14.0 INSPECTION AND TESTING:
14.1 General
(a) The Owner's inspector shall have free access to all concerned areas, where
the actual work is being performed. The contractor shall also accord the
Owner's Inspector all means and facilities necessary to carry out inspection.
(b) The Owner is entitled to depute his own inspector to the shop or field where
prefabrication and erection of pipe lines is in progress for (but not limited
to) the following objectives:
(a) Welders shall be qualified in accordance with the ASME Section-IX or other
applicable codes. The Owners inspector shall witness the test and certify the
qualification of each welder separately. Only those welders who have been
approved by the Owner's Inspector shall be employed for welding.
Contractor shall submit the welder qualification test reports in the format as
per Exhibit-E (attached) and obtain express approval before commencement
of work. It shall be the responsibility of Contractor to carry out qualification
tests of welders. For welding of the steam piping, falling under the purview
of Indian Boiler Regulations only those welders with IBR Certification,
qualified by Boiler Inspectorate, and acceptable to the local Boiler Inspector
authority shall be employed.
(b) The welders shall always have in their possession the identification card as
shown in Exhibit4 and shall produce it on demand by the Owner's inspector.
It shall be the responsibility of the Contractor to issue the identify cards
after it has been duly certified by the Inspector.
(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.
(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 owner's safety requirements
while Handling X-ray and Gamma-ray equipments.
(g) The Contractor shall provide the Owner's Inspector all the necessary
facilities at site such as a dark room with controlled temperature, illuminator
(viewer) suitable for varying densities, a duly calibrated electronic
densitometer with batteries, magnifying glass, tracing papers, ruler marking
pencils etc. to enable him to review the radiographs.
(h) Where random radiography is specified, the first weld of each welder shall
be completely radiographed. In the case of pipe of size 6" and below, the
first two welds shall be completely radiographed.
(i) For each weld performed by a welder found unacceptable, two additional
checks shall be carried out on welds performed by the same welder. This
operation is iterative and of the two additional welds for each weld deemed
unsatisfactory shall be continued till such time that two consecutive welds of
satisfactory quality are found for every defective weld.
(j) The Contractor shall carry out these additional radiographic testing at his
own expense. To avoid the possibility of too many defective welds by a
single welder remaining undetected for a long period to time, the Contractor
shall promptly arrange for Radiographic Examination so that there is no
accumulation of defective joints.
(k) Contractor shall quote rates for X-ray as well as Gamma Ray for joints
indicated to be radiographed by X-ray in Table of Exhibit-H.
(a) Owner shall select 5% of the total joints radiographed on a day for check
shots. Contractor shall carry out check shots as directed.
(b) Weld profiles of check shots shall be compared with weld profile observed in
the earlier Radiographs. In the event of any one variation in the check shots
and earlier Radiographs, contractor shall re-shoot the entire lot of joints
radiographed by particular Radiography agency on the particular date. All
the re-shot films shall be compared with the originally submitted films.
(b) For austenitic stainless steels and other nonmagnetic materials, liquid (dye)
penetrant test shall be carried out. For carrying out this test, the materials
shall be brought within a temperature limit of 15 - 500C.
Hardness requirements for welds shall be as per the Welding Specification Chart
(attached). Hardness testing shall be carried out by Vickers Hardness Tester during
welding procedure qualification and shall be cross sectional. In all other cases,
hardness testing may be carried out by Portable Shore Seleroscope hardness
tester. Contractor shall produce documentary evidence / calibration certificate to
the Owner's Inspector and obtain approval of the equipment.
Hydrostatic and pneumatic tests shall be performed as per the requirements laid
down by respective flushing and Testing specification/applicable codes to
demonstrate the soundness of the welds. The tests shall be conducted after
fulfilling the requirement of visual examinations, radiography etc. and after the
entire work has been certified by the Owner's inspector to be fit for being
subjected to such tests.
(a) Defects ascertained, through the inspection methods, which are beyond
acceptable limits shall be removed after the joint is completely radiographed
by the process of chipping and grinding.
(b) When the entire joint is judged unacceptable, the welding shall be
completely cut and edges suitably prepare as per required alignment
tolerances. The re-welded joint shall again be examined following standard
practices.
(c) No repair shall be carried out without prior permission of the Owner's
inspector.
(d) Repairs and / or work of defective welds shall be done in time to avoid
difficulties in meeting the construction schedules.
(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.
Manufacturer's Name :
Brand Name :
Pre-heat temperature :
Visual examination :
1
2
3
Batch No. :
%C %S %P % Si % Mn % Cr % Ni % Mo OTHER
Welding Positions :
Base Materials :
1)
2)
3)
Remarks :
In combination with :
Position of welding :
Preheat temperature :
Radiography :
H. Conclusions :
Contractor : -
_____________________________________________________
________________________________________________________
Width of Insulation_________
Method of Cooling_____________________________________
JOINTS
Description shod show the general arrangement of the parts to be welded. Where
applicable, the root spacing and the details of weld groove may be specified
___________________________________________________
(At the option of the Manufacturer sketches may be attached to illustrate joint
design weld layers and bead sequence e.g. for notch toughness procedures, for
multiple process procedures, etc.)
BASE METALS
Thickness Range:
Base Metal: Groove ___________ Fillet _______________
Deposited Weld Metal: Groove Fillet______ Fillet__________
Pipe Dia Range: Groove: ____________________ Fillet _______________
Other ______________________________________________________
ELECTRICAL CHARACTERISTICS
TECHNIQUE
Filler
Current Travel
Weld Metal Volt
Process Speed Others
Layers Type Amp. Range
Class Dia. Range
Polarity Rating
ex.:
Remarks,
Comments,
Hot wire
Addition,
Technique
Torch
Angle, etc.
JOINTS
PREHEAT TECHNIQUE
Preheat Temp. ________________ Travel Speed ___________________
Inter pass Temp. ______________ String or weave bead _____________
Oscillation _____________________
Multi pass or single pass __________
Single or Multiple electrodes _______
Other _________________________
TOUGHNESS TESTS
Lateral
Drop weight
Specimen Notch Notch Test Impact Expansion
No. Location Type Temp. Value % No
Mils Break
Shear Break
OTHER TESTS
We certify that the statements in this record are correct and test welds were
prepared, welded and tested in accordance with the requirements of Section
IX of the ASME Code.
(Details of record of tests are illustrative only and may be moulded to conform
to the type and number of tests required by codes and specifications)
Thickness
Groove __________________ _________________
Filler __________________ _________________
Diameter
Groove __________________ _________________
Filler __________________ _________________
Filler Metal
Spec. No. __________________ _________________
Class __________________ _________________
F. No. __________________ _________________
Electrical Characteristics
Current __________________ _________________
Polarity __________________ _________________
Fracture Test (Describe the location, nature and size of any crack of tearing of
the specimen _____________________________________
Length and Per Cent of Defects ________________ inches _______%
Macro Test - Fusion ________________________________________
Appearance - Fillet Size(ing) _____ x _____ Convexity or Concavity __
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.
1. Location
2. Date of Testing
3. Name of the Contractor/Agency
4. Material: Carbon steel/Alloy Steel / Stainless Steel
4 A. Technique: DWSI/SWSI/DWDI
5. Diameter & Thickness:
6. Type of Weld Joint:
7. Radiation Source:
8. Intensifying Screens/Lead Screens:
9. Geometric Relationship:
10. Limit of Film Coverage:
11. Film Type and Make:
12. Exposure Time:
13. Processing:
14. Density:
15. Sensitivity:
16.* Type of penatrameter (source side):
17.* Type of penatrameter (Film side):
1. Name:
2. Identification:
3. Date of Testing:
4. Process PHOTOGRAPH
5. Thickness range
6. Diameter range
7. F. No.
9. Position
2. Very fine grain (High contrast) films slower than the above may have to
be used, if required radiographic sensitivity is not achieved consistently.
SPECIFICATION REV-0
GAIL (INDIA) LTD INSTRUCTIONS TO VENDOR FOR
QUALITY DATA REQUIREMENTS S-04-02-035 Page 1 of 10
NEW DELHI
CONTENTS
1.0 INTRODUCTION
2.0 PURPOSE
3.0 SCOPE
4.0 DEFINITIONS
5.0 INSTRUCTIONS
6.0 ATTACHMENT
SPECIFICATION REV-0
GAIL (INDIA) LTD INSTRUCTIONS TO VENDOR FOR
QUALITY DATA REQUIREMENTS S-04-02-035 Page 2 of 10
NEW DELHI
1.0 INTRODUCTION
1.1 As a part of services rendered to the Client, GAIL purchases Products/ Services for
Projects on behalf of client (including in house projects) from various vendors.
2.0 PURPOSE
2.1 The purpose of this standard is to describe the vendor Quality Data Requirements
which shall form a part of every Material Requisition (MR)/ Purchase Requisition (PR)
released by GAIL, so as to ensure that all purchased products/ services consistently
conform to planned Quality and projects’ stated and implied needs are met to Client’s
total satisfaction.
3.0 SCOPE
The requirements of this standard are applicable to all Vendors for supply of Packages,
Equipments and Materials which are:
4.0 DEFINITIONS
4.1 “Vendor” means the person(s), firm, company, organization from whom GAIL procures
products/ services on behalf of Client, as a part of services to the Client for Projects
handled by GAIL, or for its in house projects rendered.
5.0 INSTRUCTIONS
Vendor during bidding stage, shall confirm compliance to his QUALITY ASSURANCE
(QA) Plans (consisting of relevant Procedures covering various activities like design and
engineering, material procurement, manufacture, inspection and testing,
documentation, dispatch to site, erection and commissioning where applicable and
maintenance of Quality records) which have already been approved at the time of
vendor enlistment. In the post order stage, the vendor shall confirm the validity of their
QA Plans and submit only revisions/ deviations if any to these plans, to the concerned
SPECIFICATION REV-0
GAIL (INDIA) LTD INSTRUCTIONS TO VENDOR FOR
QUALITY DATA REQUIREMENTS S-04-02-035 Page 3 of 10
NEW DELHI
GAIL Inspection office/ Third Party Inspection Agency for approval within 2 weeks from
the date of receipt of PR.
Vendor shall submit Inspection and Test plan for approval within 2 weeks of PR and
before commencement of manufacture to concerned GAIL Inspection Office/ Third
Party Inspection Agency (TPIA). The Inspection and Test Plan shall also cover “bought
out” items from sub-vendors.
Vendor shall submit a total index of drawings and documents required for review/
records based on the Vendor Data Requirement given in the PR along with the
scheduled date of submission of each drawing/ document within 2 weeks from Tele-fax
Letter of Intent. The Drawing schedule shall be specific with regard to drawing/
document No., the exact title and the size of the drawings/documents.
Vendor shall submit Monthly Progress Report and updated procurement, engineering
and Manufacturing Schedule every month, beginning within 2 weeks from Tele-fax/
Letter of Intent.
Vendor shall strictly comply with PR stipulations and no deviations shall be permitted.
However, if the need for deviation arises under exceptional circumstances, on the post-
order stage, such deviation shall be subject to the approval of GAIL/ OWNER and shall
be submitted through GAIL Regional - Inspection Office in the prescribed “WAIVER/
DEVIATION REQUEST” format.
All critical materials such as casting, forging, fittings, pressure holding parts, electrical
and instrument accessories, etc. shall be purchased by the Vendor from GAIL approved
suppliers meeting Qualification Criteria stipulated if any. Vendor shall submit a list of
bought out materials and sub-vendors for these bought out materials for GAIL approval
within 2 weeks from Tele-fax Letter of Intent.
Vendor shall use only calibrated measuring and test instruments and maintain
calibration records. Vendor shall furnish records of calibration of measuring and test
SPECIFICATION REV-0
GAIL (INDIA) LTD INSTRUCTIONS TO VENDOR FOR
QUALITY DATA REQUIREMENTS S-04-02-035 Page 4 of 10
NEW DELHI
instruments including recalibration records to concerned GAIL Inspection Office/ Third
Party Inspection Agency.
Inspection and Test status of products shall be identified by using markings, authorised
stamps, tags, route cards, inspection records etc. during the course of manufacture to
clearly indicate acceptance/ rejection of tests/stages of inspection performed during its
manufacturing cycle. The identification of inspection and test status shall be
maintained and records thereof shall be submitted as and when demanded by GAIL
Inspection Engineer or Third Party Inspection Agency.
Vendor shall maintain quality records as per his procedures. Inspection Reports & Test
Record copies- shall be furnished to GAIL Inspection Engineer or Third Party Inspection
Agency.
Vendor shall establish and maintain a standard written procedure for identifying the
products from applicable drawings, specification or other documents during all stages
of production, delivery and installation, A copy of this Standard procedure shall be
made available at concerned GAIL Inspection office. On job to job basis, vendor shall
confirm its validity and only revisions/ deviations if any, shall be submitted for
approval. The vendor shall ensure that each product which is going in the process of
fabrication / manufacture/ construction/ erection has proper identification throughout
the process including the final output.
ii) Review of the vendor Drawings by GAIL would be only to review the compatibility
with basic designs and concepts and in no way absolve the vendor of his
responsibility to comply with PR requirements, applicable codes, specifications and
statutory rules/ regulations.
iii) Unless otherwise agreed, submission of Documents for Review/ Records shall
commence within 04 weeks from the date of Telefax/ Letter of Intent.
iv) Unless otherwise agreed, vendor shall submit all Drawings and Documents in
number of copies, as stipulated in the Vendor Data Requirement Form, along with
Document Index. The Documents shall be supplied in soft copies where specified.
SPECIFICATION REV-0
GAIL (INDIA) LTD INSTRUCTIONS TO VENDOR FOR
QUALITY DATA REQUIREMENTS S-04-02-035 Page 5 of 10
NEW DELHI
5.11.1 A blank space duly marked measuring 75 mm (W) x 38 mm (H) shall be provided
on the body of all Vendor Drawings for marking of Review Codes by GAIL.
5.11.2 Documents for Review and Documents for Records shall be submitted in separate
folders with separate - covering letter to facilitate expeditious processing at GAIL.
5.11.3 Before forwarding the drawings and documents, vendor shall ensure that the
following information is properly entered in each drawing:
PURCHASE REQUISITION :
NAME OF EQUIPMENT :
NAME OF PROJECT :
CLIENT :
5.11.4 The Drawing/ Documents shall be checked, approved and duly signed/ stamped by
vendor before -submission. Revision Number shall be changed during submission of
the revised Vendor Documents and all revisions shall be highlighted by clouds.
Before submitting any sub-vendor drawings for review by GAIL, the vendor shall
ensure that these sub-vendor drawings have been reviewed, commented and
stamped by the vendor. Direct submission of sub-vendor’s drawings without
vendor’s review shall not be entertained.
5.11.5 While resubmitting the Drawings/ Documents, the vendor shall, in a covering
letter, specifically confirm whether all the comments have been incorporated, if not,
shall furnish reasons with justification.
5.11.6 Multi-sheet Documents other than Drawings shall be submitted in their entirety in
the event of a resubmission even if only few sheets are revised.
5.11.7 Vendor shall forward all Drawings/ Documents (transparencies and printed
matter), to GAIL (India) Limited, Attention: Vendor Print Control, and the copy of
forwarding letter/ transmittal to GAIL Inspection Department as well as to the
Client.
V - Void
Documents under this category are meant for GAIL Records. These documents
would not be returned to vendor. However, comments, if any, will be
communicated to vendor.
5.12.2 Final Documentation shall be bound in Hard board folder(s) of size 265 mm x 315
mm (10 and a half inch x 12 and a half inch) and shall not be more than 90 mm
thickness, it may be of several volumes and each volume shall have a volume
number, index of volumes and index of contents of that particular volume.
5.12.3 Each volume shall contain a Title Block indicating Equipment Tag No., Equipment
Name, P.O./ Purchase Requisition No., Name of Project and Name of Client.
6.0 ATTACHMENT
SPECIFICATION REV-0
GAIL (INDIA) LTD INSTRUCTIONS TO VENDOR FOR
QUALITY DATA REQUIREMENTS S-04-02-035 Page 7 of 10
NEW DELHI
WAIVER/ DEVIATION REQUEST
Format No-F1 Rev-0
WAIVER/ DEVIATION PERMIT
Under Present constraints requested Waiver/ Deviation is not optimum for the project and
does not involve any security and safety hazard, and shall meet the stipulated performance
requirements.
Date: Signature
Contractor/ Vendor (with seal)
SPECIFICATION REV-0
GAIL (INDIA) LTD INSTRUCTIONS TO VENDOR FOR
QUALITY DATA REQUIREMENTS S-04-02-035 Page 8 of 10
NEW DELHI
Decision on Waiver/ Deviation including decision, on time and cost implications
(To be filled by the Inspection engineer at [PROJ/ HO] or Project Manager responsible for
conveying the decision to the Vendor/ Contractor, after resolution)
Date:___________ Signature:_____________
SPECIFICATION REV-0
GAIL (INDIA) LTD INSTRUCTIONS TO VENDOR FOR
QUALITY DATA REQUIREMENTS S-04-02-035 Page 9 of 10
NEW DELHI
WAIVER/ DEVIATION REQUEST
Date:__________ Signature:______________
Name: ______________
PROJ/ Site Name:______________
Date:___________ Signature:_____________
Name:______________
Date:___________ Signature:_______________
Name:_______________
Date:___________ Signature:_______________
Name:_______________
Date:___________ Signature:_______________
Name:_______________
2. CEMENT
4. PIPING MATERIAL
5. EQUIPMENTS
6. CABLES
7. LINE PIPES
Whenever any material is issued by Owner, following conditions for issue of material in
addition to other conditions specified in the contract shall be applicable:
1.1 Necessary indents will have to be raised by the Contractor as per procedure laid
down by the GAIL from time to time, when he requires the above material for
incorporation in permanent works.
1.2 Materials will be issued only for permanent works and not for temporary works,
enabling works etc. unless specifically approved by the Engineer-in-Charge and
the same shall not be taken into account for the purpose of materials
reconciliation.
1.3 The Contractor shall bear all other cost including lifting, carting from issue points
to work site/Contractor's store, custody and handling etc. and return of
Surplus/serviceable scrap materials to Owner's storage points to be designated
by the Engineer-in-Charge etc. No separate payment for such expenditure will be
made.
1.4 No material shall be allowed to be taken outside the plant without a gate pass.
1.5 The Contractor shall be responsible for proper storage, preservation and watch &
ward of the materials.
1.6.1 All unused/scrap materials shall be the property of the Owner and shall be
returned in good and acceptable condition size wise, category wise by the
Contractor at his own cost to Owner's Store(s).
1.6.2 No credit will be given to the Contractor for return of scrap. The Contractor
should quote the rates accordingly.
1.6.3 In case the Contractor fails to return unused/scrap materials, then recovery for
such quantity of materials, not returned by the Contractor shall be affected at
following penal rates from the Contractor's bills or from any other dues of the
Contractor to the Owner. Contractor shall make his own arrangements for
weighing the off cuts to be returned to Owner's stores.
(b) Penal rates for non return of Twice the Issue Rates
Unused material/excess scrap or
Twice the Landed Rates
(in case Issue Rates are
not indicated in the
Contract)
NOTE : 1) Landed Rate shall be arrived from the latest Purchase Order of
respective material received at site by Owner.
2.0 CEMENT
2.1 Cement as received from cement Manufacturer/ Stockists will be issued to the
contractor. The theoretical weight of cement in each bag for issue purpose will be
considered as 50 Kgs. or 20 bags per MT. However, cement bags weighing upto 4%
less shall be accepted by the Contractors and charged for as full bag. Any type of
cement and in any package as received from Manufacturer/Stockists shall be issued to
the Contractor. No claim whatsoever shall be entertained on this account.
2.2 The Contractor will have to submit their design mix for different grades of concrete,
keeping in view the requirements stipulated in IS:456 and IS 10262, specifically
regarding durability, slump and water cement ratio, and specific gravity of materials
brought to site as analysed in the laboratories. The design shall be based upon absolute
volume method and theoretical consumption of cement shall be worked out on this
basis. For other than concrete items, the coefficients for consumption of cement shall
be adopted as per CPWD practice.
2.3 The permissible variation between Cement actually used on the job and theoretical
consumption worked out on the basis stipulated in above para 2.2 and as determined
by Engineer-in-Charge shall be 3% (Three percent only).
2.3.2 If the actual consumption is less than 97% of the theoretical consumption then
recovery at the penal rates for the quantity of cement used less than the limit of
97% of the theoretical consumption shall be affected from the Contractor's bill(s)
or any other dues of the Contractor to the Owner, provided that the quality of
the work has been found acceptable by the Owner.
2.4 Unused quantity of cement shall be returned by the Contractor to the Owner's stores in
good condition. In case the Contractor fails to do so, then recovery at penal rates shall
be affected from the Contractor's bill(s) or any other dues of the Contractor to the
Owner.
2.5 The Contractor shall maintain a good store for storing cement issued to him. The
flooring of the storage house, the clearances of cement bags from the side walls/ floor
& stack height etc. shall be as instructed by the Engineer-in-Charge.
2.6 The cement store shall be open for inspection and verification by the Engineer-in-
Charge or his authorised representative at any time when the Engineer-in-Charge feels
the need to do so.
2.7 Periodical stock taking as decided by the Engineer-in-Charge shall be done by the
Contractor in the presence of Engineer-in-Charge or his authorised representative and a
statement of stocks duly verified shall be submitted to Engineer-in-Charge.
2.8 Empty cement bags shall be the property of the Contractor and shall have to be
disposed off by him.
2.9 Penal rates for excess/less consumption and/or non return of unused quantity w.r.t.
theoretical consumption " allowance as explained in each type of material shall be
charged as given in the Contract.
3.1 The scrap allowance for the reinforcement bars/structural steel including steel plate
issued by the Owner, shall be total 3% (2.5% accountable and 0.5% non-accountable)
of the actual consumption as incorporated in the works.
3.3 Reinforcement bars/structural steel/steel plates shall be issued only for those items
where Owner's supply has been specifically mentioned in Schedule of Rates/ Scope of
Supply.
3.4 All reinforcement bars/structural steel except M.S. Plates in length of 2 meters and
above shall be considered as serviceable materials provided the material is in good and
acceptable condition. Reinforcement bars/structural steel section except M.S. Plates in
lengths less than 2M shall be treated as scrap.
3.5 For the purpose of accounting of the plates, all plates measuring not less than 1 Sq.m
in area and having any dimensions not less than 200mm when returned to Owner's
store, will be considered as serviceable material. All other pieces will be treated as
wastage/ scrap. The Contractor will prepare a plate cutting diagram in such a way that
the minimum scrap is generated. Also the cut plates should be used at a proper place to
reduce scrap.
3.6 Above serviceable cut pieces as mentioned in 3.4 & 3.5 above shall be considered as
unused material.
3.7 For non return of unused quantity of material shall be charged at penal rates.
3.8 The wastage generated by the Contractor in excess of the allowable percentage shall
also be charged at the penal rates.
4.1 All pipes shall be issued in available lengths/shapes and no claims for extra payments
on account of issue of non-standard length & shape will be entertained. Pipes shall be
issued on linear measurement basis. All valves, flanges, fittings etc. shall be issued on
number(s) basis. Contractor shall store the materials in such a way so as to avoid
mixing of different types of material and shall maintain complete identification and
traceability at all times.
4.2 The scrap allowance for pipes issued by the Owner shall be 3% (2½% accountable +
½% non accountable) of the actual consumption as incorporated in the works.
4.3 All pipes in length of 2 meters and above shall be considered as serviceable material
provided the material is in good and acceptable condition and has clear identification
STANDARD CONDITIONS FOR ISSUE AND SPECIFICATION REV-0
GAIL (INDIA) LTD RECONCILLIATION OF MATERIALS
NEW DELHI S – 04 – 02 – 036 Page 6 of 9
Copyright GAIL – All rights reserved
and traceability (Manufacturer’s name, heat number/batch number and test
certificates). Pipes in lengths less than 2 M shall be treated as scrap.
4.4 For the non account of pipes drawn by the Contractor over and above the actual
consumption as determined by the Engineer-in-Charge, plus 3% (2½% accountable +
½% non accountable) thereof to cover the scrap allowance, recovery at penal rate shall
be effected from the Contractor's bill(s) or from any other dues of the Contractor to the
Owner.
4.5 All unused/scrap pipes, valves, flanges, forged fitting like elbows, reducers tees shall be
returned by the Contractor category wise duly cleaned, greased and spec. marked at his
own cost to Owner's stores. In case the Contractor fails to do so then recovery for such
quantity of pipes not returned by the Contractor at the penal rates shall be effected
from the Contractor's bill(s) or from any other dues of the Contractor to the Owner.
5.0 EQUIPMENTS
All materials supplied by the Owner shall be duly protected by the Contractor at his own
cost with appropriate preservative like primer, lacquer coating, grease etc. as required.
6.0 CABLES
6.1.1 All the surplus and serviceable cables out of the cables quantity(ies) issued by the
Owner to the Contractor shall be returned by the Contractor to the Owner's store in
good condition and as directed by the Engineer-in-Charge.
6.1.2 The Contractor shall be allowed a cutting/wastage allowance of 1.5% for power cables
and 3% for the control cables. This cutting/wastage allowance shall be computed on
the length of cables actually laid, measured and accepted.
6.1.3 All cables being returned to store should carry Aluminium sheet tags indicating the size
& type of cable. Cables of less than 15 meters length will be termed as scrap. Cables of
lengths 15 M and above shall be termed as serviceable material & shall be returned size
wise and category wise to the Owner's store in wooden drums. Cables of serviceable
length being returned to stores in drum(s) shall be accepted only after Megger value
6.1.4 While carrying out material appropriation with the Contractor, the above points will be
taken into account. All serviceable materials returned by the Contractor (size wise &
category wise) shall be deducted from the quantity(ies) issued to the Contractor for the
respective sizes. Scrap generated for power cable and control cable shall also be
returned to Owner’s store on Lot basis.
6.1.5 Material appropriation shall be done & allowable scrap quantity calculated. The wastage
generated by the Contractor in excess of the allowable percentage shall be charged at
the penal rates.
7.1 All coated line pipes as per Line Pipe specifications shall be issued on linear
measurement basis. The line pipes shall be issued in available lengths and shapes and
no claim for extra payment on account of issue of non-standard length and shape will
be entertained. Contractor shall store and maintain the line pipes in proper manner to
avoid mixing of different classes of pipes. Contractor shall maintain complete
identification and traceability at all times. All cut pieces when returned to Owner's
storage points after bevelling, shall be considered as serviceable material provided:
7.1.2 Pipe pieces have pipe specifications, manufacturer’s logo/name and heat number
duly authenticated with hard stamp of the authorised inspector as per approved
procedure.
All cut pieces of pipes measuring less than 2 M will be treated as wastage/scrap.
7.2 For the purpose of accounting of coated line pipes, following allowances shall be
permitted:
b) Scrap (All cut pieces of pipes measuring less than 2 Meter) 0.25%
Scrap shall be accounted at actuals as per site assessment subject to maximum limits
as stated above.
STANDARD CONDITIONS FOR ISSUE AND SPECIFICATION REV-0
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NEW DELHI S – 04 – 02 – 036 Page 8 of 9
Copyright GAIL – All rights reserved
The percentage allowance shall be accounted on the basis of pipe book chainage for
main pipeline
7.2.1 Material appropriation shall be done & allowable scrap quantity calculated. The
wastage generated by the Contractor in excess of the allowable percentage shall
be charged at the penal rates as given in the contract.
For the purpose of accounting of optical fibre cable, all cut pieces measuring in length
of 40 m and above when returned to Owner's storage points shall be treated as
serviceable materials. All cut pieces of cable measuring less than 40 M will be treated as
scrap.
For the purpose of accounting of OFC (Optical Fibre Cable) following allowances shall be
permitted:
(ii) Scrap (All cut pieces of cables measuring less than 40 M) 0.25%
Material appropriation shall be done & allowable scrap quantity calculated. The wastage
generated by the Contractor in excess of the allowable percentage shall be charged at
the penal rates as given the contract.
The Contractor shall make a schedule for use of Cable jointing kits and get the same
approved from Engineer-in-charge. The quantity mentioned in this schedule will be
termed as ‘planned’ usage quantity which shall be issued to the Contractor. However,
any jointing based on site requirements as decided by Engineer-in-charge shall be
included in planned quantity.
Any unplanned jointing required to be carried out by Contractor due to reasons not
attributable to GAIL shall be issued from spare quantity, if available with Owner. Such
unplanned OFC Jointing Kits shall be charged from the Contract at penal rates.
SI.No. Description
1.0 INTRODUCTION
1.1 The Pipeline Information Management System (PIMS) shall be used for the construction
progress on a real time basis and shall be updated daily. The progress needs to be
displayed electronically on a web based format s per the scope of work detailed below.
2.2 The scope of work includes all materials, hardware, software, manpower, services etc.
required for customized pipeline data information management solution for the Pipeline
Project. The work shall include the following as the minimum:
2.5.2 The system shall enable quick retrieval and printing of relevant pipeline data/ as built
information through a suitable application.
2.5.3 The proposed system shall be equipped with security facilities to prevent
datatampering, data theft, sabotage and virus attack.
2.5.4 The CONTRACTOR shall collect, store, classify, handle and protect all input data and
STANDARD SPECIFICATION FOR SPECIFICATION REV-0
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acquired data in good shape till completion and handing over of finished work.
CONTRACTOR shall not make any unauthorised alteration, modification and copies of
any input data unless explicitly authorised by the COMPANY. All input and acquired data
shall be returned to the COMPANY at the completion of work in its original form.
3.1 The CONTRACTOR shall be solely responsible for arranging all resources, facilities and
logistic supports etc. required to complete the work under this contract. In broad, the
CONTRACTOR shall be responsible for providing the following:
d. All consumables for scanning, printing, storing, and creation of backup data
CD’s/DVDs.
The scope of work shall also include any other item/Work required to complete the
work in all respects as per specifications and instructions of COMPANY’s representative
whether specifically mentioned here in or not, but required to fulfill the intended
purpose of this tender document and this specification.
4.0 EXPERIENCE CRITERIA
The bidder shall submit information about the Agency’s experience in providing such a
solution. A project specific detailed methodology to carry out all the above activities
shall be submitted for COMPANY’s review. The subcontractor and his software shall
be approved by COMPANY.
1.0 GENERAL
1.1 All pipes and their dimensions, tolerances, chemical composition, physical properties, heat
treatment, hydrotest and other testing and marking requirements shall conform to latest
codes and standards specified in the material requisition (MR). Deviation(s), if any, shall be
clearly highlighted in the offer.
1.2 Testing
1.2.1 Test reports shall be supplied for all mandatory tests as per the applicable material
specifications. Test report shall also be furnished for any supplementary tests as specified in
the MR and clauses 1.10 & 1.11.
1.2.2 Material test certificates (Physical property, chemical composition & heat treatment report)
shall also be furnished for the pipe supplied.
1.2.3 PMI shall be performed as per the scope and procedures as defined in the GAIL standard
spec. for PMI at vendor’s work
1.3.2 All longitudinally welded pipes other than IS 3589 should employ only automatic welding.
1.4 Pipe shall be supplied in single or double random length of 4 to 7 and 7 to 14 meters
respectively.
1.5 a. Seamless and ERW pipes shall not have any circumferential seam joint in a
random length. However, in case of E.FS.W. pipe, in one random length one
welded circumferential seam of same quality as longitudinal weld is
permitted. This weld shall be at least 2.5 m from either end. The longitudinal
seams of the two portions shall be staggered by 900. Single random length in
such cases shall be 5 to7 m.
b. Unless otherwise mentioned in the respective material code, E.FS.W. pipes <
36” shall not have more than one longitudinal seam joint and E.FS.W pipes ≥
36” shall not have more than two longitudinal seam joints.
1.6 Pipe with screwed ends shall have NPT external taper pipe threads
conforming to ASME/ ANSI B1,20.1 up to 1.5” NB & IS 554 for 2” to 6”
NB.
1.7 Pipe with beveled end shall be in accordance with ASME B 16.25. Weld
contour shall be as follows:
1.8 Galvanised pipes shall be coated with zinc by hot dip process conforming to IS 4736 /
ASTM A 153.
1.9 All austenitic stainless steel pipes shall be supplied in solution annealed condition. All types
of 321 or 347 stainless steel pipes shall be in a stabilized heat treated condition. Stabilized
heat treatment shall be carried out subsequent to the normal solution annealing. Soaking
time & holding temp. for stabilizing heat treatment shall be 9000 C & 4 hrs respectively.
1.10.1 For all austenitic stainless steel pipes intergranular corrosion test shall have to be conducted
as per following:
ASTM A 262 Practice “B” with acceptance criteria of “60 mils/year (max.)”.
OR
ASTM A 262 Practice “E” with acceptance criteria of “No cracks as observed from 20X
magnification” & ‘Microscopic structure to be observed from 250X magnification”
1.10.2 When specifically asked for in MR for high temperature application of some grades of
austenitic stainless steel (eg. SS 309, 310, 316, 316 H etc.) ASTM A 262 Practice “C” with
acceptance criteria of “15 mils/year (max)” shall have to conducted.
1.10.3 For the IGC test as described in 1.10.1 & 1.10.2, two sets of samples shall be drawn from
each solution annealing lot; one set corresponding to highest carbon content and the other
set corresponding to the highest pipe thickness. When testing is conducted as per Practice
“E”, photograph of microscopic structure shall be submitted for record.
1.11 All welded pipes indicated as “CRYO” & “LT” in MR shall be impact tested per
requirement and acceptance criteria of ASME B 31.3. The impact test temperature shall be
(-)1960 C & (-) 450 C for stainless steel and carbon steel respectively unless specifically
mentioned otherwise in the MR.
1.12 Pipes under “NACE” category shall meet the requirements given in MR-01-75
1.14 For black or galvanized pipes to IS 1239, the minimum percentage of elongation shall be 20
%.
1.15 All 1 Cr – 0.5 Moly & 1.25 Cr – 0.5 Moly seamless pipes shall be normalized and tempered.
1.16 For all welded Alloy steel pipes with mandatory requirement of heat treatment and
radiography, radiography shall be performed after heat treatment.
2.1.1 Pipes under purview of IBR shall be accompanied with IBR certificate original in Form
IIIA, duly approved and countersigned by IBR authority/ local authority empowered by the
Central Boiler of India. Photocopy of the original certificate duly attested by the local boiler
inspector where the supplier is located is the minimum requirement for acceptance.
2.1.2 For material 1 ¼ Cr – ½ Mo (ASTM A335 Gr.P11 / A691 Gr. 1 ¼ Cr) & 2 ¼ Cr – 1 Mo
(ASTM A 335 Gr. P22 / A 691 Gr. 2 ¼ Cr), Form III-A approved by IBR shall include the
tabulation of Et, Sc & Sr values for the entire temperature range given below. Et, Sc & Sr
values shall be such that throughout the temperature range
Et / 1.5 ≥
Sr / 1.5 ≥ SA
Sc ≥
Where,
A335 Gr. 17200 16700 16200 15600 15200 15000 14500 12800 9300 6300 4200 2800
P 11
A691 Gr. 18900 18300 18000 17600 17300 16800 16300 15000 9900 6300 4200 2800
1 ¼ Cr
A 335 Gr. 17900 17900 17900 17900 17900 17800 14500 12800 10800 7800 5100 3200
P22 /
A691 Gr.
2 ¼ Cr
Note: SA values given above are as per ASME B 31.3 – 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 :
The chemical composition as indicated in this cluse is not applicable for pipes other than
IBR services.
Refer Annexure – I
4.1 All pipes shall be marked in accordance with the applicable codes, standards and
specifications. In addition the purchase order number, the item code & special condition like
“IBR”, “CRYO”, “NACE” etc. shall also be marked.
4.2 Pipes under “IBR”, “CRYO”, “NACE”, “H2 (Hydrogen)” shall be painted in red stripes,
light purple brown stripes, canary yellow stripes and sea green stripes respectively
longitudinally throughout the length for easy identification. Marking of pipes
circumferentially for sizes 1” and below at one meter interval along the length of pipes is
also acceptable.
4.3 Paint or ink for marking shall not contain any harmful metal or metallic salts such as zinc,
lead or copper which cause corrosive attack on heating.
4.5 Pipes shall be protected from rust, corrosion and mechanical damage during transportation,
shipment and storage.
4.6 Rust preventive used on machined surfaces to be welded shall be easily removable with a
petroleum solvent and the same shall not be harmful to welding.
4.7 Both ends of the pipe shall be protected with the following material:
4.8 Pipes may be provided with plastic push fit type end caps/ steel caps without belt wire..
4.9 Plastic caps can also be used as end protector for galvanized pipe ends.
a) Carbon Steel
The hydrostatic test pressure in kg/cm2 for the following materials shall be as given below :
Material Gr. 1 :ASTM A 312 TP 304 / 304 H/ 316 / 316H/ 321/ 347 welded.
Material Gr. 2 :ASTM A 312 TP 304 L/ 316L welded.
Size Pipe Schedule : 10S Pipe Schedule : 40S Pipe Schedule : 80S
Material Material Material Material Material Material
Gr.1 Gr.2 Gr.1 Gr.2 Gr.1 Gr.2
2” 100 80 155 130 230 190
3” 80 60 155 130 230 190
4” 80 50 155 130 230 190
6” 65 35 90 75 155 130
IS 1239 IS 1239
IS 3589 IS 3589
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CONTENTS
S. NO. TITLE
1.0 GENERAL
2.0 DOCUMENTATION
4.0 OPERATION
8.0 MARKING
9.0 DESPATCH
10.0 ATTACHMENTS
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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
2.1.2 Detailed dimensioned cross section drawing with parts /material lists, weight etc.for the ball
valves, plug valves, butterfly valves, diaphragm valves and valves to manufacturer’s standard.
2.1.3 Drawings for valves with accessories like gear operator, hydraulic / pneumatic operator,
motor, extension bonnet, extended stems with stands, bypass etc. giving major salient
dimensions.
2.1.4 One copy of the valve specification sheets signed as “Accepted” by the manufacturer with all
deviations marked clearly.
2.1.5 If the valve is regretted or has no deviation, the manufacturer shall write clearly on valve
specification sheets as “Regret” or “No Deviation”.
2.1.6 For subject notes, if there is any deviation, the same shall be listed clause-wise. Even clauses
which are acceptable shall be categorically confirmed as “Accepted”.
2.1.7 On failure to submit documents as specified in clauses 2.1.1 to 2.1.6 above, the offer is likely
to be rejected.
2.2 The following documents shall be submitted after placement of the order:
2.2.1 Vendor shall submit for approval drawings mentioned in clauses 2.1.2 & 2.1.3 before start of
manufacture. No other drawing shall be submitted for approval.
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2.2.2 Test report shall be supplied for all mandatory tests as per the applicable code. Test reports
shall also be furnished for any supplementary tests as specified in clauses 3.13, 3.14 & 3.15.
2.2.3 Material test certificates (physical properties, chemical composition & heat treatment report)
of the pressure containing parts shall be furnished for the valves supplied. Material test
certificates for the other parts shall also be furnished for verification during inspection.
3.1 Valve shall be designed, manufactured, tested, inspected and marked as per the
manufacturing standards; design codes and standards (latest editions) indicated in the
respective valve specification sheets. Any conflict between the requisition, enclosures,
specification sheets and referred standard codes shall be brought to the notice of the purchaser
for clarifications. But generally, specification sheets and enclosures of the requisition
including subject notes shall govern. After issue of the Purchase Requisition (PR) no
deviation to specification / standards shall be permitted through vendor drawing approval.
Approval of drawings shall be valid only for design / constructional features.
3.2 All flanged valves shall have flanges integral (except forged valves) with the valve body.
Flange face finish shall be normally specified in the valve specification sheet as serrated
finish, 125 AARH etc. The interpretation for range of face finish shall be as follows:
Serrated Finish / Smooth Finish/ 125 AARH : Serrations with 125 to 250 µ in
AARH
3.3. For all weld end valves with bevel end as per ASME B16.25 the contour of bevel shall be as
follows:
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3.4 For flanged valves with ring joint flanges the hardness shall be as follows
3.5 Following requirements for check valves shall be met over and above the valve spec sheet
requirements:
3.5.1 Unless specified otherwise in the data sheet all check valves 3” & above (except in 900#,
1500# & 2500# rating) shall have a drain boss at location “G” (Refer Fig.No.1 of ASME
B16.34). A tapped drain hole with plug shall be provided as per ASME B16.34. Threads shall
be as per ASME B1.20.1 (Taper) NPT.
3.5.2 Wherever check valve disc assembly is supported from the cover of the check valves the
following shall be ascertained.
ii) Hinge pin design must permit accurate alignment of the disc and valve seat.
3.5.3 For heavy check valves, provisions shall be available for lifting by way of lugs, eye bolts and
other such standard devices.
3.6 If an overlay weld-deposit is used for the body seat ring seating surface, the corrosion
resistance of the seat ring base material shall be at least equal to the corrosion resistance of
the material of the shell.
3.7.1 By-pass requirement for Gate valves is indicated in the respective data sheets. As a rule, the
following shall be followed:
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ANSI 600 Class : On sizes 6” 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:
3.7.4 Vendor shall supply the by-pass valve duly tested and fitted to the main valve. Valves with
by-pass shall have the direction of flow marked on the main valve. By- pass attachment to the
main valve body shall not be screwed. All fillet welds for bypass installation shall be 100%
examined by DP/ MP test.
3.8 Valve body / bonnet shall be forged / cast as specified. Forgings are acceptable in place of
casting but not vice-versa.
3.9 Material of construction of yoke shall be minimum equivalent to body / bonnet material.
3.10 Stem shall be forged or machined from forged / rolled bar. No casting is permitted. However,
integral stern of cast stainless steel ball valve is acceptable.
3.11 Stelliting / Hardfacing by deposition, shall be minimum 1.6 mm. Renewable seat rings shall
he seal welded.
3.12 For Low Temperature & Cryogenic valve requirements, refer Specification. @ Sheet no-17.
3.13 Valves under “NACE” category shall meet the requirements specified in MR unless
otherwise specified.
3.14 For all austenitic stainless steel valves Inter Granular Corrosion (IGC) test shall be conducted
as per the following:
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3.15.1 ASTM A262 Practice “B” with acceptance criteria of “60 mils/year (max.)” for all materials -
forged, rolled, wrought and casting.
Qr
ASTM A262 Practice “E” with acceptance criteria of “No cracks as observed from 20X
magnification” for all materials other than castings. Microscopic structure to be observed
from 250X magnification” in addition.
3.15.2 When specifically asked for in MR for high temperature application of some grades- of
austenitic stainless steel (e.g. SS 309, 310, 316, 316H etc) ASTM A262 Practice “C” with
acceptance criteria of “15 mils/year (max.)” shall be conducted.
3.15.3 For the IGC test as described in Clauses 3.15.1 & 3.15.2, two sets of samples shall be drawn
from each solution annealing lot. One set shall correspond to the highest Carbon content and
the other to the highest pressure rating. When testing is conducted as per practice “E”,
photograph of the microscopic structure shall be submitted for record.
3.16 All types of 321 or 347 stainless steel valves shall be in a stabilised heat treated condition.
Stabilising heat treatment shall be carried out subsequent to the normal solution annealing.
Soaking temperature and holding time for stabilising heat treatment shall be 900°C and 4
hours respectively.
3.17 Spiral wound bonnet gaskets are to be provided with inner/ outer ring except when
encapsulated gaskets type body-bonnet joints are employed. Outer ring may be avoided in
case of non-circular spiral wound gasket used in 150# valve provided the outermost layer of
spiral touches the bolts ascertaining the centering.
3.18.1 As a prequalification, fire safe test as per API 607 / API 6FA / BS 6755 Part II shall be
carried out on soft seated ball, plug & butterfly valves and also on lubricated plug valves. The
test shall be witnessed and certified by a third party inspection agency like Lloyds, B.V.,
DNV etc. The vendor has to submit test certificate for the particular design of the valve
offered.
3.18.2 Each valve shall be supplied with a lever / wrench except for gear operated / motor operated
valves.
3.18.3 Soft-seated ball, plug & butterfly valves shall he supplied with antistatic devices.
3.18.4 Soft-seated BW / SW end ball valves shall have a 100mm long seamless pipe nipple welded
to each end of the valve. Nipples are to be welded prior to assembling Teflon seats I seals.
Specifications of the nipples shall be as indicated in the MR.
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3.18.5 The face-to-face dimensions of all ball valves shall be same as those of gate valves of the
corresponding ANSI class (except 10” onwards in Class 150 where the face-to-face
dimensions shall be as per API 6D long pattern).
3.18.6 The ball of ball valve shall not protrude outside the end flanges of valve.
3.18.7 Ball valves shall be of floating ball/ trunnion mounted type as per following:
3.18.8 Unless otherwise specified in the data sheets, bore of all reduced bore ball valves shall be
limited to one size lower than the nominal bore.
3.19 The MOVs are to be installed in an open area and the actuators shall be suitable for all
weather conditions. The testing of complete assemblies of MOVs along with the actuators
shall be done by the supplier at his works. Torque details for MOVs shall be furnished by the
bidder / supplier in the format attached with the MR.
4.0 OPERATION
4.1 Generally the valves are hand wheel or lever operated. Gear operation shall be provided as
under:
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For sizes lower than these ranges, hand wheel / lever / wrench shall be provided. For pressure
balance plug valves manufacturer’s recommendation shall be acceptable provided the
requirements specified in clause 4.6 are met.
4.2 Gear operator shall be as under, with position indicators for open / close positions and with
limit stops. (Limit stops are not applicable for gate and globe valves).
For Gate / Globe / Diaphragm Totally enclosed bevel gear in grease case with grease
Valves nipples / plugs.
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4.3 Where gear operator is not called for as per Clause 4.1 but vendor recommends a gear
operator, he shall highlight such case(s).
4.4 Gear operator shall be so designed as to operate effectively with the differential pressure
across the closed valve equal to the cold non-shock pressure rating.
4.5 Ball, plug and butterfly valves, even with wrench or lever operators shall have “Open”
position indicators with limit stops.
4.6 Hand wheel diameter shall not exceed 750mm and lever length shall not exceed 500mm on
either side. Effort to operate shall not exceed 35 Kg at hand-wheel periphery. However,
failing to meet the above requirements, vendor shall offer gear operated valve and quote as
per clause 4. 3.
5.1 Every valve shall be subjected to all the mandatory tests and checks called in the respective
codes / data sheet by GAIL inspection or any third party as approved by the owner. For IBR
valves refer clause 7.0.
5.2 Every valve, its components and auxiliaries must be subjected to all the mandatory tests and
checks called for in the respective codes, data sheets etc. by the manufacturer.
5.3 Though the extent of inspection shall be as under, exact extent with hold points shall he
decided by GAIL inspection office and recorded in the form of inspection plan. In case of
third party inspection, the inspection plan shall be approved by the purchaser.
Forged Valves:
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6, Strip check is required for 1 % of total ordered quantity of valves (mm. 1 No.) against
each specification lot.
Samples for strip check shall be selected at random and shall generally be in the highest
size in the lot.
5.4 In case of motor operated or actuator operated valves, functional / operational checks as per
the requirements of the specifications shall be made on each valve.
5.5 Positive Material Identification (PMI) shall be performed as per the scope and procedures as
defined in the ‘Specification for Positive Material Identification (PMI) at Vendor’s Works’
6.1 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.
*No radiography is required for valves of size ≥ 26” in cooling water service.
Radiography specified as random 10% or 20% etc. in the respective valve data sheet implies
10% or 20% etc. of number of valves ordered against each item number with a minimum of
one valve against each item.
6.2 Radiography procedure, areas of casting to be radiographed shall be as per ASME B16.34
and acceptance criteria shall be as per ASME B16.34 Annexure-B. However for areas of
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casting to be radiographed for types of valves not covered in ASME B16.34, vendor shall
enclose details of areas to be radiographed in line with ASME B16.34.
6.3 For random radiography wherever specified in individual data sheets, the sampling shall be as
per size of the quantity ordered for each foundry.
6.4 Radiography wherever specified in the data sheets or as per clause 6.1 shall be done by X- ray
/ γ-ray to get the required sensitivity.
6.5 Over and above the stipulations laid down in clauses 6.1, 6.2, 6.3 & 6.4, all valve castings
when sourced indigenously shall only be procured from foundries approved by GAIL.
7.1 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:
7.3 Valves coming under the purview of “IBR” (Indian Boiler Regulations) shall each be
individually accompanied by IBR certificate original in Form Ill-C duly approved by IBR
authority / local authority empowered by the Central Boiler Board of India. Photocopy of
original certificate duly attested by the local boiler inspector where the supplier is located is
the minimum requirement for acceptance.
7.4 All “IBR” valves shall be painted red in body-bonnet/ body-cover joint.
8.0 MARKING
8.1 Valve markings, symbols, abbreviations etc. shall be in accordance with MSS-SP-25 or the
standard referred in specification sheet as applicable. Vendor’s name, valve rating, material
designation, nominal size, direction of flow (if any) etc. shall be integral on the body.
8.2 Each valve shall have a corrosion resistant tag giving size, valve tag / code no., securely
attached to the valve body.
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8.3 Paint or ink for marking shall not contain any harmful metal or metal salts such as zinc, lead
or copper which cause corrosive attack on heating.
8.4 Carbon Steel / Alloy Steel valves shall be painted with one coat of inorganic zinc silicate
(minimum DFT 65 to 75 microns).
9.0 DISPATCH
9.1 Valve shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind.
9.2 Valves shall be protected from rust, corrosion and any mechanical damage during
transportation, shipment and storage.
9.3 Rust preventive on machined surfaces to be welded shall be easily removable with a
petroleum solvent or shall not be harmful to welding.
9.4 Each end of valve shall he protected with the following materials
9.5 End protectors of wood/ plastic to be used on flange faces shall be attached by at least three
bolts and shall not be smaller than the outside diameter of the flange. However plastic caps
for SW & SCRD end valves shall be press fit type.
9.6 End protectors to be used on bevelled end shall be securely and tightly attached.
9.7 For special service valves additional requirement of dispatch shall be prescribed in data sheet.
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BYPASS PIPING ARRANGEMENT
NOTES:
The orientation & location of hand wheel of bevel gear operator & the bypass
arrangement shall be strictly as per this sketch.
2. The bypass pipe ends shall be socket/butt welded to the body wall of the main valve.
3. The bypass arrangement shall be properly clamped to & supported by the body of the
main valve.
4. Basic design of bypass shall be to MSS-SP-45 & ASME B16.34.
5. Material of bypass pipe & 90° elbows shall be same or equivalent to the body material
of the Valve.
6. Vendor shall furnish dimensions L1 to L8.
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SPECIAL REQUIREMENTS FOR LOW TEMPERATURE & CRYOGENIC VALVES
1.0 Scope
All valves of Low Temperature Carbon Steel (LTCS) and all grades of austenitic SS (CRYO)
material are categorized as cryogenic valves. All these valves shall have extended bonnet as
per BS 6364 except check valves. Valves shall be suitable for installation in any position (on
vertical, horizontal or skewed pipe line).
Following qualification criteria shall be met by the valve vendors to quote valves for
cryogenic services.
Both cryogenic test (clause 2.1) and reference list (clause 2.2) together, as indicated herein
shall be considered for vendor qualification and vendor shall furnish the same, along with his
offer. Vendors whose current supply does not cover valves of all sizes, materials and ratings
(cryogenic test and reference list) required by MR, should confirm/ furnish the following for
consideration of their offer:
i). Evidence of having conducted successfully at least one cryogenic test as per BS 6364.
Test certificate and reference list shall be furnished with the offer.
ii). Vendor shall confirm to conduct cryogenic test per clauses 2.1 & 2.3 for the
remaining valves not later than 12 weeks from the date of purchase order.
Offers of vendors who do not comply with above requirements would be rejected.
Cryogenic test need not be conducted for every order. Test conducted previously, which need
not be against GAIL order, is sufficient.
Vendors to furnish copies of cryogenic test certificate for tests conducted as per details given
below:
ii). Test temperature, unless specifically called for otherwise in the individual MR, shall
be -45°C for LTCS and -196°C for all grades of austenitic stainless steel.
iii). Tests carried out on a particular size of one type of valve, pressure rating and material
shall qualify all sizes equal to and below the test valve size for the same type, pressure
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rating and material. In case of austenitic SS any one grade would qualify for all other
grades of austenitic SS.
iv). Tests shall have to be witnessed and certified by any one of the following third party
inspection agencies; M/s Lloyd, By, DNV, TUV or GAIL.
Vendor shall furnish reference list for valves supplied for cryogenic service indicating the
name of client, year of supply. size, material, pressure rating, type of valve and quantity.
i). Before conducting post order testing, vendor shall submit the following for approval:
c). Schematic of test rig (as per BS 6364) with complete details.
ii). Test has to be conducted on largest size of order for each type of valve and for each
material and class rating. Vendor shall offer one, two or three valves for selection of
test valve by inspector depending upon whether quantity of largest valve in the order
is one, two or three and more than three respectively.
In the event of failure of the test valve to meet the specification requirements, the
vendor shall conduct test on two more valves. If the other two valves which pass test
successfully are of lower size, then the qualification will be valid only to sizes up to -
which test has been conducted successfully.
3.0 Bonnet extension, wherever specified in the valve sheet to BS:6364 shall be for “non cold
box application” unless otherwise specified in the MR. Even if not called for in valve sheet,
valves indicated as “LT” or ‘CRYO” shall be supplied with bonnet extension.
4.0 Bonnet and Gland extension joints shall be of butt welded construction.
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5.0 Repair welding procedure for austenitic stainless steel valves in “CRYO” service shall have
to be qualified for impact test as per ASME B31.3. Minimum acceptable impact energy shall
he 20 J or lateral expansion of 0.38 mm at temperature of -1960C
6.0 Wherever impact test of SS studs / nuts is called for in the data sheet, the impact value shall
be 27 J at the intended service temperature specified in the data sheets.
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DATASHEET FORMAT REV-0
GAIL (INDIA) LTD DATSHEET FOR TORQUE VALUES OF MOV Page 1 of 1
NEW DELHI
Copyright GAIL – All rights reserved
TECHNICAL NOTES
FOR
BUTT WELDED, SOCKET WELDED
AND SCREWED FITTINGS
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:
Upto 10 mm Figure 4
Alloy Steel, Stainless Steel
& Low Temp. Carbon > 10 mm & Upto 25 mm Figure 5 Type A
Steel
>25 mm Figure 6 Type A
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.
1.7.5 Welded pipes employed for manufacture of fittings shall be made by automatic welding
only.
1.7.6 All welded carbon steel, alloy steel & stainless steel fittings shall have maximum negative
tolerance of 0.3 mm.
1.7.7 Specified heat treatment for carbon steel & alloy steel fittings shall be carried out again after
weld repairs.
1.7.8 Irrespective of the material code requirement, all welded fittings indicated in the MR as
“Cryo”& “LT” shall meet impact test requirements of ASME B31.3. The impact test
temperature shall be -196 0C & -45 0C for stainless steel & carbon steel respectively unless
specifically mentioned otherwise in the MR.
1.8.1 All stainless steel fittings shall be supplied in solution heat treated condition.
1.8.2 Solution annealing for stainless steel fittings shall be carried out again after weld repairs.
1.8.3 For all stainless steel fittings Inter Granular Corrosion (IGC) test shall have to be conducted
as per the following:
ASTM A 262 Practice “B” with acceptance criteria of “60 mils/year (max.)”.
Or
ASTM A 262 Practice “E” with acceptance criteria of “no cracks as observed from 20X
magnification” & “microscopic structure to be observed from 250X- magnification
1 .8.4 When specifically asked for in MR for high temperature application of some grades of
austenitic stainless steel (e.g. SS309, 310,316,316H etc.) ASTM A 262 Practice “C” with
acceptance criteria of “15 mils/year” shall have to be conducted.
1.8.5 For the IGC test as described in Clauses 1.8.3 & 1.8.4, two sets of samples shall be drawn
from each solution treatment lot, one set corresponding to the highest carbon content and
other set to the highest fitting thickness. When testing is conducted as per ASTM A 262
Practice “E”, photograph of microscopic structure shall be submitted for record.
1.9 Fittings under “NACE” category shall meet the requirements of MR-01-75.
1.10 Thickness I schedule lower or higher than specified shall not be accepted.
1.11 The gasket contact surfaces of stub ends shall be flat with face finish specified in the
requisition. Interpretation on the specified face finish is as follows:
1.12 Seamless stub ends shall not have any welds on the body.
1.13 Galvanized fittings shall be coated with zinc by hot dip process conforming to IS 4736 /
ASTM A153.
14 Threaded ends shall have NPT taper threads in accordance with ASME/ANSI B1.20.1 upto
1.5” NB & IS 554 from 2” to 6” NB.
1.15 Unless and otherwise specified in the MR, all socket welded and screwed fittings shall be in
accordance with ASME B16.11 to the extent covered in the specification except for unions
which shall be in accordance with MSS-SP-83.
1.16 Special fittings like weld-o-let, sock-o-let, sweep-o-let etc. which are not covered in ASME,
MSS-SP & GAIL Standards shall be as per manufacturer’s standards. Contours of these
fittings shall meet the requirements of ASME B31.3. Manufacturer shall submit drawings /
catalogues of these items along with the offer.
1.17 Length of all long half couplings shall be 100 mm unless otherwise specified in the MR.
1.18 All seamless pipes employed for manufacturing of fittings shall be required to have
undergone hydro test to ASTM A 530. Welded pipes employed for manufacture of fittings
shall be tested as given below:
P= 2ST/D
API5L
S = 85% of SMYS.
ASTM A358 TP 304, 304L, 304H, 318, 318L, 318H, 321, 347
T = Nom. Wall Thickness
(Cl. 1, 3, 4)
D = O.D. of Pipe.
1.19 The bevel ends of all butt weld fittings shall undergo 100% MP/ DP test.
2.1.1 Fittings under the purview of “IBR” (Indian Boiler Regulations) shall be accompanied with
original IBR certificate in Form Ill-C duly approved and countersigned by IBR authority /
local authority empowered by Central Boiler Board of India. Photocopy of the original
certificate duly attested by the local boiler inspector where the supplier is located is the
minimum requirement for acceptance.
2.1.2 For materials 1¼Cr - ½Mo (ASTM A234 Gr.WP11 & ASTM A234 Gr.WP11W) & 2¼Cr -
1Mo (ASTM A234 Gr.WP22 & ASTM A234 Gr.WP22W), where fittings are manufactured
from pipe, Form III-C approved by IBR shall include the tabulation of Et, Sc, & Sr values for
the entire temperature range given below. Et, Sc, & Sr values shall be such that throughout
the temperature range
Et: Yield point (0.2% proof stress at the working metal temperature)
Sc: The average stress to produce elongation of 1% (creep) in 100000 hrs at the working
metal temperature.
Sr : The average stress to produce rupture in 100000 hrs at the working metal temperature
and in no case more than 1.33 times the lowest stress to produce rupture at this
temperature.
2.2 For carbon steel fittings described “IBR” chemical composition shall conform to the
following:
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.
1.1 All items, their dimensions, tolerances, chemical composition, physical properties, heat
treatment and testing etc. shall conform to the latest codes and standards specified in the
requisition. Deviations, if any, shall be clearly highlighted on a separate sheet by the vendor
in the quotation itself.
1.2 Testing
1.2.1 Test reports shall be supplied for all mandatory tests as per the relevant material
specifications. Test reports shall also be furnished for any supplementary tests as specified in
the requisition & Clauses 1.11, 1.12 & 1.15.
1.2.2 Material test certificates (physical property, chemical composition & heat treatment report)
shall also be furnished for the flanges supplied.
1.2.3 Positive Material Identification (PMI) shall be performed as per the scope and procedures as
defined in the ‘Specification for Positive Material Identification (PMI) at Vendor’s Works.
1.3 Ends of weld neck flanges shall be bevelled to suit the schedule / thickness of matching pipe,
as specified in the requisition.
1.4 Bevel end details for welding neck flanges shall be as per ASME B 16.25. Contour of bevel
end shall be as follows:
1.5 Bore of socket weld flanges & reducing blind flanges shall suit the outside diameter and
schedule/ thickness of matching pipe.
1.6 Bore of slip on flanges shall suit the outside diameter of matching pipe.
1.7 Flange face finish shall be normally specified in the requisition as serrated finish, 125 AARH
etc. The interpretation for range of face finish shall be as follows:
1.9 Ends of screwed flanges unless otherwise specified shall have taper threads as per ASME/
ANSI B1.20.1 (upto 1.5” NB) and IS 554 (for 2” to 6” NB).
1.10 For ring joint flanges, blinds and spacers the hardness shall be as follows:
1.11 For ring joint flanges, blinds and spacers, the hardness shall be recorded in the test report.
1.12 Flanges, blinds, drip rings under “NACE” category shall meet the requirements given in MR-
01-75 unless otherwise specified.
1.13 All austenitic stainless steel flanges shall be supplied in solution annealed condition.
1.14.1 For all austenitic stainless steel flanges, blinds, drip rings & Fig.8 flanges inter-granular
corrosion test shall have to be conducted as per following:
ASTM A262 Practice ‘B’ with acceptance criteria of “60 mils/year (max.)”.
OR
ASTM A262 Practice ‘E’ with acceptance criteria of “No cracks as observed from 20X
magnification” & “Microscopic structure to be observed from 250X magnification”
1.14.2 When specifically asked for in requisition for high temperature application of some grades
of austenitic stainless steel (like SS309, 310, 316, 316H etc.) ASTM A262 Practice ‘C’ with
acceptance criteria of “15 mils/year” shall have to be conducted. When testing is conducted
as per Practice ‘E’, photograph of microscopic structure shall be submitted for record.
1.14.3 For the IGC test as described in 1.15.1 & 1.15.2 two sets of samples shall be drawn from
each solution treatment lot; one set corresponding to highest carbon content and the other
corresponding to the highest rating / thickness.
1.15 All types of 321 or 347 stainless steel flanges shall be in a stabilised heat treated condition.
Stabilising heat treatment shall be carried out subsequent to the normal solution annealing.
Soaking temperature and holding time for stabilising heat treatment shall be 900°C and 4
hours respectively.
TECHNICAL NOTES REV- 0
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NEW DELHI SPECTACLE BLINDS AND DRIP RINGS
Copyright GAIL – All rights reserved
1.16 AWWA C207 flanges shall be hub type.
2.1.1 Flanges coming under the purview of IBR (Indian Boiler Regulations) shall be accompanied
with 1BR Certificate original in Form III C duly approved and countersigned by IBR
authority / local authority empowered by Central Boiler Board of India. Photocopy of
original certificate duly attested by the local boiler inspector where the supplier is located is
the minimum requirement for acceptance.
2.2 For carbon steel flanges described as “IBR”, chemical composition shall conform to the
following:
The chemical composition as indicated in this clause is not applicable for flanges other than
IBR.
3.1.1 All carbon steel flanges having wall thickness 9.53 mm and above shall be normalised. The
normalising heat treatment shall be a separate heat treatment operation and not a part of the
hot forming operation.
3.1.2 All alloy steel (Cr-Mo) flanges shall be normalised and tempered. The normalising and
tempering shall be a separate heat treatment operation and not a part of the hot forming
operation.
3.2.1 For all carbon steels and alloy steels with wall thickness over 19 mm, Charpy-V Notch
impact testing shall be carried out in accordance with paragraph UG-84 of ASME Section
VIII, Div-I per heat of material and per heat treating batch. Impact test specimen shall be in
accordance with ASTM A370. Impact energies at 0 °C shall average greater than 27J (20 ft-
lb) per set of 3 specimens, with a minimum of 19J (15 ft-lb).
4.1 All items shall be legibly and conspicuously stamped in accordance with the requirements of
applicable ASME, API and MSS Standards. In addition, GAIL item code, purchase order
number & special conditions like “IBR”, “CRYO”, “NACE” ‘H2” etc. shall also be
stamped.
4.3 Paint or ink for marking shall not contain any harmful metal or metal salts such as zinc, lead
or copper which cause corrosive attack on heating.
4.4 All items shall be dry, clean and free from moisture, dirt and loose foreign materials of any
kind.
4.5 All items shall be protected from rust, corrosion and mechanical damage during
transportation, shipment and storage.
4.6 Rust preventive on machined surfaces to be welded shall be easily removable with a
petroleum solvent and the same shall not be harmful to welding.
4.7 Each end of flange shall he protected with the following materials:
4.8 Each size of flanges, blinds, etc. shall be supplied in separate packagings marked with the
purchase order number, item code number, material specification, size and rating.
5.0 ATTACHMENTS
1. The process of manufacture, heat treatment, chemical and mechanical requirements and
marking for all stud bolts, m/c bolts, jack screws and nuts shall be in accordance with the
codes/standards and specifications given in the requisition. Deviation (s), if any, shall be
clearly highlighted in the quotation. The applicable identification symbol in accordance
with the material specification shall be stamped on each bolt and nut.
2. a. Test reports shall be supplied for all mandatory tests as per the relevant material
specifications.
b. Material test certificate shall also be furnished. (Heat Analysis, Product Analysis
and Mechanical Requirement)
3. All bolting shall be as per ANSI B 18.2.1 for studs, M/c bolts and jack screws and ANSI B
18.2.2 for nuts.
4. Threads shall be unified (UNC for 1” dia and 8UN for > 1” dia) as per ANSI B. 1.12 with
class 2A fit for studs, M/c bolts and jack screws and class 2B fit for nuts.
5. Stud bolts shall be threaded full length with two heavy hexagonal nuts. Length tolerance
shall be in accordance with the requirement of table F2 of Annexure-F of ANSI B 16.5.
6. The nuts shall be double chamfered, semi-finished, heavy hexagonal type and shall be made
by the hot forged process and stamped as per respective material specification.
7. Heads of jack screws and m/c bolts shall be heavy hexagonal type. Jack screw end shall be
rounded.
8. Each size of studs & m/c bolts with nuts and jack screws shall be supplied in separate
containers marked with size and material specifications. ‘CRYO’ shall be marked
additionally in case ‘CRYO’ is specified in the requisition.
9. All items shall be inspected and approved (stagewise) by GAIL inspector or any other
agency authorised by GAIL.
10. The heat treatment for stud bolts & nuts shall be as per code unless mentioned otherwise.
11. All austenitic stainless steel bolts, nuts, screws shall be supplied in solution annealed
condition unless specified otherwise in the material specification.
12. Any additional requirements specified in the requisition shall be fully complied with.
13. Stud bolts, m/c bolts, nuts & jack screws shall be impact tested wherever specified in the
material specification and also where the material specification is indicated as “CRYO”.
For S.S. nuts and bolts minimum impact energy absorption shall be 27 Joules and test
temperature shall be -196.0C unless mentioned otherwise in code. For other materials
impact energy and test shall be as per respective code.
15. When specified as galvanised, the studs, m/c bolts and nuts shall be hot dip zinc coated in
accordance with requirements of class C of ASTM A153.
1.1 All gaskets shall conform to the codes/standards and specifications given in the
requisition. Vendor shall strictly comply with MR/PR stipulations and no deviations
shall be permitted
1.2 Process of manufacture, dimensions and tolerances not specified in requisition shall
be in accordance with the requirements of the manufacturer’s standards.
1.3 Testing
1.3.1 Test reports shall be supplied for all mandatory tests for gaskets as per the
standards specified in the requisition.
1.3.2 Chemical composition and hardness of RTJ gaskets shall also be furnished in
the form of test reports on samples.
1.3.4 PMI shall be performed as per the scope and procedures defined in the
Specification for PMI at Vendor’s works for ring type joint gaskets.
1.4 Full face gaskets shall have bolt holes punched out.
1.5 Filler material for spiral wound gaskets shall not have any color or dye.
1.6 All spiral wound gaskets shall be supplied with outer ring. Material of outer ring
shall be CS unless otherwise specified in the MR.
1.7 For spiral wound gaskets, material of Inner Compression ring shall be same as
spiral strip material. In addition to the requirements as per code and as specified in
the MR, inner ring shall be provided for the following:
1.8 Hardness of metallic RTJ gaskets shall not exceed the values specified below unless
otherwise specified in MR:
Soft Iron 90
5 Cr., ½ Mo 130
1.10 Gaskets of different types and sizes shall be placed in separate shipping containers
and each container clearly marked with the size, rating, material specification and
item code.
1.11 All items shall be inspected and approved by GAIL Inspector or any other agency
authorized by GAIL.
1.12 Any additional requirements specified in the requisition, shall be fully complied
with.
1.13 Non-metallic ring gaskets as per ASME B16.21 shall match flanges to ASME B 16.5
up to 24” (except 22” size) and to ASME B 16.47 B above 24” unless specified
otherwise. For 22” size, the matching flange standard shall be MSS-SP44 unless
specified otherwise.
1.14 Spiral wound gasket as per ASME B 16.20 shall match flanges to ASME B 16.5 up to
24” (except 22” size) and to ASME B 16.47 B above 24” unless specifically
mentioned otherwise. For 22” size, the matching flange standard shall be MSS-SP44
unless specified otherwise.
1.15 Abbreviation
1. SCOPE
3. BASIS OF WORK
4. FABRICATION
5. ERECTION
2.1 Transportation of required piping materials (as described in Cl.2.l.1), pipe support
(material as described in Cl. 2.3) and all other necessary piping materials from
Owner’s storage point or contractor’s storage point (in case of contractor’s scope of
supply) to work site/ shop including raising store requisitions for issue of materials in
the prescribed format & maintaining an account of the materials received from
Owner’s stores.
2.1.1 Piping materials include the following but not limited to the same.
h. Specialty items like online filters, ejectors, sample coolers, steam traps,
strainers, air traps etc.
i. Online instruments like control valve, orifice flange, rotameter, safety valves
etc.
2.2 Shop & field fabrication and erection of piping in accordance with documents listed
under C1.3.0 i.e. ‘BASIS OF WORK’ including erection of all piping materials
enumerated above.
2.4
2.4.1 Fabrication of piping specials like special radius bends, reducers, miters etc.
2.4.2 Fabrication of plain and threaded nipples from pipes as required during erection.
2.4.4 Fabrication of odd angle elbow like 60°, 30° or any other angle from 90/45° elbows as
and when required.
2.4.5 Fabrication of flange, reducing flange, blind flange, spectacle blinds as and when
required.
2.4.7 Grinding of edges of pipes, fittings, flanges etc. to match mating edges of uneven/
different thickness wherever required.
2.5 Modifications like providing additional cleats, extension of stem of valve, locking
arrangement of valves etc. as and when required.
2.6 Preparation of Isometrics, bill of materials, supporting details of all NON-IBR lines upto
2- ½” within the unit battery limit and get subsequent approval from Engineer-in-
Charge as and when called for.
2.7 Obtaining approval for drawings prepared by contractor from statutory authority, if
required.
2.8 Spun concrete lining of the inside of pipes 3” NB & above including fittings and flanges
as required in accordance with specification.
2.9 Rubber lining inside pipes, fittings, flanges as and when required, in accordance with
specification.
2.10 Radiography, stress relieving, dye penetration, magnetic particle test etc. as required
in specification.
2.11 Performing PMI using alloy analysers as per ‘Standard Specification for Positive
Material Identification at Construction Sites.
2.12 Casting of concrete pedestals and fabrication & erection of small structures for pipe
supports including supply of necessary materials.
2.14 Making material reconciliation statement and return of Owner’s supply left over
materials to Owner’s storage.
2.15 Flushing and testing of all piping systems as per standard specification for inspection,
flushing and testing of piping systems.
2.16 Pickling (as and when applicable) as per standard specification for chemical cleaning
of C.S. suction piping of compressors.
2.17 Submission of job execution procedure as per standard specification for review and
approval of Engineer-in-charge covering all above activities.
3.1 The complete piping work shall be carried out in accordance with the following
3.1.1 “Approved for Construction” drawings and sketches issued by GAIL to the Contractor -
Plans and/ or Isometrics.
3.1.2 “Approved for Construction” drawings and sketches issued by Turn-key bidders to the
Contractor - Plans and/or Isometrics.
d. Line list
e. Piping support indices (only in offsite), if supports are not shown in plan.
c. IBR Regulations
d. IS: 823 : Code for procedure for Manual Metal Arc welding
MR-0 1-75
Note: All codes referred shall be latest edition, at the time of award of contract.
3.2 Deviations
Where a deviation from the “Basis of Work and approved job procedure described
above is required or where the basis of work does not cover a particular situation, the
matter shall be brought to the notice of Engineer - in - Charge and the work carried
out only after obtaining
4.0 FABRICATION
Pipe, pipe fittings, flanges, valves, gaskets, studs bolts etc. used in a given piping
system shall be strictly as per the “Piping Material Specification” for the “Pipe Class”
specified for that system. To ensure the above requirement, all piping material
supplied by the Owner / Contractor shall have proper identification marks as per
relevant standards / GAIL specifications/ Licensors specification. Contractor shall
provide identification marks on left over pipe lengths wherever marked up pipe lengths
Cold bends for lines 1-1/2” and below, with a bend radius of 5 times the nominal
diameter shall be used as required in place of elbows wherever allowed by piping
specifications. Bending of pipes 2” and above may be required in some cases like that
for headers around heaters, reactors etc.
The completed bend shall have a smooth surface, free from cracks, buckles, wrinkles,
bulges, flat spots and other serious defects. They shall be true to dimensions. The
flattening of a bend, as measured by the difference between the maximum and
minimum diameters at any cross-section, shall not exceed 8% and 3% of the nominal
outside diameter, for internal and external pressure respectively.
Forging and forming of small bore fittings, like reducing nipples for piping 1-1/2” and
below, shall be as per ASME B 31.3.
The specific application of welded mitre bends and fabricated reducers shall be
governed by the Piping Material Specifications. Generally all 90 deg. mitres shall be 4-
piece 3-weld type and 45 deg. mitres shall be 3-piece 2-weld type as per GAIL
Standard unless otherwise specified. Reducers shall be fabricated as per directions of
Engineer-in-Charge. The radiographic requirements shall be as per Material
Specifications for process and utility systems and NDT Specification for steam piping
under IBR, radiographic requirements of IBR shall be complied with.
Components like pipes, elbows, couplings, half-couplings etc. shall be cut / trimmed /
edge prepared wherever required to meet fabrication and erection requirements, as
per drawings and instructions of Engineer-in-Charge. Nipples as required shall be
prepared from straight length piping.
Galvanized carbon steel piping shall be completely cold worked, so as not to damage
galvanized surfaces. This piping involves only threaded joints and additional external
threading on pipes may be required to be done as per requirement.
4.16 Miscellaneous
4.16.1 Contractor shall fabricate miscellaneous elements like flash pot, seal pot, sample
cooler, supporting elements like turn buckles, extension of spindles and interlocking
arrangement of valves, operating platforms as required by Engineer-in-Charge.
The work of inside spun concrete lining of pipes and specials of diameter 3 and above
shall be done as per material specifications and special condition contract.
Pipes shall be fabricated at site as and when required as per the specifications
attached and the actual Piping Material Specification.
5.0 ERECTION
Before erection all pre-fabricated spool pieces, pipes, fittings etc. shall be cleaned
inside and outside by suitable means. The cleaning process shall include removal of all
foreign matter such as scale, sand, weld spatter chips etc. by wire brushes, cleaning
tools etc. and blowing with compressed air/or flushing out with water. Special cleaning
requirements for some services, if any shall be as specified in the piping material
No deviations from the piping route indicated in drawings shall be permitted without
the consent of Engineer-in-Charge.
In case of fouling of a line with other piping, structure, equipment etc. the matter shall
be brought to the notice of Engineer-in-Charge and corrective action shall be taken as
per his instructions.
Wherever cold pull is specified, the Contractor shall maintain the necessary gap, as
indicated in the drawing. Confirmation in writing shall be obtained by the Contractor
from the Engineer-in-Charge, certifying that the gap between the pipes is as indicated
in the drawing, before drawing the cold pull. Stress relieving shall be performed before
removing the gadgets for cold pulling.
5.4 Slopes
Slopes specified for various lines in the drawings / P&ID shall be maintained by the
Contractor. Corrective action shall be taken by the Contractor in consultation with
Engineer- in-Charge wherever the Contractor is not able to maintain the specified
slope.
5.5.1 All Expansion joints / Bellows shall be installed in accordance with the specification
and Installation drawings, supplied to the Contractor.
5.5.2 a. Upon receipt, the Contractor shall remove the Expansion Joints/ Bellows from
the Case (s) and check for any damage occured during transit.
b. The Contractor shall bring to the notice of the Engineer-in- Charge any damage
done to the bellows / corrugations, hinges, tie-rods, flanges / weld ends etc.
c. Each Expansion Joint / Bellow shall be blown free of dust! foreign matter with
compressed air or cleaned with a piece of cloth.
STANDARD SPECIFICATION FOR SPECIFICATION REV-0
GAIL (INDIA) LTD
NEW DELHI FABRICATION AND ERECTION OF PIPING S – 05 – 02 – 011 Page 12 of 16
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5.5.3 a. For handling and installation of Expansion Joints, great care shall be taken
while aligning. An Expansion Joints shall never be slinged from bellows
corrugations / external shrouds, tie / rods, angles.
b. An Expansion Joints / Bellow shall preferably be slinged from the end pipes/
flanges or on the middle pipe.
5.5.4 a. All Expansion Joints shall be delivered to the Contractor at “Installation length”,
maintained by means of shipping rods, angles welded to the flanges or weld
ends or by wooden or metallic stops.
5.5.5 a. The pipe ends in which the Expansion Joint is to be installed shall be perfectly
aligned or shall have specified lateral deflection as noted on the relevant
drawings.
b. The pipe ends/ Flanges shall be spaced at a distance specified in the drawings.
5.5.6 The Expansion Joint shall be placed between the mating pipe ends / flanges and shall
be tack welded/ bolted. The mating pipes shall again be checked for correct
alignment.
5.5.7 Butt-welding shall be carried out at each end of the expansion joint. For flanged
Expansion Joint, the mating flanges shall be bolted.
5.5.8 After the Expansion Joint is installed the Contractor shall ensure that the mating pipes
and Expansion Joints are in correct alignment and that the pipes are well supported
and guided.
5.5.9 The Expansion Joint shall not have any lateral deflection. The Contractor shall
maintain parallelism of restraining rings or bellows convolutions.
5.5.10 Precautions
a. For carrying out welding, earthing lead shall not be attached with the Expansion
Joint.
b. The Expansion bellow shall be protected from arc weld spot and welding
spatter.
While fitting up mating flanges, care shall be exercised to properly align the pipes and
to check the flanges for trueness, so that faces of the flanges can be pulled together,
without inducing any stresses in the pipes and the equipment nozzles. Extra care shall
be taken for flange connections to pumps, turbines, compressors, cold boxes, air
coolers etc. The flange connections to these equipments shall be checked for
misalignment, excessive gap etc. after the final alignment of the equipment is over.
The joint shall be made up after obtaining approval of Engineer-in-Charge.
The assembly of a flange joint shall be done in such a way that the gasket between
these flange faces is uniformly compressed. To achieve this, the bolts shall be
tightened in a proper sequence. All bolts shall extend completely through their nuts
but not more than 1/4”.
Steel to C.I. flange joints shall be made up with extreme care, tightening the bolts
uniformly after bringing flange flush with gaskets with accurate pattern and lateral
alignment.
High point vents and low point drains shall be provided as per the instructions of
Engineer- in-Charge, even if these are not shown in the drawings. The details of vents
and drains shall be as per piping material specifications / job standards.
5.8 Valves
Valves shall be installed with spindle / actuator orientation / position as shown in the
layout drawings. In case of any difficulty in doing this or if the spindle orientation /
position is not shown in the drawings, the Engineer-in-Charge shall be consulted and
work done as per his instructions. Care shall be exercised to ensure that globe valves,
check valves, and other uni-directional valves are installed with the “Flow direction
arrow “on the valve body pointing in the correct direction. If the direction of the arrow
is not marked on such valves, this shall be done in the presence of Engineer-in-Charge
before installation.
5.9 Instruments
Fabrication and erection of piping upto first block valve / nozzle / flange for installation
of offline Instruments for measurement of level, pressure, temperature, flow etc. shall
also form part of piping construction work. The limits of piping and instrumentation
work will be shown in drawings / standards / specifications. Orientations / locations of
take-offs for temperature, pressure, flow, level connections etc. shown in drawings
shall be maintained.
Flushing and testing of piping systems which include instruments mentioned above
and the precautions to be taken are covered in flushing, testing and inspection of
piping (GAIL Stds). Care shall be exercised and adequate precautions taken to avoid
damage and entry foreign matter into instruments during transportation, installation,
testing etc.
Installation of line mounted items like filters, strainers,, steam traps, air traps,
desuperheaters, ejectors, samples coolers, mixers, flame arrestors, sight glasses etc.
including their supporting arrangements shall form part of piping erection work.
The Contractor shall apply molycoat grease mixed with graphite powder (unless
otherwise specified in piping classes) all bolts and nuts during storage, after erection
and wherever flange connections are broken and made-up for any purpose
whatsoever. The grease and graphite powder shall be supplied by the Contractor
within the rates for piping work.
Pipe supports are designed and located to effectively sustain the weight and thermal
effects of the piping system and to prevent its vibrations. Location and design of pipe
supports will be shown in drawings for lines 3” NB & above for line below 3” NB
Contractor shall locate and design pipe supports in line with GAIL Stds. and obtain
approval of Engineer - in - Charge on drawings prepared by Contractor, before
erection. However, any extra supports desired by Engineer-in-Charge shall also be
installed.
Hanger rods shall be installed inclined in a direction opposite to the direction in which
the pipe moves during expansion.
Preset pins of all spring supports shall be removed only after hydrostatic testing and
insulation is over. Springs shall be checked for the range of movement and adjusted if
necessary to obtain the correct positioning in cold condition. These shall be
subsequently adjusted to hot setting in operating condition. The following points shall
be checked after installation, with the Engineer-in-Charge and necessary confirmation
in writing obtained certifying that:
- All temporary tack welds provided during erection have been fully removed.
SPECIFICATION REV- 0
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Abbreviation :-
MP : Magnetic Particle
CS : Carbon Steel
AS : Alloy Steel
SS : Stainless Steel
SPECIFICATION REV- 0
GAIL (INDIA) LTD STANDARD SPECIFICATION OF Page 2 of 16
NEW DELHI “NON-DESTRUCTIVE S – 05 – 02 – 012
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CONTENTS
2. VISUAL EXAMINATION
4. TABLE –I
6. INSPECTION
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1. GENERAL
1.1 SCOPE
The specification covers the General Requirements for Non- Destructive
Examinations of shop and field fabricated piping.
a. ASME Boiler and Pressure Vessels codes, Section V & VIII (Div.-1) including
Addenda
b. ASME B 31.3
c. ANSI B 31.8
d. ASME B16.5
e. ASME B 16.34
f. PCN/ ASNT
g. PMS
h. In addition to that all general specification dealing with welding and fabrication of
various equipment shall apply.
1.3 CONFLICT
Where a conflict occurs between this Specification and any of the above Codes or
standards the more stringent shall apply. The CONTRACTOR shall inform the
OWNER in writing and receive written certification form the OWNER/ CONSULTANT.
The CONTRACTOR shall have readily available for use at the request of the
OWNER, latest editions of all codes, specification and standards necessary for
execution of the work at work site.
The OWNER will review and approve element's i), ii) & iii) above: prior to start on
any said company work. Any approval given by the OWNER does not relieve the
CONTRACTOR of his obligations under governing, codes, rules and specifications.
All equipment shall be certified and current, to recognized calibration standard and
in first class working condition.
Full compliance with all governmental and local regulatory requirements of HS&E
which shall be fully complied with.
Visual examination shall be carried out before, during and after fabrication in
accordance with ASME Sec. V article 9 and ASME B31.3. Cracks, (regardless of size
and location) and under cutting or any evidence of poor workmanship, materials,
etc., if not repairable shall be cause for rejection.
Welds having any of imperfections which exceed the limitations specified in various
clauses of 2.1 shall be repaired by welding, grinding, overlaying etc.
However number of times of repair welding for the same weld shall be as follows:
3.1 The type and extent of Weld Examination shall be in accordance with Table-1. All
visual and supplementary methods of girth weld examination shall be in accordance
with ASME B31.3 & the requirements of this standard specification.
3.2 Welds between dissimilar material shall be examined by method & to the extent
required for the material having the more stringent examination.
3.3 Following categories of critical piping are classified under inspection Class IV (100
% radiography):
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d) Critical Service : Hydrogen, Oxygen, NACE, Caustic,
Chlorine & such other critical services.
e) High alloys : 5 Cr. & above for all pressure classes
f) High Temperature : Above 500 Deg.C
b) Piping systems which are designed and constructed in accordance with ASME
B31.8 standard for gas pipeline systems shall have all welds radiographically
inspected for 100%,
c) Hardness testing shall be carried out of welds on vessels and piping in sour
or corrosive service and 10% of local PWHT weld as per ASTM Specification
E 10, ANSI 1331.3.
3.5 The CONTRACTOR shall prepare and maintain documentation to track percentage
of welds tested and the weld repair rate. The proposed documentation shall be
made available for review and approval.
3.5 CONTRACTOR shall not deviate from any requirement of this specification
without written approval to do so from OWNER
3.7 Open drains vents or other open ended line shall be leak tested only.
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4. TABLE-I (with applicable Notes)
INSPECTION CLASS: I
IN SERVICE MATERIA TEMP PRESS PIPING TYPE TYPE OF WELD EXAMINATION
SP L (NOTE- DEG C CL. CLASS OF
N. 3) B16.5/ EXAM.
B16.34
CL
AS
S
GIR SCK ATTA FAB. FAB
TH T CHME BRNC MITR
BUT WEL NT H / RED
T D
WEL (NO
WELD WELD
D TE2) (NOTE
1)
1 CATEGO CARBON 0-186 A3A,
RY ‘D’ STEEL A3Y,
FLUID J2A, J3A,
SERVICE 150 # J5A,
UP TO A4Y, a) 100 100 100% 100% 100%
10.55 A5Y VISUAL % %
AUSTENE (-) 29 KG/ A3K
TIC SS TO 86 2
CM
HDPE (-) 20 A1Z, b) LP
TO 50 A4Z, A5Z (NOTE 4, --- --- --- 10% 10%
CUPRO (-) 29 6, 9)
NICKEL TO 60
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TABLE 1 : CLASS, TYPE & EXTENT OF WELD EXAMINATION (CONTD.)
INSPECTION CLASS: II
IN SERVICE MATE TEM PRESS PIPING TYPE OF TYPE OF WELD EXAMINATION
SP RIAL P CL. CLASS EXAM.
N. (NOTE DEG B16.5/
B16.34
CL -3) C
AS
S
GIR SOC ATTA FAB. FAB
TH KT CHME BRNC .MIT
BUT WEL NT H R/
T D
WEL (NO
WELD WELD RED
D TE- (NOTE
2) I)
II -29 A1A,
a) ALL TO A6A,
SERVICES 400 A7A,
COVERED
UNDER
150 # A8A,
INSPECTION CS UP TO A9A, a) VISUAL 100 100 100% 100% 100%
CLASS-I BUT 10.55 A11A, % %
EXCEEDING KG/ A13A,
CATEGORY- 2 A15A,
D PR./TEMP.
CM
A20A,
LIMITATION. A32A,
A33A, b)
A33Y RADIOGRAP 10% --- --- --- 50%
HY (NOTE 5,
6)
b) ALL
SERVICES
EXCEPT CS c) MP/LP/
COVERED (IBR) A2A (NOTE 4,6, --- 10% --- 10% 50%
UNDER 10,11)
CLASS – I
BUT NON-
TOXIC, NOT
SUBJECTED
TO SEVERE
d)
CYCLIC HARDNESS NO NO NOTE- NOTE- NOTE
CONDITIONS TE- TE- 7 7 -7
7 7
2. FOR A33A & A33Y FIRE WATER SERVICE, NOTE-12 IS ALSO APPLICABLE.
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TABLE 1 : CLASS, TYPE & EXTENT OF WELD EXAMINATION (CONTD.)
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5. ULTRASONIC WELD EXAMINATION
Ultrasonic Operators
Ultrasonic operators supplied by the NDE CONTRACTOR shall be certified to a
General Standards Board (ASNT/PCN) approved by the OWNER.
(ii) All category 'D' welds which are not being radio graphed and all other welds
configuration, which does not permit to be radio graphed, shall be ultrasonic tested.
(iii) All tie-in welds where pressure testing are not possible.
6. INSPECTION
The CONTRACTOR shall extend all facilities, assistance and co-operate fully with the
OWNER in all aspects of inspection and NDE and shall give adequate notice of any
required fabrication inspection stages, together with sufficient time for thorough
inspection by the OWNER. OWNER shall have the right to establish hold points at
any point in the fabrication sequence. Records and evidence of all weld
examinations shall be available at all times for OWNER to review and approve.
OWNER may use any method of inspection necessary to establish quality control
and ensure adherence to welding procedures. OWNER shall have the right to accept
or reject any weld not meeting the requirements of this specification. .
CONTRACTOR shall intimate sufficiently in advance the commencement of
qualification test, welding works and acceptance tests to enable the owner/ owner’s
representative to be present to supervise them. Any discrepancies between the
approved WPS and the production welds noted by OWNER, any or all of the work
made under these conditions is subject to rejection.
1. Branch weld shall consist of the Welds between the pipe & reinforcing element (if
any), nozzles & reinforcing element and the pipe & nozzle under the reinforcing
element. Reinforcing element to be interpreted as pads, saddles, weldolets,
sockolets etc.
2. Seal welds of threaded joints shall be given the same examination as socket welds.
b) “Random 10%” of LP/MP test shall mean testing, by applicable test, one
weld for each ten welds or less made by the same welding procedure or
operator or both. Similarly “Random 20%” shall mean testing, by applicable
test, one weld for each five welds or less made by the same welding
procedure or operator or both.
e) Girth weld, branch weld, attachment weld & socket weld of 3-1/2% Ni stell
shall be Liquid Penetrant tested only when welded with austenitic material
where MP test has been specified.
5. Radiography
General –
o X - Ray is the preferred radiographic method. Use of Gamma ray for
examination is not permitted. Particular attention shall be paid to
using radiographic ultra fine grain film suitable for the application,
maintaining correct radiographic geometry during exposure, obtaining
correct density also required by the appropriate standard and the
correct placement and exposure of image quality indicators (IQI's or
penetrameters).
o ASTM wire type IQI's are preferred. GAIL may permit the use of ASTM
hole type IQI's on a pre-approved basis, provided the NDT
CONTRACTOR can demonstrate satisfactory results.
o Radiographic technique shall produce maximum contrast and good
definition of IQI wires. The inability to view the appropriate wire or
hole on any radiograph shall be cause for automatic rejection of that
radiograph which shall be re- radiographed at no expense to GAIL
o Operator Certification
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Radiographers supplied by the CONTRACTOR shall be certified to
ASNT Level II, AWS QC] and as per AWS B1.10 (guide for non-
destructive inspection of welds). An operator qualified to ASNT Level I
may assist the Level II operator but all film and sentencing
interpretation shall be carried out by a Level ll or higher operator who
shall sign off all report sheets. Visual welding inspection shall be
conducted only by a qualified welding inspector, who shall have a
minimum AWS (QC. I) CWI or CSWIP 3.1 certification. GAIL shall
review and approve all QA/QC personnel prior to deployment on the
project.
a) “Random 10% or 20% radiography” shall mean examination not less than
one from each 10 welds or less in case of “Random 10% radiography” or one
from each five welds or less in case of “Random 20% radiography” made by
the same welding procedure or Welder or both. Irrespective of percentage,
no. of welds to be radiographed shall be minimum 1. However first two
welds made by each welder shall also be radiographed in case of “Random
radiography”. Welds selected for examination shall not include flange welds
and shall be radiographed for their entire length. However, where it is
impossible or impracticable to examine the entire weld length of field welds
for either random or 100% radiography, and if the same impossibility is
agreeable to GAIL site-in-charge, then a single 120 Deg. Exposure of the
weld length may be given a Magnetic Particle test or Liquid Penetrant test.
However in such case for ferro-magnetic materials, only MP test shall be
acceptable for classes higher than 600#.
b.1 Two additional examination of the same type shall be made of the
same kind of item (if welded joint, then by the same welding
procedure or operator or both).
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reexamined as required and all items represented by this additional
examination shall be accepted.
b.4 If all the items examined as required by b.3 are acceptable, the items
requiring repair shall be repaired or replaced and reexamined as
required, and all items represented by this further examination shall
be acceptable.
b.5 Number of times repair welding could b done for the same weld
before acceptance shall be as follows:
b.6 Welds not found acceptable for allowed number of times of repair as
per b.5 above shall be replaced and reexamined.
7. Hardness Test:
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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.
g) The hardness limit applies to the weld and heat affected zone. Following
hardness values shall be maintained:
8. For IBR service lines, following IBR requirements shall apply in addition to the notes
4, 5, 6, 7, 12 and Table-I. In case of conflict between above notes and these
requirements , the more stringent ones shall apply. IBR Piping shall be erected of
IBR inspector approved material and construction procedure. Erected piping shall
be hydrotested, inspected and approved by IBR inspector.
b) Piping 102 mm (4”0 bore and under, but not less than 38 mm (1-1/2”) bore:
2% of welds made by each welder on a pipeline with a minimum of one weld
per welder, selected at random, shall be subjected to radiography or may be
cut for visual examination and tests.
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c) Piping less than 38 mm (1.5”) bore:
Special tests are not normally required but 2% of weldfs by each welder on a
pipe line may be cut out from the pipeline for the visual examination and
bend tests.
d) Retests:
9. For fabricated fittings LP test shall be done on the final pass of welding only, in
addition to visual examination.
10. For mitres and fabricated reducers, LP/ MP test shall be done on root pass in
addition to radiography applicable to circumferential joint of respective piping class.
11. For branch connections, LP/ MP test shall be done on root pass and final pass.
12. 10% of the butt weld joints shall be radiographed, however 50% of these butt weld
joints shall be field weld joints.
13. For lined specs, testing (MP/LP/Radiography etc.) shall be performed before lining.
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STANDARD SPECIFICATION
FOR
INSPECTION, FLUSHING AND TESTING
OF PIPING SYSTEMS
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GAIL (INDIA) LTD. S TANDARD SPECIFICATION FOR SPECIFICATION
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CONTENTS
1. SCOPE
2. INSPECTION
3. FLUSHING
4. TESTING
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Abbreviations
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1.0 SCOPE
This specification covers the general requirements for inspection, flushing and
testing of piping systems. However testing of steam lines falling under IBR shall
also be governed by Indian Boiler Regulations.
Flushing and testing of all piping systems shall be witnessed by the Engineer-In-
Charge.
2.0 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:
- PMI has been performed as per ‘Standard Specification for Positive Material
Identification at Construction Sites, S-14-02-001.
3.0 FLUSHING
Flushing shall be done by fresh potable water or dry compressed air, wherever
water flushing is not desirable, to clean the pipe of all dirt, debris or loose foreign
material.
Required pressure for water flushing shall meet the fire hydrant pressure or utility
water pressure. For air flushing, the line / system will be pressurised by
compressed air at the required pressure which shall be 50 psi maximum. The
pressure shall then be released by quick opening of a valve, already in line or
installed temporarily for this purpose. This procedure shall be repeated as many
times as required till the inside of the pipe is fully cleaned.
In line instruments like control valves, orifice plates, rotameters, safety valves and
other instruments like thermowells which may interfere with flushing shall not be
included in flushing circuit.
The screens / meshes shall be removed from all permanent strainers before
flushing. Screens I meshes shall be reinstalled after flushing but before testing.
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During flushing temporary strainers shall be retained. These shall be removed,
cleaned and reinstalled after flushing but before testing.
In case an equipment such as column, vessel, exchanger etc. form part of a piping
circuit during flushing. This shall be done with the approval of Engineer-In-Charge.
However, equipments thus included in the circuit shall be completely drained and
dried with compressed air after flushing is completed.
During flushing discharged water/air shall be drained to the place directed by the
Engineer-In-Charge. If necessary, proper temporary drainage shall be provided by
the contractor.
The contractor shall carry out all the activities required before, during and after the
flushing operation, arising because of flushing requirements, such as but not
limited to the following:
Dropping of valves, specials, distance pieces, inline instruments and any other
piping part before flushing. The flanges to be disengaged for this purpose shall be
envisaged by the contractor and approved by the Engineer-In-Charge. These
flanges shall be provided with temporary gaskets at the time of flushing.
After flushing is completed and approved, the valve distance pieces, piping specials
etc. shall be reinstalled by the contractor with permanent gaskets. However,
flanges at equipment nozzles and other places where isolation is required during
testing, only temporary gaskets shall be provided.
Records in triplicate shall be prepared and submitted by the contractor for each
piping system for the flushing done in the proforma provided/approved by the
Engineer-in-Charge.
4.0 TESTING
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.
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Pumps, compressors and other rotary equipments shall not be subjected to field
test pressure.
Lines which are directly open to atmosphere such as vents, drains, safety valves
discharge need not be tested, but all joints shall be visually inspected. Wherever
necessary, such lines shall be tested by continuous flow of fluid to eliminate the
possibility of blockade. However, such lines if provided with block valve shall be
pressure tested up to the first block valve.
Seats of all valves shall not be subjected to a pressure in excess of the maximum
cold working pressure of the valve. Test pressure applied to valves shall not be
greater than the manufacturer’s recommendation nor less than that required by the
applicable code. Where allowable seat pressure is less than test pressure, test shall
be made through an open valve.
Instruments in the system to be tested, shall be excluded from the test by isolation
or removals, unless approved otherwise by the Engineer-In-Charge.
Restrictions which interfere with filling, venting and draining such as orifice plates
etc. shall not be installed unless testing is complete.
Control valves shall not be included in the test system. Where bypasses are
provided test shall be performed through the bypass and br necessary spool shall
be used in place of the control valve.
Pressure gauges which are part of the finished system, but cannot withstand test
pressure shall not be installed until the system has been tested. Where piping
systems to be tested are directly connected at the battery limits to piping for which
the responsibility rests with other agencies, the piping to be tested shall be isolated
from such piping by physical disconnection such as valve or blinds.
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.
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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.
Open ends of piping system where blanks cannot be used, such as pumps,
compressors, turbines or wherever equipment or pipe spools have been recovered
or disconnected prior to hydrostatic testing, shall be blinded off by using standard
blind flanges of same rating as the piping system being tested.
Pressure gauges used in testing shall be installed as close as possible to the lowest
point in the piping system to be tested, to avoid overstressing of any of the lower
portions of the system. For longer lines and vertical lines , two or more pressure
gauges shall be installed at locations decided by the Engineer-in-Charge.
For lines containing check valves any of the following alternatives shall be adopted
for pressure testing:
Replace the valve by a temporary spool and reinstall the valve after testing.
Provide blind on valve flanges and test the upstream and downstream of the line
separately and remove the blind after testing. At these flanges, temporary gaskets
shall be provided during testing and shall be replaced by permanent gaskets
subsequently.
For check valves in lines 1 ½” and below flapper or seat shall be removed during
testing (if possible). After completion of testing the flapper! seat shall be refitted.
Gas lines when hydrostatically tested shall be provided with additional temporary
supports during testing as directed by the Engineer-in-Charge.
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supports shall be removed only after testing is completed and test fluid is
completely drained.
When testing any piping system, air or steam of approximately 2 kg/cm2g may be
used as preliminary test to detect missing gaskets etc. as this avoids the necessity
of draining the line to make repairs. However, steam shall not be used for this
purpose, if the steam temperature is more than the design temperature of the line.
For jacketed pipes testing of core pipes shall be done on individual pieces where
the pipe is continuously jacketed, before it is jacketed. The outer jacket shall be
tested separately as a system. For piping with discontinuous jacketing the core pipe
and the jacket shall be tested as separate continuous systems.
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.
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:
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All gauges used for field testing shall have suitable range so that the test pressure
of the various systems falls in 40% to 80% of gauge scale range. Gauge shall be of
a good quality and in first class working condition.
Prior to the start of any test or periodically during the field test programme, all test
gauges shall be calibrated using a standard dead weight gauge tester or other
suitable approved testing apparatus. Any gauge showing an incorrect zero reading
or error of more than ± 2% of full scale range shall be discarded .The Engineer-in-
Charge shall check the accuracy of master pressure gauge used for calibration.
All vents and other connections used as vents shall be left open while filling the line
with test fluid for complete removal of air. In all lines for pressurising and
depressurising the system, temporary isolating valves shall be provided if valve
vents, drains do not exist in the system.
Pressure shall be applied only after the system / line is ready and approved by the
Engineer-in- charge.
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.
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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).
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.
Records in triplicate shall be prepared and submitted by the contractor for each
piping system, for the pressure test done in the proforma provided/approved by the
Engineer-in-Charge. Records shall also be submitted for the PMI undertaken as per
GAIL Std. Specification No. S-14-02-001
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STANDARD SPECIFICATION FOR
SHOP & FIELD PAINTING
1.0 GENERAL
2.0 SCOPE
3.0 CODES & STANDRADS
4.0 EQUIPMENT
5.0 SURFACE PREPARATION
6.0 PAINT MATERIALS
7.0 PAINT SYSTEMS
7.1 PRE-ERECTION / PRE-FABRICATION AND SHOP PRIMING FOR CARBON
STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL, STEEL
STRUCTURES, PIPING AND EQUIPMENT ETC.
7.2 REPAIR OF PRE-ERECTION / FABRICATION AND SHOP PRIMING AFTER
ERECTION / WELDING FOR CARBON STEEL, LOW TEMPERATURE CARBON
STEEL & LOW ALLOY STEELS, ITEMS IN ALL ENVIRONMENTS
8.0 FILED PAINT SYSTEM FOR NORMAL CORROSIVE ENVIRONMENT (FOR CARBON
STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL)
9.0 FILED PAINT SYSTEM FOR CORROSIVE ENVIRONMENT (FOR CARBON STEEL,
LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL)
10.0 FILED PAINT SYSTEM FOR HIGHLY CORROSIVE ENVIRONMENT (FOR CARBON
STEEL & LOW ALLOY STEEL), EXTERNAL SURFACES OF UNINSULATED COLUMNS,
VESSELS, HEAT EXCHANGERS, BLOWERS, PIPING, PUMPS, TOWERS,
COMPRESSORS, FLARE LINES, STRUCTURAL STEEL ETC.
11.0 FIELD PAINT SYSTEM FOR CARBON STEEL STORAGE TANKS (EXTERNAL) FOR ALL
ENVIRONMENTS
12.0 FIELD PAINT SYSTEM FOR CARBON STEEL & LOW ALLOY STEEL STORAGE TANKS
(INTERNAL)
13.0 COATING SYSTEM FOR EXTERNAL SIDE OF UNDER GROUND CARBON STEEL
PLANT PIPING AND TANKS
14.0 PAINTING UNDER INSULATION (HOT, COLD & SAFETY) FOR CARBON STEEL, LOW
TEMPERATURE CARBON STEEL, STAINLESS STEEL PIPING AND EQUIPMENT IN
ALL ENVIRONMENT
15.0 INTERNAL PROTECTION OF CARBON STEEL WATER BOXES AND TUBE SHEETS OF
COOLERS / CONDENSERS
16.0 FIELD PAINTING SYSTEM FOR GI TOWERS / NON-FERROUS TUBE SHEETS
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17.0 STORAGE
18.0 COLOUR CODE FOR PIPING
19.0 IDENTIFICATION OF VESSELS, PIPING ETC.
20.0 PAINTING FOR CIVIL DEFENCE EQUIPMENT
21.0 INSPECTION AND TESTING
22.0 GUARANTEE
23.0 QUALIFICATION CRITERIA OF PAINTING CONTRACTOR
24.0 PROCEDURE FOR APPROVAL OF NEW PAINT MANUFACTURERS
ANNEXURE – I LIST OF RECOMMENDED MANUFACTURERS
ANNEXURE – II LIST OF RECOMMENDED MANUFACTURER’S PRODUCTS
1.1 These technical specifications shall be applicable for the work covered by the
contract, and without prejudice to the various codes of practice, standard
specifications etc. It is understood that contractor shall complete the work in all
respects with the best quality of materials and workmanship and in accordance
with the best engineering practice and instructions of Engineer-in-charge.
Any deviation from this standard without written deviation permit from
appropriate authority will result in rejection of job.
2.0 SCOPE
Scope of work covered in the specification shall include, but not limited to the
following.
2.1 This specification defines the requirements for surface preparation, selection and
application of paints on external surfaces of equipment, vessels, machinery,
piping, ducts, and steel structures, external & internal protection of storage tanks
for all services, RCC Chimney & MS Chimney with or without Refractory lining
and Flare lines etc.
2.2.1 The following surfaces and materials shall require shop, pre-erection and field
painting :
b. All un-insulated carbon and low alloy piping fittings and valves (including
painting of identification marks), furnace, ducts and stacks.
d. All structural steel work, pipe, structural steel supports, walkways, hand
rails, ladders, platforms etc .
i. Supply of all primers, paints and all other materials required for painting
other than Owner's supply.
k. Painting under insulation for carbon steel and stainless steel as specified.
2.2.2 The following surfaces and materials shall not be painted unless otherwise
specified:
2.3.1 The contractor shall perform the work in accordance with the following
documents issued to him for execution of work.
2.4 Unless otherwise instructed final painting on pre-erection / shop primed pipes
and equipments shall be painted in the field, only after mechanical completion
and testing on system are completed, as well as, after completion of steam
purging wherever required.
2.5 Changes and deviations required for any specific job due to clients requirement
or otherwise shall be referred to GAIL for deviation permit.
3.1 Without prejudice to the provision of Clause 1.1 above and the detailed
specifications of the contract, the following codes and standards shall be followed
for the work covered by this contract.
3.3 The contractor shall arrange, at his own cost, to keep a set of latest edition of
any one of the above standards and codes at site.
4.1 All tools, brushes, rollers, spray guns, abrasive material, hand / power tools for
cleaning and all equipments, scaffolding materials, shot / wet abrasive blasting,
water blasting equipments & air compressors etc. required to be used shall be
suitable for the work and all in good order and shall be arranged by the
contractor at site and in sufficient quantity.
4.2 Mechanical mixing shall be used for paint mixing operations in case of two pack
systems except that the Engineer-in-Charge may allow the hand mixing of small
quantities at his discretion.
5.1 General
5.1.1 In order to achieve the maximum durability, one or more of following methods of
surface preparation shall be followed, depending on condition of steel surface
and as instructed by Engineer-in-Charge. Adhesion of the paint film to surface
depends largely on the degree of cleanliness of the metal surface. Proper surface
preparation contributes more to the success of the paint protective system:
c. Blast cleaning.
5.1.2 Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure
that a clean and dry surface is obtained. The minimum acceptable standard in
case of manual or hand tool cleaning shall be St.2 or equivalent, in case of
mechanical or power tool cleaning it shall be St.3 or equivalent, in case of blast
cleaning it shall be Sa 2 ½ or equivalent as per Swedish Standard SIS-055900-
1967 / ISO-8501-1-1988. Where highly corrosive conditions exist, blast cleaning
shall be Sa3 as per Swedish Standard.
Remove all other contaminants, oil, grease etc. by use of an aromatic solvent
prior to surface cleaning.
5.1.3 Blast cleaning shall not be performed where dust can contaminate surfaces
undergoing such cleaning or during humid weather conditions having humidity
exceeding 85% .
5.1.4 Irrespective of the method of surface preparation, the first coat of primer must
be applied on dry surface. This should be done immediately and in any case
within 4 hours of cleaning of surface. However, at times of unfavorable weather
conditions, the Engineer-in-Charge shall have the liberty to control the time
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period, at his sole discretion and / or to insist on re-cleaning, as may be
required, before primer application is taken up. In general, during unfavorable
weather conditions, blasting and painting shall be avoided as far as practicable.
5.1.5 The external surface of R. C .C. chimney to be painted shall be dry and clean.
Any loose particle of sand, cement, aggregate etc. shall be removed by
scrubbing with soft wire brush if necessary, acid etching with 10 - 15% HCL
solution for about 15 minutes shall be carried out and surface must be
thoroughly washed with water to remove acid & loose particles then dry
completely before application of paint.
The surfaces shall be blast cleaned using one of the abrasives: Al2O3, particles
chilled cast iron or malleable iron and steel at pressure of 7 kg/cm2 at appropriate
distance and angle depending on nozzle size maintaining constant velocity and
pressure. Chilled cast iron, malleable iron and steel shall be in the form of shot or
grit of size not greater than 0.055" maximum in case of steel and malleable iron
and 0.04" maximum in case of chilled iron. Compressed air shall be free from
moisture and oil. The blasting nozzles should be Venturi style with tungsten
carbide or boron carbide as the materials for liners. Nozzles orifice may vary from
3/16" to 3/4". On completion of blasting operation, the blasted surface shall be
clean and free from any scale or rust and must show a grey white metallic lusture.
Primer or first coat of paint shall be applied within 4 hours of surface preparation.
Blast cleaning shall not be done outdoors in bad weather without adequate
protection or when there is dew on the metal which is to be cleaned. Surface
profile shall be uniform to provide good key to the paint adhesion (i.e. 35 to 50
microns). If possible vacuum collector shall be installed for collecting the
abrasives and recycling.
Environmental, health and safety problems associated with abrasive blast cleaning
limit the application of Air Blast Cleaning in many installations. In such case
water blast cleaning is resorted to.
Water Blast Cleaning can be applied with or without abrasive and high pressure
water blasting. The water used shall be inhibited with sodium chromate /
phosphate. The blast cleaned surface shall be washed thoroughly with detergents
and wiped with solvent and dried with compressed Air. For effective cleaning,
abrasives are used. The most commonly used pressure for high pressure
water blast cleaning for maintenance surface preparation is 3000 to 6000 psi at
35-45 liters / minute water volume and pressures up to 10000 psi and water
volume of 45 liters / minute provide maximum cleaning.
Special equipments for water blast cleaning with abrasives now available shall
be used.
Manual or hand tool cleaning is used only where safety problems limit the
application of other surface preparation procedure and hence does not appear in
the specifications of paint systems.
b. Hand scraping
Rust, mill scale spatters, old coatings and other foreign matter, shall be removed
by hammering, scrapping tools, emery paper cleaning, wire brushing or
combination of the above methods. On completion of cleaning, loose material
shall be removed from the surface by clean rags and the surface shall be brushed,
swept, de-dusted and blown off with compressed air / steam to remove all loose
matter. Finally the surface may be washed with water and dried for effective
cleaning.
5.4 Shop coated (coated with primer & finishing coat) equipment should not be
repainted unless paint is damaged.
5.5 Shop primed equipment and surfaces will only be 'spot cleaned' in damaged
areas by means of power tool brush cleaning and then spot primed before
applying one coat of field primer unless otherwise specified. If shop primer is not
compatible with field primer then shop coated primer should be completely
removed before application of selected paint system for particular environment.
5.6 For packaged units / equipment, shop primer should be as per the paint system
given in this specification. However, manufacturer's standard can be followed
after review.
5.7.1 Surface shall not be coated in rain, wind or in environment where injurious
air bone elements exists, when the steel surface temperature is less than 50F
above dew point, when the relative humidity is greater than 85% or when the
temperature is below 40°F.
5.7.2 Blast cleaned surface shall be coated with one complete application of primer as
soon as practicable but in no case later than 4 hrs. in the same day.
5.7.3 To the maximum extent practicable, each coat of material shall be applied as a
continuous film uniform thickness free of probes. Any spots or areas missed in
application shall be recoated and permitted to dry before the next coat is applied.
Applied paint should have the desired wet film thickness.
5.7.4 Each coat shall be in proper state of cure or dryness before the application of
succeeding coat. Material shall be considered dry for recoating when an
additional coat can be applied without the development of any detrimental film
irregularities, such as lifting or loss of adhesion of the under coat. Manufacturer
instruction shall be followed for inter coat interval.
5.7.5 When the successive coat of the same colour have been specified, alternate coat
shall be tinted, when practical, sufficiently to produce enough contrast to indicate
complete coverage of the surface. The tinting material shall be compatible with
the material and not detrimental to its service life.
a. The equipment used shall be suitable for the intended purpose, shall be
capable of properly atomizing the paint to be applied, and shall be equipped
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with suitable pressure regulators and gauges. The air caps, nozzles, and
needles shall be those recommended by the manufacturer of the equipment
for the material being sprayed. The equipment shall be kept in satisfactory
condition to permit proper paint application.
d. The pressure on the material in the pot and the air at the gun shall be
adjusted for optimum spraying effectiveness. The pressure on the material
in the pot shall be adjusted when necessary for changes in elevation of the
gun above the pot. The atomizing air pressure at the gun shall be high
enough to properly atomize the paint but not so high as to cause excessive
fogging of paint, excessive evaporation of solvent, or less by overspray.
e. Spray equipment shall be kept sufficiently clean so that dirt, dried paint, and
other foreign materials are not deposited in the paint film.
f. Paint shall be applied in a uniform layer, with overlapping at the edge of the
spray pattern. The spray patterns shall be adjusted so that the paint is
deposited uniformly. During application, the gun shall be held perpendicular
to the surface and a distance which will ensure that a wet layer of paint is
deposited on the surface. The trigger of the gun should be released at the
end of each stroke.
g. All runs and sags shall be brushed out immediately or the paint shall be
removed and the surface repainted.
j. Edges of structural shapes and irregular coated surfaces shall be coated first
and an extra pass made later.
5.7.7 Airless spray application shall be in accordance with the following procedure: as
per steel structure paint Manual Vol. 1 & Vol.2 by SSPC, USA. Air less spray
relies on hydraulic pressure rather than air atomization to produce the desired
spray. An air compressor or electric motor is used to operate a pump to produce
pressures of 1,000 to 6,000 psi. Paint is delivered to the spray gun at this pressure
through a single hose within the gun; a single paint stream is divided into separate
streams, which are forced through a small orifice resulting in atomization of paint
without the use of air. This results in more rapid coverage with less overspray.
Airless spray usually is faster, cleaner, more economical and easier to use than
conventional air spray.
a. Brushes shall be of a style and quality that will enable proper application of
paint.
b. Round or oval brushes are most suitable for rivets, bolts, irregular surfaces,
and rough or pitted steel. Wide flat brushes are suitable for large flat areas,
but they shall not have width over five inches.
5.7.9 Manual Application by sling (where 6’O clock position of pipe is not approachable)
A canvas strip (alternatively a tinplate strip) about 450mrn wide and 1.5m long is
hold under the pipe by two men. Liquid coating is poured on the sling at each
side of the pipe. The men holding this sling move it up and down and walk
slowly forward while fresh coating is poured on the pipe and they manipulate the
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sling so that an even coating is obtained all round the bottom. This work shall be
done very carefully and by experienced personnel. There shall not be any
formation of "Whiskers" and holes in the coating. The coating film shall be
inspected by mirror.
5.7.10 For each coat, the painter should know the WFT corresponding to the specified
DFT and standardize the paint application technique to achieve the desired WFT.
This has to be ensured in the qualification trial.
5.8.1 No coat shall be applied until the preceding coat has dried. The material shall be
considered dry for re-coating when another coat can be applied without the
development of any film irregularities such as lifting or loss of adhesion of
undercoats. Drying time of the applied coat should not exceed maximum specified
for it as a first coat; if it exceeds the paint material has possibly deteriorated or
mixing is faulty.
5.8.2 No paint shall be force dried under conditions which will cause checking,
wrinkling, blistering formation of pores, or detrimentally affect the condition of
the paint.
5.8.3 No drier shall be added to a paint on the job unless specifically called for in the
manufacturer's specification for the paint.
5.8.4 Paint shall be protected from rain, condensation, contamination, snow and
freezing until dry to the fullest extent practicable.
5.9.1 Where paint has been damaged in handling and in transportation, the repair of
damaged coating of pre-erection / fabrication shall be as given below.
5.9.2 Repair of damaged inorganic zinc silicate primer after erection / welding:
Quickly remove the primer from damaged area by mechanical scraping and
emery paper to expose the white metal. Blast clean the surface if possible.
Feather the primer over the intact adjacent surface surrounding the damaged
area by emery paper.
5.9.3 Repair of damaged pre-erection and shop priming in the design temperature of -
90°C to 500°C.
5.10.2 Shop priming / pre-erection priming with F9 or F12 shall be done only with
airless spray.
5.10.3 For large flat surface field painting shall be done by airless spray otherwise brush
can be used.
5.11 Documentation
A written quality plan with procedure for qualification trials and for the actual work.
Particulars of surface preparation and paint application during trials and during the
work.
Paint manufacturer shall furnish all the characteristics of the paint material on
printed literature, along with the test certificate for all the specified characteristics
given in this specification. All the paint materials shall be of first quality and
confirm to the following general characteristics as per tables 6.1, 6.2 & 6.3.
F-15: Two pack cold cured epoxy phenolic coating suitable for -450C to 125°C for
application under insulation
Notes:
1.0 Covering capacity and DFT depends on method of application. Covering capacity
specified above are theoretical. Allowing the losses during the application,
minimum specified DFT should be maintained.
2.0 All primers and finish coats should be cold cured and air dried unless otherwise
specified.
3.0 All paints shall be applied in accordance with manufacturer's instructions for
surface preparation, intervals, curing and application. The surface preparation,
quality and workmanship should be ensured.
4.0 Technical data sheets for all paints shall be supplied at the time of submission of
quotations.
The paints shall conform to the specifications given above and the best quality in
their products range of the manufacturers listed in Annexure-I.
The paint system should vary with type of environment envisaged in and around
the plants. Three types of environment as given below are considered for selection
of paint system. The paint system is also given for specific requirements.
PRIMERS
17.1 All paints and painting materials shall be stored only in rooms to be arranged by
contractor and approved by Engineer-in-charge for the purpose. All necessary
precautions shall be taken to prevent fire. The storage building shall preferably
be separate from adjacent building. A signboard bearing the words "PAINT
STORAGE- NO NAKED LIGHT- HIGHLY INFLAMABLE" shall be clearly displayed
outside.
For identification of pipelines, the colour code as per Table 18.1 shall be used.
Paint materials for color coding shall be as specified in this standard in clause-
6.0.
18.1 Colour coding scheme for pipes, equipment, machinery & structures:
18.3 Ground Colours as given in Table-18.1 shall be applied throughout the entire
length for un insulated pipes, on the metal cladding & on surfaces covered by
Clause 2.2.2, ground colour coating of minimum 2m length or of adequate length
not to be mistaken as colour band shall be applied at places requiring colour
bands. Colour band(s) shall be applied at the following location.
c. Other points, such as midway of each piping way, near valves, junction
joints of service appliances, walls, on either side of pipe culverts.
18.4.1 Flow direction shall be indicated by an arrow in the location stated in Para a,
b ,c & d and as directed by Engineer-in-Charge.
18.4.2 Colours of arrows shall be black or white and in contrast to the colour on which
they are superimposed.
18.4.3 Product names shall be marked at pump inlet, outlet and battery limit in a
suitable size as approved by Engineer-in-Charge.
18.5.1 As a rule, minimum width of colour band shall conform to the following table.
Note: For insulated pipes, nominal pipe size means the outside diameter of the
insulation.
19.1 Equipment number shall be stenciled in black or white on each vessel, column,
equipment & machinery (insulated or un insulated) after painting. Line number in
black or white shall be stenciled on all the pipe lines of more than one location
as directed by Engineer-in-Charge, Size of letters printed shall be as below:
21.1 Following items shall be painted for camouflaging if required by the client.
a. All columns
b. All tanks in offsites.
c. Large Vessels
d. Spheres
20.2 Two coats of selected finishing paint as per defense requirement shall be applied
in a particular pattern as per 20.3 and as per the instructions of Engineer-in-
Charge.
20.3.1 Disruptive painting for camouflaging shall be done in three Colours in the ratio of
5:3:2 (Dark Green : Light Green : Medium Brown) (all matt finish).
20.3.4 The patches should be continuous where two surfaces meet at an angle.
21.1 All painting materials including primers and thinners brought to site by contractor
21.2 Engineer-in-Charge at his discretion may call for tests for paint formulations.
Contractor shall arrange to have such tests performed including batch wise test of
wet paints for physical & chemical analysis. All costs there shall be borne by
the contractor.
a. Surface preparation
b. Primer application
In addition to above, record should include type of shop primer already applied
on equipment e. g. Red oxide zinc chromate or zinc chromate or Red lead primer
etc.
Any defect noticed during the various stages of inspection shall be rectified by
the contractor to the entire satisfaction of Engineer-in-Charge before proceeding
further. Irrespective of the inspection, repair and approval at intermediate stages
of work, contractor shall be responsible for making good any defects found
during final inspection / guarantee period / defect liability period as defined in
general condition of contract. Dry film thickness (DFT) shall be checked and
recorded after application of each coat and extra coat of paint should be applied to
make-up the DFT specified without any extra cost to owner, the extra cost
should have prior approval of Engineer-In-Charge .
After surface preparation, the primer should be applied to cover the crevices,
corners, sharp edges etc. in the presence of inspector nominated by Engineer-in-
Charge.
21.5 The shades of successive coats should be slightly different in colour in order to
ensure application of individual coats, the thickness of each coat and complete
coverage should be checked as per provision of this specification. This should be
approved by Engineer-in-Charge before application of successive coats.
21.6 The contractor shall provide standard thickness measurement instrument with
appropriate range(s) for measuring Dry film thickness of each coat, surface profile
page for checking of surface profile in case of blast cleaning, Holiday detectors and
DOCUMENT NO. REV-0
GAIL (INDIA) LTD STANDARD SPECIFICATION FOR
SHOP AND FIELD PAINTING Page 39 of 49
NEW DELHI S-05-02-014
Copyright GAIL – All rights reserved
pinhole detector and positector whenever required for checking in case of
immersion conditions.
21.8 At the discretion of Engineer-in-Charge, the paint manufacturer must provide the
expert technical service at site as and when required. This service should be free
of cost and without any obligation to the owner, as it would be in the interest of
the manufacturer to ensure that both surface preparation and application are
carried out as per their recommendations.
21.9 Final inspection shall include measurement of paint dry film thickness, Adhesion,
Holiday detection check of finish and workmanship. The thickness should be
measured at as many points/locations as decided by Engineer-in-Charge and
shall be within + 10% of the dry film thickness, specified in the specifications.
21.10 The contractor shall arrange for spot checking of paint materials for Sp. gr., flow
time(ford cup) and spreading rate.
22.0 GUARANTEE
22.1 The contractor shall guarantee that the chemical and physical properties of paint
materials used are in accordance with the specifications contained herein / to be
provided during execution of work.
22.2 The contractor shall produce test reports from manufacturer regarding the
quality of the particular batch of paint supplied. The Engineer-in-Charge shall
have the right to test wet samples of paint at random, for quality of same, as
stipulated in Clause 11 above. Batch test reports of the manufacturer's for each
batch of paints supplied shall be made available by the contractor.
Painting contractor who is awarded any job for GAIL, Projects under this standard
must have necessary equipments, machinery, tools and tackles for surface preparation,
paint application and inspection. The contractor must have qualified, trained and
experienced surface preparator , paint applicator, inspector and supervisors. The
contractor supervisor, inspector, surface preparator and paint applicator must be
conversant with the standards referred in this specification. The contractors capacity,
capability and competency requirements for the job shall be quantified in the
tender document and shall be assessed by GAIL team before awarding any job.
24.1 The manufacturer should arrange testing of the inorganic zinc silicate coating
materials as per the list of tests given in para 24.5 below from one of the reputed
Government laboratories.
24.3 All test panels should be prepared by Govt. testing agency coloured photographs
of test panels should be taken before and after the test and should be enclosed
along with test report.
Sample batch no. and manufacturer's test certificate should be enclosed along
with the report. Test report must contain details of observation and rusting if
any, as per the testing code. Suggested Government laboratories are:
RRL ,Hyderabad
HBTI, Kanpur
DMSRDE, Kanpur
IIT, Mumbai
BIS Laboratories.
UDCT, Mumbai
RITES, Calcutta
PDIL
24.4 Manufacturers should intimate the Company, details of sample submitted for
testing, name of Govt . testing agency, date, contact personnel of the Govt.
testing agency. At the end of the test the manufacturer should submit the test
reports to the company for approval. The manufacturer(s) shall be qualified
based on the results of these tests and other assessment and the Company's
decision in this regard shall be final and binding on the manufacturer.
24.5 Test required for evaluation of acceptance of coating materials for offshore
application.
FILM CHARACTERSTICS
ADHESION - D 2197
ABRASION RESISTANCE - D 968 / D 1044
DFT / COAT - AS PER SSPC GUIDELINES
STORAGE STABILITY - D 1849
RESISTANCE TO
HUMIDITY FOR 2000 HRS. - D 2247
SALT SPRAY FOR 2000 HRS B 117
ACCELERATED WEATHERING D 822
%Zn IN DFT - G 53
24.6 Coating system for panel test shall be decided after discussion with GAIL.
INDIAN VENDORS
SPECIFICATION REV- 0
GAIL (INDIA) LTD INSPECTION AND TEST PLAN FOR GASKETS
NEW DELHI S – 05 – 06 - 001 Page 1 of 4
Copyright GAIL – All rights reserved
SL. STAGE COMPONENT CHARACTER METHOD OF QUANTUM REFERENCE ACCEPTANCE RECORD SCOPE OF INSPECTION
NO. ISTICS CHECK OF CHECK DOC. NORMS
SUB VENDO GAIL
VENDOR R
1.0 CAF
GASKETS
1.1 Raw Material CAF Material Physical Visual, 100 % IS 2712 Gr. IS 2712 Gr. Manufacturer’s W R -
Inspection Dimensional, TC W/1 W/1 TC
Verification
1.2 In process CAF Material Identification Visual, As per ANSI B ANSI B 16.21, Inspection - W -
inspection Verification Dimensional internal QA 16.21, PO, PO, Material Report
(punching & Plan Material Specification
finishing) Specification
1.3 Final Gasket Identification Visual, 100% by ANSI B ANSI B 16.21, Inspection - W R
Inspection Verification Dimensional Vendor, at 16.21, PO, PO, Material Report
random by Material Specification
GAIL Specification
2.0 SPIRAL
WOUND
2.1 Raw Material Metaalic spiral Chemical, Lab Check Visual 100 % lots Applicable Applicable Manufacturer’s - W&R -
Inspection winding Visual, Material Material TC
(Review of material, Dimensional specification specification
mfr’s centering ring,
certificate and Inner ring
check test)
2.2 Raw Material Non- Metallic Physical Visual Dimension 100 % Applicable Applicable Manufacturer’s - W&R -
Inspection filler material TC Verification Material Material TC
(Review of specification specification
mfr’s
certificate and
check test)
SPECIFICATION REV- 0
GAIL (INDIA) LTD INSPECTION AND TEST PLAN FOR GASKETS
NEW DELHI S – 05 – 06 - 001 Page 2 of 4
Copyright GAIL – All rights reserved
SL. STAGE COMPONENT CHARACTER METHOD OF QUANTUM REFERENCE ACCEPTANCE RECORD SCOPE OF INSPECTION
NO. ISTICS CHECK OF CHECK DOC. NORMS
SUB VENDO GAIL
VENDOR R
2.3 Raw material Spiral Wound Compression Test Jig Lots of every ANSI B ANSI B 16.20, Inspection report - W H
inspection & recovery size / rating 16.20, PO, PO, Material
test Material Specification
Specification
2.4 Final Gasket Identification Visual Dimension, 100 % by ANSI B ANSI B 16.21, Inspection report - W R
Inspection Verification Marking vendor, at 16.21, PO, PO, Material
random by Material Specification
GAIL Specification
3.1 Raw material Seamless ring Properties Chemical 100 % ANSI B ANSI B 16.20, TC, Inspection W W R
inspection gasket material Dimension, visual, 16.20, PO, PO, Material report
(Document Hardness Material Specification
Review) Specification
3.2 Raw material Ring Gasket Properties Dimension, visual, At random ANSI B ANSI B 16.20, Inspection report - W -
inspection Material Hardness 16.20, PO, PO, Material
(Check Test) Material Specification
Specification
3.3 Final Gasket Identification, Dimension, visual, At random ANSI B ANSI B 16.20, TC, Inspection - W H
Inspection Verification Hardness 16.20, PO, PO, Material report
Material Specification
Specification
3.4 Final Gasket PMI Check X-Ray Std. Spec for Std. Spec for Material Inspection - W H
Inspection Floorescence/ PMI PMI Specification Report
(Non CS) Emission
Spectrometer
SPECIFICATION REV- 0
GAIL (INDIA) LTD INSPECTION AND TEST PLAN FOR GASKETS
NEW DELHI S – 05 – 06 - 001 Page 3 of 4
Copyright GAIL – All rights reserved
4.0 JACKETED
GASKET
4.1 Raw material Metal Jacketed Properties Chemical, As per IS 513 IS 513 TC, Inspection - W -
Inspection Dimension sampling report
thickness, Visual plan
4.2 Raw material Filler Properties Dimension, visual, At random ANSI B ANSI B 16.20, Inspection report - W -
Inspection Hardness 16.20, PO, PO, Material
Material Specification
Specification
4.3 Final Gasket Identification Dimension, visual, At Random ANSI B ANSI B 16.20, TC, Inspection - W H
Inspection verification Hardness 16.20, PO, PO, Material report
Material Specification
Specification
4.4 Final Gasket PMI Check X-Ray Std. Spec for Std. Spec for Material Inspection - W H
Inspection Floorescence/ PMI PMI Specification Report
(Non CS) Emission
Spectrometer
Legend : H – Hold (Offer for witness & obtain clearance), W – Witness, R – Review, A – Approval, I – Information, X – Submit, PO – Purchase Order, PR – Purchase Requisition.
In case of conflict between purchase specification , contract documents and ITP more stringent conditions shall be applicable.
SPECIFICATION REV- 0
GAIL (INDIA) LTD INSPECTION AND TEST PLAN FOR GASKETS
NEW DELHI S – 05 – 06 - 001 Page 4 of 4
Copyright GAIL – All rights reserved
STANDARD SPECIFICATION
FOR
POSITIVE MATERIAL IDENTIFICATION
(PMI)
AT VENDOR’S WORKS
1.0 SCOPE
3.0 DEFINITIONS
8.0 MARKING
1.2 Any post order deviation from this specification must be approved by Owner/ GAIL in
the Deviation/ Waiver Permit Format enclosed with Material Requisition.
1.3 This specification covers the procedures and methodology to be adopted to assure that
the chemical composition of the alloy material is consistent with the material
specifications as specified in purchase documents using “Alloy Analyzer” at the time of
final inspection before dispatch.
1.4 The scope of this specification shall include but shall not be limited to Positive Material
Identification (PMI) to be performed on Alloy Materials listed below:
1.5 All grades of material supplies including Stainless Steels shall be liable for PMI test at
site. In case of any defective materials being found at site, the vendor shall be
responsible to effect replacement of such defective materials at project site without any
delays to the satisfaction of GAIL.
3.0 DEFINITIONS
3.1 Vendor: Any Supplier or Manufacturer on whom an order is placed for the supply of
referred items. This definition shall also include any sub-vendor or manufacturer on
whom a sub- order is placed by the vendor.
3.2 Inspection Lot: A group of items offered for inspection covered under same size, Heat
and Heat treatment lot.
3.3 Alloy Material: Any metallic material (including welding filler material) that contains
alloying elements such as chromium, nickel, molybdenum or vanadium, which are
intentionally added to enhance mechanical or physical properties and/ or corrosion
resistance.
4.1 The vendor shall submit a procedure of PMI to comply with the requirements of this
Specification Approval of PMI Procedure shall be obtained from Owner/ GAIL/ TPI prior
to commencing manufacture/ inspection of product.
4.3 The Vendor shall identify all incoming alloy materials and maintain full traceability of all
alloy materials, including all off-cuts. Transfer of identification marks shall be
undertaken prior to cutting to ensure maintenance of identification on off-cuts.
4.4 The Vendor shall ensure that all alloy materials are segregated and stored in separately
identified locations to prevent the mix up of materials of different alloy specifications or
alloy material with carbon steel. Non ferro-magnetic materials shall be segregated at all
times from ferro-magnetic materials.
5.1 The method used for PMI examination shall provide a quantitative determination of the
alloying elements like Cr, Mo, Ni, V in Alloy Steel items.
5.3 The acceptable instruments for alloy analyzer shall be either “Portable X-Ray
Fluorescence” or Optical Emission” type each capable of verifying the percentage of
alloy elements within specified range.
5.4 Chemical spot testing, magnets, alloy sorters and other methods using eddy current or
triboelectric testing methods are not acceptable for PMI examination.
5.5 The PMI instruments shall have the sensitivity to detect the alloying elements in the
specified range.
5.6 All PMI instruments shall have been serviced within a 6 month period of the time of use
to verify the suitability of batteries, sources etc, the data of the last service shall be
stated on the PMI Report Form (Sample enclosed).
5.7 Each analyzer must be calibrated according to the manufacturer’s specification at the
beginning and end of each shift. Instrument must be checked against known standard
for each alloy type to be inspected during the shift.
5.8 Certified samples, with full traceability, of a known alloy materials shall be available for
use as a random spot check on the instrument calibration.
5.9 The surfaces to be examined shall be prepared by light grinding or abrasive paper and
solvent cleaner. Evidence of Arc burn resulting from examination shall be removed by
light grinding or abrasive paper.
5.10 Alloy Steel ring type joint gaskets shall be inspected by using portable X-Ray
Flourescence instrument.
5.11 Testing shall be done as per the procedures outlined by the manufacturers of alloy
analyzer being used. Modification of these procedures if any, must be approved by
Owner/ GAIL.
5.12 The persons performing PMI shall demonstrate their capabilities to the satisfaction of
Owner/ GAIL visiting engineer. If the vendor has qualified operator on their rolls, he
may perform the examination. Otherwise PMI examination shall be sub-contracted to an
independent testing agency approved by GAIL.
5.13 Whenever material is identified as not meeting requirements by the visiting engineer a
rejection note shall be issued.
6.1 Following sampling plan shall be applicable for PMI examination of various alloy items:
C. Fasteners
Note:
a. For Welded Pipes and Fittings, PMI shall be performed on base metal as well as
weldments.
b Whenever any sample drawn to PMI test on the basis of percentage selection in
B & C above, fails to meet specification requirements, 100% of items of lot shall
be tested for PMI
8.0 MARKING
8.1 All alloy materials tested by PMI shall be identified using either of the following methods
by indicating “PMI OK”
BULK MATERIAL
Accept/ Reject
Element Cr Mo Ni V t
Specified range
Actual Observations
1.
2.
3.
Instrument Type/ ID
4. EXTRA COVER REQUIREMENTS SHALL BE PROVIDED AT OVER BENDS AND SAG BENDS
AS REQUIRED DURING CONSTRUCTION.
2. A MODIFIED PIPELINE WARNING SIGN SHALL BE INSTALLED WHERE THE PIPELINE CROSSES
AN EXISTING PIPELINE CARRYING HAZARDOUS FLUID.
3. CONCRETE SLAB SHALL BE PCC M15 AS PER IS 456 / PLASTIC GRATING SHALL BE 6 MM THK.
3. REFER API 1102 (LATEST EDITION) FOR OTHER DESIGN AND INSTALLATION
REQUIREMENTS.
4. ANGLE OF INTERSECTION BETWEEN PIPE LINE AND THE ROAD / HISGHWAY SHALL BE AS
CLOSE TO 900 AS POSSIBLE, BUT IN NO CASE LESS THAN 300.
5. IN CASE PIPE LINE COATING IS LIABLE TO GET DAMAGED WHILE BORING / JACKING, A
PROTECTIVE COATING OF CONCRETE OR ANY OTHER SUITABLE MATERIAL SHALL BE
PROVIDED ON CARRIER PIPE IN ACCORDANCE WITH SPECIFICATIONS AND AS DIRECTED BY
COMPANY.
6. CONTRACTOR SHALL VERIFY THE ACTUAL DIMENSIONS WITH RESPECT TO SURVEY DETAILS
FOR EACH ROAD / HIGHWAY CROSSED AND PREPARE DETAILED DRAWING FOR INDIVIDUAL
CROSSING FOR COMPANY’S APPROVAL BEFORE COMMENCEMENT OF CONSTRUCTION.
2. VENT AND DRAIN OFF TO FACE LEFT WHEN LOOKING IN DIRECTION OF FLOW AND SHALL BE
PARALLEL TO CROSSING.
4. PORTION OF VENT AND DRAIN OFF PIPES WHICH ARE UNDER GROUND OR WHICH MAY BE
UNDER WATER ARE TO BE COATED WITH COAL TAR EPOXY (MIN. 300 MICRON THK.) PAINTING
FOR PORTION ABOVE GROUND / WATER LEVEL SHALL BE AS PER STANDARD SPECIFICATION
FOR SHOP AND FIELD PAINTING NO. S-05-02-014.
6. FOR CASING PIPE REFER, STANDARD NO. S-04-01-008, SCOPE OF WORK AND SOR.
1. THE CASING PIPE SHALL BE DESIGNED IN ACCORDANCE WITH API 1102 (LATEST EDITION).
2. CASING PIPE, NORMALLY, IS NOT TO BE COATED. HOWEVER, IN HIGHLY CORROSIVE AREAS THE
CASING SHALL BE COATED, WRAPPED AND CATHODIC PROTECTION PROVIDED WITH
SACRIFICIAL ANODE.
5. ELECTRICAL INSULATION BETWEEN THE CASING AND CARRIER PIPE SHALL BE CHECKED WITH
SUITABLE MEGGER.
6. CASING INSULATORS AND END SEALS SHALL BE AS PER THE SPECIFICATIONS ISSUED FOR THE
SAME.
7. END SEALS SHOWN HERE ARE ONLY INDICATIVE, POSSIBILITY OF PROVIDING OHER TYPES OF
FLEXIBLE END SEALS MAY BE CONSIDERED.
8. TO PREVENT DAMAGE TO COATING AND WRAPPING (IF APPLIED) TO CASING PIPE IN CASE OF
BORED / JACKED CROSSING, A PROTECTIVE COATING OF CONCRETE OR SUITABLE MATERIAL
SHALL BE PROVIDED ON CASING PIPE.
2. A MODIFIED PIPELINE WARNING SIGN SHALL BE INSTALLED WHERE THE PIPELINE CROSSES
AN EXISTING PIPELINE CARRYING HAZARDOUS FLUID.
3. CONCRETE SLAB SHALL BE PCC M15 AS PER IS 456 / PLASTIC GRATING SHALL BE 6 MM THK.
7. DIMENSION ‘D’ SHALL BE THE LARGEST DIAMETER OF THE PIPELINE LAID IN SAME TRENCH.
2. A MODIFIED PIPELINE WARNING SIGN SHALL BE INSTALLED WHERE THE PIPELINE CROSSES
AN EXISTING PIPELINE CARRYING HAZARDOUS FLUID.
3. CONCRETE SLAB SHALL BE PCC M15 AS PER IS 456 / PLASTIC GRATING SHALL BE 6 MM THK.
7. DIMENSION ‘D’ SHALL BE THE LARGEST DIAMETER OF THE PIPELINE LAID IN SAME TRENCH.
2. A MODIFIED PIPELINE WARNING SIGN SHALL BE INSTALLED WHERE THE PIPELINE CROSSES
AN EXISTING PIPELINE CARRYING HAZARDOUS FLUID.
3. CONCRETE SLAB SHALL BE PCC M15 AS PER IS 456 / PLASTIC GRATING SHALL BE 6 MM THK.
7. DIMENSION ‘D’ SHALL BE THE LARGEST DIAMETER OF THE PIPELINE LAID IN SAME TRENCH.
3. SUITABLE MEASURES SHALL BE TAKEN FOR THE PROTECTION OF THE LINE AND SECURITY
OF PERSONNEL WHEREVER FOUND NECESSARY.
6. DIMENSION ‘D’ SHALL BE THE LARGEST DIAMETER OF THE PIPELINE LAID IN SAME TRENCH.
7. CONCRETE SLAB SHALL BE PCC M15 AS PER IS 456 / PLASTIC GRATING SHALL BE 6 MM THK.
4. THE MINIMUM COVER IS FOR STRAINGHT PIPE RUNS. EXTRA COVER REQUIREMENTS TO BE
ESTABLISHED AT ALL OVER BENDS, SAG BENDS AND HORIZONTAL BENDS.
5. FOR MINIMUM COVER AT PIPELINE CROSSING ROADS, RAILWAY TRACKS, RIVERS, MARSHY
AREAS ETC. REFER RELEVENT STANDARD.
7. DIMENSION ‘D’ SHALL BE THE LARGEST DIAMETER OF THE PIPELINE LAID IN SAME TRENCH.
8. CLEAR SPACING BETWEEN PIPELINES IS ONLY FOR STRAIGHT LENGTHS. SPACING BETWEEN
PIPELINES AT BENDS, RAILWAY CROSSINGS, ROAD CROSSINGS, CANAL CROSSINGS, OTHER
WATER CROSSINGS, MARSHY AREAS SHALL BE AS PER APPROVED DRAWINGS /
SPECIFICATIONS. CLEAR SPACING SHALL BE REVIEWED IN CASE PIPELINES OPERATING AT
TEMPERATURES OTHER THEN AMBIENT.
3. LOCATION:
PIPE - IS-1239
2. BOUNDARY MARKERS SHALL BE INSTALLED AT THE ROU LIMITS ON EITHER SIDES AT 250 M
INTERVALS AND ALSO AT ALL TURNING POINTS, AS PER SPECIFICATIONS AND AS
SPECIFIED BY COMPANY. BOUNDARY MARKERS SHALL PREFERABLY BE PLACED ON FIELD
BENDS / UNCULTIVABLE PATCHES.
3. LOCATION:
PIPE - IS-1239
PIPE - IS-1239
C. AREAS SHOWN AS “■” ARE TO BE PAINTED AND AREAS SHOWN AS “□” ARE TO BE
PAINTED YELLOW.
F. POST SHALL BE PAINTED WITH 250MM WIDE ALTERNATIVE BANDS OF BLACK AND
WHITE PAINT.
3. LOCATION:
PIPE - IS-1239
5. FOR FLUIDS COVERED BY ASME B 31.8, MENTION GAS IN LOCATION “- - -“. FOR FLUIDS
COVERED BY ASME B 31.4, MENTION “PETROLEUM” AND OTHER FLUIDS, MENTION THE NAME
OF THE FLUID.
7. IN CASE THE WARNING SIGN IS TO BE USED WHERE THE PIPE LINE CROSSES A HAZARDOUS
FACILITY LIKE A H.T CABLE OR ANOTHER PETROLEUM / GAS PIPE LINE, THEN THE WARNING
SIGN SHALL READ “HIGH PRESSURE GAS PIPE LINE CROSSING H.T CABLE (OR THE
CONCERNED FACILITY)” IN LETTERS OF SIZE AS DECIDED BY COMPANY.
2. REFER API 1102 (LATEST EDITION) FOR OTHER DESIGN AND INSTALLATION
REQUIREMENTS.
4. AT EACH CROSSING, PIPE LINE CROSSING WARNING SIGN SHALL BE INSTALLED ON EITHER
SIDE OF THE CROSSING. THE WARNING PLATE MAY BE MOUNTED ON VENT PIPE.
5. CATHODIC PROTECTION TEST LEAD TERMINAL BOX MAY BE MOUNTED ON VENT PIPE. FOR
CP LEAD TERMINAL BOX DETAILS, REFER RELEVENT STANDARD.
6. CONTRACTOR SHALL VERIFY THE ACTUAL DIMENSIONS WITH RESPECT TO SURVEY DETAILS
OF EACH CROSSING AND PREPARE DETAILED DRAWINGS FOR INDIVIDUAL CROSSING FOR
COMPANY / CONCERNED AUTHORITIES APPROVAL BEFORE COMMENCEMENT OF
CONSTRICTION.
8. ELECTRICAL INSULATION BETWEEN CASING AND CARRIER PIPES SHALL BE CHECKED WITH
SUITABLE MEGGER.
9. AFTER INSTALLATION OF CASING AND CARRIER PIPES, THE ROAD SHALL BE RESTORED TO
THE SATISFACTION OF COMPANY / CONCERNED ROAD AUTHORITIES.
10. PIPELINE SECTION SHALL BE PRETESTED HYDROSTATICALLY, SEPARATELY FROM THE MAIN
LINE TESTING WHEN REQUIRED BY CONCERNED AUTHORITIES / COMPANY.
11. ANGLE OF INTERSECTION BETWEEN PIPE LINE AND THE ROAD / HISGHWAY SHALL BE AS
CLOSE TO 900 AS POSSIBLE, BUT IN NO CASE LESS THAN 300.
12. JACKING / BORE THRU TECHNIQUE SHALL BE USED FOR THE CROSSING UNLESS SPECIFIED
OTHERWISE.
13. FOR VENT, DRAIN AND CASING PIPE DETAILS, REFER RELEVENT SPECIFICATIONS /
DRAWINGS / STANDARDS.
2. SINGLE SAG CROSSING SHALL NORMALLY BE USED WHERE THERE IS NO EVIDENCE OF EROSION
OF BANKS AND SCOURING OR SHIFTING OF STREAM BOITOM AND WHERE BED WIDTH DOES
NOT PROHIBIT ITS USE.
3. DOUBLE SAG CROSSING SHALL BE USED WHERE THERE IS EVIDENCE OF EROSION OF BANKS,
SCOURING OR SHIFTING OF STREAM BOTTOM.
5. UNLESS OTHERWISE SPECIFIED, THE MINIMUM COVER OVER THE PIPE MEASURED BELOW THE
LOWEST BED LEVEL SHALL BE 1500 MM.
6. THE TYPE AND EXTENT OF BUOYANCY CONTROL MEASURES SHALL BE AS PER SPECIFICATION
AND AS DIRECTED BY COMPANY FOR INDIVIDUAL CROSSING AND SHALL BE SHOWN ON THE
AUGNMENT SHEETS.
7. THE FILL AT THE BANKS SHALL BE TAMPED FIRMLY AND REINFORCED WITH SACKED EARTH,
LEAN CONCRETE, RIP RAP OR BY OTHER MEANS AS DIRECTED BY COMPANY. ADDITIONAL BANK
PROTECTION MEASURES AS PER SPECIFICATIONS SHALL BE ADOPTED WHEN THERE IS
EVIDENCE OF EROSION AND SLUMPING OF BANKS OR WHEN THE BANKS ARE STEEP.
10. AFER INSTALLATION OF THE CROSSING, THE WATER COURSE SHALL BE RESTORED TO ITS
ORIGINAL CONDITION TO THE ENTIRE SATISFACTION OF THE AUTHORITIES HAVING
JURISDICTION OVER THE SAME. WHERE THE EXCAVATED MATERIAL IS UNSUITABLE, TRENCH
SHALL BE BACKFILLED WITH MATERIAL APPROVED BY COMPANY.
11. WIDTH OF CROSSING SHALL BE THAT CORRESPONDING TO THE HIGHEST WATER LEVEL. THE
HIGHEST WATER LEVEL SHALL BE DETERMINED BASED ON THE FOLLOWING:
13. STRAIGHT LENGTH OF PIPE SHALL BE USED AT LEAST FOR THE ENTIRE WIDTH OF CROSSING.
14. CONTRACTOR SHALL VERIFY THE ACTUAL DIMENSIONS WITH RESPECT TO SURVEY DETAILS FOR
EACH CROSSING AND WHEN DIRECTED BY COMPANY, CONTRACTOR SHALL PREPARE DETAILED
DRAWINGS FOR INDIVIDUAL CROSSINGS FOR COMPANY APPROVAL BEFORE COMMENCEMENT OF
CONSTRUCTION.
2. SLOPE BREAKER BAGS TO BE GUNNY BAGS FILLED WITH 10:1 SAND:PORTLAND CEMENT MIXTURE.
3. HIGHEST SLOPE BREAKER TO BE PLACED 2.0 M FROM THE OVER-BEND AND THE LOWEST SLOPE BREAKERS TO BE PLACED 2.0 M FROM THE SAG BEND.
4. DISTANCE “L” BETWEEN BREAKERS AND NUMBER OF LAYERS OF BAGS (IN VERTICAL DIRECTION) FOR SLOPE BREAKER SHALL BE DECIDED ON CASE TO
CASE BASIS DEPENDING UPON SLOPE OF THE GROUND AND CHARACTERSTICS OF SOIL BAGS. BAGS SHALL BE PLACED IN SUCH A MANNER SO AS TO HAVE A
STABLE ARRANGEMENT. HOWEVER, DISTANCE “L” SHALL NOT EXCEED 7 M.
5. BAGS TO BE PLACED VERTICAL IN THE TRENCH AND NOT IN 900 TO THE PLANE OF PIPE.
7. TOP LAYER OF TRENCH SHALL BE BACKFILLED WITH SOIL OR CRUSHED ROCK (EXCAVATED MATERIAL).
9. WHERE ROCK, GRAVEL, LUMPS OF HARD SOIL OR LIKE MATERIALS ARE ENCOUNTERED, SELECT BACKFILL MATERIALS LIKE SOIL, CLAY OR OTHER
MATERIALS CONTAINING NO GRAVEL, ROCK OR LUMPS OF HARD SOIL SHALL BE PLACED AROUND THE PIPE.
INSTALLATION PROCEDURE:
4. LACE TOP PANEL TO THE SIDE AND END PANELS AND DIAPHRAGMS.
2. CATHODIC PROTECTION TEST LEADS TERMINAL BOX MAY BE MOUNTED ON THE VENT PIPE. FOR CP LEAD TERMINAL BOX DETAILS REFER RELEVANT STD./
SPECIFICATION.
3. AT EACH CROSSING, A PIPELINE WARNING SIGN SHALL BE INSTALLED ON EITHER SIDE OF CROSSING. WARNING SIGN PLATE MAY BE MOUNTED ON THE
VENT PIPE.
5. ELECTRICAL INSULATION BETWEEN CASING AND CARRIER PIPES SHALL BE CHECKED WITH SUITABLE MEGGER.
6. AFTER INSTALLATION OF CASING AND CARRIER PIPES, THE AREA SHALL BE RESTORED TO THE SATISFACTION OF THECONCERNED AUTHORITIES/COMPANY.
8. CONTRACTOR SHALL VERIFY THE ACTUAL DIMENSIONS WITH RESPECT TO SURVEY DETAILS FOR EACH CROSSING AND PREPARE DETAILED DRAWINGS FOR
COMPANY'S / CONCERNED AUTHORITY'S APPROVAL BEFORE COMMENCEMENT OF CONSTRUCTION.
9. PIPELINE SECTION SHALL BE PRE-TESTED HYDROSTATICALLY, SEPARATELY FROM THE MAIN LINE TESTING WHEN REQUIRED BY THE AUTHORITIES
CONCERNED AND/OR AS DIRECTED BY THE COMPANY.
10. ANGLE OF INTERSECTION BETWEEN PIPELINE AND RAILWAY SHALL BE AS CLOSE TO 900 AS POSSIBLE BUT IN NO CASE LESS THAN 850.
11. CASING PIPE SHALL BE EXTENDED FOR A DISTANCE OF UPTO 14.00m FROM CENTRE LINE OF OUTERMOST RAILWAY TRACK OR 0.6m BEYOND RAILWAY ROW
LIMITS ON EITHER SIDE, WHICHEVER IS MORE.
12. JACKING / BORE THRU' TECHNIQUE SHALL BE USED FOR THE CROSSING.
13. SEPARATE C.S. CONDUIT FOR OFC SHALL BE INSTALLED AT MINIMUM DISTANCE FROM CASING FOR CARRIER PIPE, IF SPECIFIED.
16. FOR VENT, DRAIN, CASING PIPE, INSULATORS, INSULATOR SPACING, CASING END SEASL ETC. REFER RELEVENT STANDARDS (S-04-01-007 & S-04-01-008)
2. SELECT BACK FILL MUST HAVE MIN. AS PLACED DRY DENSITY OF 1800 KG/M3. IF FOUND
NECESSARY IN FIELD, THE SELECT BACK FILL SHALL BE COMPACTD TO ACHIEVE A DRY
DENSITY OF MIN. 1800 KG/M3.
2. FOR ALL PIPELINES TO BE CONSTRUCTED IN THE LAND, MINIMUM COVER SHALL BE 1000
MM. ANY EXTRA COVER REQUIREMENT SHALL BE IN ACCORDANCE WITH SPECIFICATIONS /
STANDARDS / DRAWINGS.
5. SUITABLE DRAIN SHALL BE PROVIDED PARALLEL, ALL ALONG THE PIPE LINE TRENCH AND
ACROSS AT EVERY 250 M.
INSTALLATION PROCEDURE:
4. LACE TOP PANEL TO THE SIDE AND END PANELS AND DIAPHRAGMS.
2. CATHODIC PROTECTION TEST LEADS TERMINAL BOX MAY BE MOUNTED ON THE VENT PIPE. THE
NUMBER OF WARNING SIGNS SHALL BE:
3. FOR SYMBOLS, TRENCH DIMENSIONS, ROW DETAILS, MARKER ETC. REFER RELEVANT JOB
STANDARDS.
4. ELECTRICAL INSULATION BETWEEN CASING AND CARRIER PIPES SHALL BE CHECKED WITH
SUITABLE MEGGER.
5. AFTER INSTALLATION OF CASING AND CARRIER PIPES, THE CANAL SHALL BE RESTORED TO THE
SATISFACTION OF THE CONCERNED AUTHORITIES/COMPANY.
7. CONTRACTOR SHALL VERIFY THE ACTUAL DIMENSIONS WITH RESPECT TO SURVEY DETAILS FOR
EACH CANAL CROSSED AND PREPARE DETAILED DRAWINGS FOR COMPANY'S / CONCERNED
AUTHORITY'S APPROVAL BEFORE COMMENCEMENT OF CONSTRUCTION.
9. SEPARATE CASING PIPES SHALL BE INSTALLED FOR OFC AT MINIMUM DISTANCE FROM CASING
FOR CARRIER PIPE, IF SPECIFIED.
DOCUMENT NO. REV-0
GAIL (INDIA) LTD TYPICAL LINED CANAL CASED
CROSSING DETAIL Page 1 of 2
NEW DELHI S-04-01-029
Copyright GAIL – All rights reserved
10. JACKING/BORE THRU' TECHNIQUE SHALL BE USED FOR THE CROSSING.
12. FOR DRAIN, VENT, CASING PIPE, INSULATOR, INSULATOR SPACING, END SEALS ETC. REFER
RELEVENT STANDARD / SPECIFICATIONS.
4. FOR SYMBOLS, TRENCH DIMENSIONS, ROW DETAILS, MARKERS ETC. REFER RELEVENT JOB
STANDARDS.
5. ANGLE OF INTERSECTION BETWEEN PIPELINE AND THE CANAL SHALL BE AS CLOSE TO 900 AS
POSSIBLE IN NO CASE LESS THAN 300.
7. CONTRACTOR SHALL VERIFY THE ACTUAL DIMENSIONSWITH RESPECT TO SURVEY DETAILS FOR
EACH CANAL CROSSED AND PREPARE DETAILED DRAWINGS FOR COMPANY’S / CONCERNED
AUTHORITY’S APPROVAL BEFORE COMMENCEMENT OF CONSTRUCTION.
2. A DRAIN SHALL BE PROVIDED TO DRAIN OFF WATER FROM ROU. THIS DRAIN SHALL BE
CONNECTED TO THE NEAREST STREAM/NALA. CROSS DRAINS SHALL ALSO BE PROVIDED AT
SUITABLE LOCATIONS AS PER INSTRUCTIONS OF ENGINEER-IN-CHARGE.
3. WHENEVER THE PIPELINE IS CROSSING ANY STREAM/ NALA, ENTIRE WIDTH OF SUCH STREAM/
NALA SHALL BE PROVIDED WITH A MINIMUM 100 MM THICK LAYER OF PCC TO PREVENT SOIL
WASH OFF DURING RAINS. THE PCC LAYER SHALL COVER THE ENTIRE WIDTH OF PREPARED
ROU.
6. THE BACKFILLING OF THE TRENCH AND OTHER TRENCH STABILIZATION MEASURES SHALL BE AS
INDICATED IN APPROVED FOR CONSTRUCTION ALIGNMMENT SHEETS OR AS DIRECTED BY
ENGINEER-IN-CHARGE.
A. ±3 MM MAX. FROM INDICATED DIMENSIONS FOR FACE TO FACE, CENTER TO FACE LOCATION OF
THE ATTACHMENTS ETC. TOLERENCE CAN NOT BE ADDED.
B. ± 1.5 MM MAX. LATERAL TRANSLATION IN ANY DIRECTION FROM THE INDICATED POSITION.
D. ± 1 MM MAX. OUT OF ALIGNMENT FROM THE INDICATED POSITION MEASURED ACROSS ANY
DIAMETER AS SHOWN.
DOCUMENT NO. REV-0
GAIL (INDIA) LTD TOLERENCE FOR FABRICATION Page 1 of 2
NEW DELHI S-05-01-016
Copyright GAIL – All rights reserved
E. FLATTENING, MESAURED AS DIFFERENCE BETWEEN MAX. AND MIN. OD AT ANY CROSS SECTION.
NOTE:
1. LOADS ON FILLET WELDS OF GUIDE / CROSS GUIDE / ANCHOR SHALL BE LIMITED TO VALUES
TABULATED ABOVE AGAINST VARIOUS TEMPERATURES, FOR RESPECTIVE WELD SIZE, RUNNING
LENGTH OF WELD. LOADS MAY BE INTERPOLATED FOR INTERMEDIATE TEMPERATURES.
2. SHOE LENGTH SHALL BE TAKEN AS 300 MM FOR FIG. 1,2,3 AND 6 AND 400 MM FOR FIG. 4 AND
5, UNLESS SPECIFIED OTHERWISE. FOR FIG. 1, 2 OR 3, FOR AXIAL MOVEMENTS EXCEEDING 100
MM, SHOE LENGTH SHALL BE INCREASED ACCORDINGLY.
3. FOR FIG. 3 & 4, IF THE REQUIRED GUIDE GAP IS MORE THAN 3 MM, THE DIMENSIONS OF GUIDE
PLATE SHALL BE SUITABLY MODIFIED.
5. FOR CROSS GUIDES IN FIG. 4 & 5, LENGTH OF ANGLE SHALL BE SAME AS SHOE WIDTH.
6. IN CASE OF BEAM TYPE SUPPORTED STEEL, PLATES SHALL BE PROVIDED ON BOTH SIDES AS
SHOWN IN FIG. 5. HEIGHT OF PLATE SHALL BE BASED ON SIZE OF THE SUPPORTING STEEL
MEMBER.
7. LONGITUDINAL PIPE MOVEMENT NOT TO EXCEED 150 MM AND SHOE LENGTH NOT TO EXCEED
400 MM.
2. SHOE LENGTH SHALL BE TAKEN AS 300MM FOR FIG. 1,2,3 AND 6 AND AS 400MM FOR FIG. 4 AND
5, UNLESS SPECIFIED OTHERWISE. FOR FIG. 1,2 OR 3, FOR AXIAL MOVEMENT EXCEEDING
100MM, SHOE LENGTH SHALL BE INCREASED CORRESPONDINGLY.
5. FOR CROSS GUIDE IN FIG. 4 AND 5, LENGTH OF ANGLE SHALL BE SAME AS SHOE WIDTH.
6. IN CASE OF BEAM TYPE OF SUPPORTING STEEL, PLATES SHALL BE PROVIDED ON BOTH SIDES AS
SHOWN IN FIG. 5. HEIGHT OF PLATE SHALL BE BASED ON THE SIZE OF THE SUPPORTING STEEL
BEAM.
7. FOR FIG. 4 AND 5, IF THE VERTICALMOVEMENT IS 15MM, PROVIDE 3 NO.S OF GUSSET PLATES
(IS-2062) EQUALLY SPACED.
8. LONGITUDINAL PIPE MOVEMENT NOTTO EXCEED 150MM AND SHOE LENGTH NOT TO EXCEED
400MM.
9. PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR ROLLED FROM PLATE OF MATERIAL
EQUIVALENT TO THAT OF PIPE. THICKNESS OF PROTECTION SHIELD SHALL BE SAME AS THAT
OF LINE PIPE OR 12MM, WHICHEVER IS LESS.
1. LOADS ON FILLET WELDS OF GUIDE / CROSS GUIDE / ANCHOR SHALL BE LIMITED TO VALUES
TABULATED ABOVE AGAINST VARIOUS TEMPERATURES, FOR RESPECTIVE WELD SIZE, RUNNING
LENGTH OF WELD. LOADS MAY BE INTERPOLATED FOR INTERMEDIATE TEMPERATURES.
2. IN CASE THE PIPE SCHEDULE IS NOT THE SAME AS TABULATED ABOVE, THE DIMENSIONS ‘A’
AND ‘h’ SHALL BE MODIFIED ACCORDINGLY.
3. PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR ROLLED FROM PLATE OF MATERIAL
EQUIVALENT TO THAT OF PIPE. THICKNESS OF PROTECTION SHIELD SHALL BE SAME AS LINE
PIPE OR 12 MM WHICHEVER IS LESS.
5. IN CASE OF SIZE REDUCTION (S) IN STRAIGHT RUN WITH BOP, PROTECTION SHIELS THICKNESS
FOR ALL SIZES SHALL BE EQUAL TO THAT FOR THE LARGEST DIAMETER PIPE.
2. SHOE LENGTH SHALL BE TAKEN AS 300MM FOR FIG. 1,2,3 AND 6 AND AS 400MM FOR FIG. 4 AND
5, UNLESS SPECIFIED OTHERWISE. FOR FIG. 1,2 OR 3, FOR AXIAL MOVEMENT EXCEEDING
100MM, SHOE LENGTH SHALL BE INCREASED CORRESPONDINGLY.
3. FOR FIG. 3 AND 4, IF THE REQUIRED GUIDE-GAP IS MORE THAN 3MM, DIMENSIONS OF THE
GUIDE PLATE SHALL BE SUITABLE MODIFIED.
5. FOR CROSS GUIDE IN FIG. 4 AND 5, LENGTH OF ANGLE SHALL BE SAME AS SHOE WIDTH.
6. IN CASE OF BEAM TYPE OF SUPPORTING STEEL, PLATES SHALL BE PROVIDED ON BOTH SIDES AS
SHOWN IN FIG. 5. HEIGHT OF PLATE SHALL BE BASED ON THE SIZE OF THE SUPPORTING STEEL
BEAM.
7. LONGITUDINAL PIPE MOVEMENT NOTTO EXCEED 150MM AND SHOE LENGTH NOT TO EXCEED
400MM.
8. PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR ROLLED FROM PLATE OF MATERIAL
EQUIVALENT TO THAT OF PIPE. THICKNESS OF PROTECTION SHIELD SHALL BE SAME AS THAT
OF LINE PIPE OR 12MM, WHICHEVER IS LESS.
1. INSERT AND SLIDING PLATE MATERIAL SHALL BE CARBON STEEL WHER TEMP. IS ≥4000C WITH
h ≤ 200 MM. SLIDING PLATE MATERIAL SHALL BE EQUIVALENT TO PIPE MATERIAL.
2. DIMENSION ‘M’ LOCATES THE POINT OF MATERIAL TRANSITION ON THE SUPPORT. THE STUB
MATERIAL SHALL BE EQUIVALENT TO THAT OF LINE PIPE AND THE LOWER SUPPORT PIPE SHALL
BE CARBON STEEL. MINIMUM VALUE OF ‘M’ SHALL BE ‘INSULATION THICKNESS + 25 MM’.
A. FOR CARBON STEEL LINE PIPE, THE ENTIRE SUPPORT PIPE SHALL BE CS I.E. M=0.
B. FOR ALLOY STEEL / STAINLESS STEEL LINE PIPE, SUPPORT PIPE SHALL CONSIST OF
THE FOLLOWING:
3. IN CASE SIZE AND / OR SCHEDULE OF SUPPORT PIPE (D1) LISTED IN THE TABLE IS NOT
AVAILABLE USE NEXT HIGHER SIZE AND / OR NEAREST HIGHER THICKNESS AVAILABLE.
4. PROTECTION SHIELD (LENGTH = K MM) CUT FROM LINE PIPE OR EQUIVALENT PLATE SHALL BE
PROVIDED ON HORIZONTAL LINE AS FOLLOWS:
1. FOR THE APPLICABLE SIZE NOS., DIMENSIONS TABLE AND NOTES, REFER GAIL STANDARD
S-05-01-021.
1. FOR THE APPLICABLE SIZE NOS., DIMENSION TABLE, NOTES AND VIEW A-A, REFER GAIL
STANDARD S-05-01-021.
NOTES:
1. ALL PLATES SHALL BE CARBON STEEL WHERE DESIGN TEMPERATURE ≥ 4000C WITH h≤
200mm. BASE PLATE MATERIAL SHALL BE EQUIVALENT TO PIPE MATERIAL.
3. IN CASE SIZE AND / OR SCHEDULE OF SUPPORT PIPE (D1) LISTED IN TABLE ABOVE IS
NOT AVAILABLE, USE THE NEXT HIGHER SIZE AND / OR NEARESR HIGHER THICKNESS
AVAILABLE.
NOTES:
NOTES:
1. ALL PLATES SHALL BE CARBON STEEL. THE STUB PIPE MATERIAL SHALL BE
EQUIVALENT TO THAT OF LINE PIPE AND THE LOWER SUPPORT PIPE SHALL BE OF
CARBON STEEL.
3. IN CASE SIZE AND / OR SCHEDULE OF SUPPORT PIPE (D1) LISTED IN TABLE ABOVE IS
NOT AVAILABLE, USE THE NEXT HIGHER SIZE AND / OR NEARESR HIGHER THICKNESS
AVAILABLE.
NOTES:
1. ALL PLATES SHALL BE CARBON STEEL. THE STUB PIPE MATERIAL SHALL BE
EQUIVALENT TO THAT OF LINE PIPE AND THE LOWER SUPPORT PIPE SHALL BE OF
CARBON STEEL.
2. DIMENSION “M” LOCATES THE POINT OF MATERIAL TRANSITION ON THE SUPPORT. THE
STUB MATERIAL SHALL BE EQUIVALENT TO THAT OF LINE PIPE AND THE REST OF SUPPORT
PIPE SHALL BE CARBON STEEL. MINIMUM VALUE OF “M” SHALL BE INSULATION THICKNESS
+ 25MM.
FOR CARBON STEEL LINE PIPE, THE ENTIRE SUPPORT PIPE SHALL BE CARBON STEEL
I.E. M=0.
3. IN CASE SIZE AND / OR SCHEDULE OF SUPPORT PIPE (d) LISTED IN ABOVE TABLE IS NOT
AVAILABLE, USE NEXT HIGHER SIZE AND / OR NEAREST HIGHER THIOCKNESS AVAILABLE.
2. DIMENSION “M” LOCATES THE POINT OF MATERIAL TRANSITION ON THE SUPPORT. THE
STUB MATERIAL SHALL BE EQUIVALENT TO THAT OF LINE PIPE AND THE REST OF SUPPORT
PIPE SHALL BE CARBON STEEL. MINIMUM VALUE OF “M” SHALL BE INSULATION THICKNESS
+ 25MM.
FOR CARBON STEEL LINE PIPE, THE ENTIRE SUPPORT PIPE SHALL BE CARBON STEEL
I.E. M=0.
DUMMY PIPE SUPPORT FOR DOCUMENT NO. REV-0
GAIL (INDIA) LTD INSULATED PIPE, SIZE 2” THRU 24”, Page 1 of 2
NEW DELHI TYPE- B40 S-05-01-036
Copyright GAIL – All rights reserved
FOR ALLOY STEEL / STAINLESS STEEL LINE PIPE, SUPPORT PIPE SHALL CONSIST OF
THE FOLLOWING:
3. IN CASE SIZE AND / OR SCHEDULE OF SUPPORT PIPE (d) LISTED IN ABOVE TABLE IS NOT
AVAILABLE, USE NEXT HIGHER SIZE AND / OR NEAREST HIGHER THIOCKNESS AVAILABLE.
1. LOADS ON FILLET WELDS OF GUIDES SHALL BE LIMITED TO THE VALUES TABULATED ABOVE
AGAINST VARIOUS TEMPERATURES FOR RESPECTIVE WELD SIZE, FOR RUNNING LENGTH OF WELD.
LOADS MAY BE INTERPOLATED FOR INTERMEDIATE TEMPERATURES.
3. GUIDE ANGLES SHALL BE SUITABLY TRIMMED WHENEVER THEY ARE OBSTRUCTING ADJACENT
GUIDE ANGLES.
4. PROTECTION SHIELD SHALL BE PROVIDED ON ALL LINES 14” AND ABOVE. IT SHALL BE CUT FROM
LINE PIPE OR ROLLED FROM PLATE OF MATERIAL EQUIVALENT TO LINE PIPE. THICKNESS OF
PROTECTION SHIELD SHALL BE SAME AS LINE PIPE OR 12MM, WHICHEVER IS LESS.
1. LOADS ON FILLET WELDS OF CROSS GUIDES SHALL BE LIMITED TO THE VALUES TABULATED ABOVE
AGAINST VARIOUS TEMPERATURES FOR RESPECTIVE WELD SIZE, FOR RUNNING LENGTH OF WELD.
LOADS MAY BE INTERPOLATED FOR INTERMEDIATE TEMPERATURES.
3. PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR ROLLED FROM PLATE OF MATERIAL
EQUIVALENT TO LINE PIPE. THICKNESS OF PROTECTION SHIELD SHALL BE SAME AS LINE PIPE OR
12MM, WHICHEVER IS LESS.
4. IN CASE OF BEAM TYPE SUPPORTING STEEL, PLATES SHALL BE PROVIDED ON BOTH SIDES AS SHOWN.
HEIGHT OF THE PLATE SHALL BE BASED ON THE SIZE OF THE SUPPORTING STEEL MEMBER.
1. LOADS ON FILLET WELDS OF GUIDES SHALL BE LIMITED TO THE VALUES TABULATED ABOVE
AGAINST VARIOUS TEMPERATURES FOR RESPECTIVE WELD SIZE, FOR RUNNING LENGTH OF
WELD. LOADS MAY BE INTERPOLATED FOR INTERMEDIATE TEMPERATURES.
3. PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR ROLLED FROM PLATE OF MATERIAL
EQUIVALENT TO LINE PIPE. THICKNESS OF PROTECTION SHIELD SHALL BE SAME AS LINE PIPE
OR 12MM, WHICHEVER IS LESS.
4. FOR SUPPORTING DETAILS OF PIPE SIZES 2” THRU 6”, REFER GAIL STANDARD S-05-01-040.
1. LOADS ON FILLET WELDS OF ANCHORS SHALL BE LIMITED TO THE VALUES TABULATED ABOVE AGAINST
VARIOUS TEMPERATURES FOR RESPECTIVE WELD SIZE, FOR RUNNING LENGTH OF WELD. LOADS MAY BE
INTERPOLATED FOR INTERMEDIATE TEMPERATURES.
2. FOR AS / SS LINES OF SIZES 2” THRU 12”, PROTECTION SHIELD AS PER NOTE-3 IS TO BE PROVIDED.
3. PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR ROLLED FROM PLATE OF MATERIAL EQUIVALENT
TO LINE PIPE. THICKNESS OF PROTECTION SHIELD SHALL BE SAME AS LINE PIPE OR 12MM, WHICHEVER IS
LESS.
4. FOR SUPPORTING DETAILS OF PIPE SIZES 2” THRU 6” , REFER GAIL STANDARD S-05-01-040. CROSS GUIDE
GAP SHALL BE MADE ZERO AND RESTRAINT FACE SHALL BE WELDED TO SLEEPER INSERT PLATES ON
EITHER SIDE.
Note:
1. Material for body shall have guaranteed minimum yield strength of 46,700 psi. In
case the same can not be guaranteed, Valves shall be supplied with PUP pieces of
500mm length, integrally welded to the valve, whose strength shall be equivalent
to connecting pipe specifications.
2. For the welding end, the out of roundness (i.e. difference between maximum and
minimum ID at pipe end) shall be 5.0mm.
3. Compressed asbestos filler (CAF) shall not be used for body sealing/ gasket
materials.
4. All valves shall be suitable for location operation & remote actuated operation as
per specification No. S-04-02-012.
Note:
1. Material for body shall have guaranteed minimum yield strength of 46,700 psi. In
case the same can not be guaranteed, Valves shall be supplied with PUP pieces of
500mm length, integrally welded to the valve, whose strength shall be equivalent
to connecting pipe specifications.
2. For the welding end, the out of roundness (i.e. difference between maximum and
minimum ID at pipe end) shall be 5.0mm.
3. Compressed asbestos filler (CAF) shall not be used for body sealing/ gasket
materials.
4. All valves shall be suitable for location operation & remote actuated operation as
per specification No. S-04-02-012.
Note:
1. Material for body shall have guaranteed minimum yield strength of 46,700 psi. In
case the same can not be guaranteed, Valves shall be supplied with PUP pieces of
500mm length, integrally welded to the valve, whose strength shall be equivalent
to connecting pipe specifications.
2. For the welding end, the out of roundness (i.e. difference between maximum and
minimum ID at pipe end) shall be 5.0mm.
3. Compressed asbestos filler (CAF) shall not be used for body sealing/ gasket
materials.
Note:
Note:
NOTES
1 THIS VALVE SPEC SHEET SHALL BE READ IN CONJUNCTION WITH TECHNICAL NOTES FOR VALVES.
2 BIDDER SHALL CLEARLY WRITE ALL/ ANY DEVIATION AGAINST EACH PART/ MATERIAL OF VALVE IN
3 THE SPACE PROVIDED FOR. WHEREVER BIDDER AGREES WITH SPEC BIDDER SHALL INDICATE
"AGREED".
4 NO CUTTING/ OVERWRITING BY BIDDER ON SPEC IS ALLOWED.
5 TESTING SHALL BE AS PER API 598
NOTES
1 THIS VALVE SPEC SHEET SHALL BE READ IN CONJUNCTION WITH TECHNICAL NOTES FOR VALVES.
2 BIDDER SHALL CLEARLY WRITE ALL/ ANY DEVIATION AGAINST EACH PART/ MATERIAL OF VALVE IN
THE SPACE PROVIDED FOR. WHEREVER BIDDER AGREES WITH SPEC BIDDER SHALL INDICATE
"AGREED".
3 NO CUTTING/ OVERWRITING BY BIDDER ON SPEC IS ALLOWED.
4 TESTING SHALL BE AS PER API 598 & BS-6364.
5 VALVES SHALL BE PROVIDED WITH EXTENDED BONNET AS PER BS 6364 (NON COLD BOX
APPLICATION).
6 VALVES TO COMPLY WITH DESIGN REQUIREMENTS OF BS-6364 ALSO.
INSTALLATION CONDITIONS:
LOCATION SULTANPUR PIG LAUNCHER STATION, NEEMRANA
PIG RECEIVER STATION
INSTALLATION ABOVE GROUND
DESIGN CONDITIONS:
BARRED TEE SIZE (NB, INCHES) 18 X 18 X 18
DESIGN CODE ASME B 31.8
DESIGN FACTOR 0.5
CORROSION ALLOWANCE NIL
DESIGN PRESSURE 99.93 KG/CM2 (G)
DESIGN TEMPERATURE (-) 28 TO 650C
IMPACT TEST TEMPERATURE (-) 280C
TRANSPORTED GAS NATURAL GAS
SOUR SERVICE NO
POST WELD HEAT TREATMENT NO
OF FIELD WELDS
IF WALL THICKNESS OF TEE IS GREATER THAN
RADIOGRAPHY INSPECTION
20MM, RI SHALL BE REPLACED WITH UT
PAINTING AS PER CLAUSE 6.0 OF SPECIFICATION
NO. S – 04 – 02 - 016
MATERIALS:
TEE MSS SP-75, Gr. WPHY-70
GUIDE BARS MANUFACTURER TO SPECIFY
NO. OF BARS 9
TEST RING (1 NO.) 18” X 500MM X 9.3 MM
INSTALLATION CONDITIONS:
LOCATION DHARUHERA TOP, BHIWADI-CHOPANKI TOP,
KHUSHKHERA TOP
INSTALLATION UNDER GROUND
DESIGN CONDITIONS:
BARRED TEE SIZE (NB, INCHES) 18 X 18 X 12
DESIGN CODE ASME B 31.8
DESIGN FACTOR 0.5
CORROSION ALLOWANCE NIL
DESIGN PRESSURE 99.93 KG/CM2 (G)
DESIGN TEMPERATURE (-) 28 TO 650C
IMPACT TEST TEMPERATURE (-) 280C
TRANSPORTED GAS NATURAL GAS
SOUR SERVICE NO
POST WELD HEAT TREATMENT NO
OF FIELD WELDS
IF WALL THICKNESS OF TEE IS GREATER THAN
RADIOGRAPHY INSPECTION
20MM, RI SHALL BE REPLACED WITH UT
PAINTING AS PER CLAUSE 6.0 OF SPECIFICATION
NO. S – 04 – 02 - 016
MATERIALS:
TEE MSS SP-75, Gr. WPHY-70
GUIDE BARS MANUFACTURER TO SPECIFY
NO. OF BARS 3
TEST RING (1 NO.) 12” X 500MM X 7.9 MM
INSTALLATION CONDITIONS:
LOCATION TOP IN U/S OF SV-1 & SV-3 IN SULTANPUR-
NEEMRANA SPUR LINE
INSTALLATION UNDER GROUND
DESIGN CONDITIONS:
BARRED TEE SIZE (NB, INCHES) 18 X 18 X 8
DESIGN CODE ASME B 31.8
DESIGN FACTOR 0.5
CORROSION ALLOWANCE NIL
DESIGN PRESSURE 99.93 KG/CM2 (G)
DESIGN TEMPERATURE (-) 28 TO 650C
IMPACT TEST TEMPERATURE (-) 280C
TRANSPORTED GAS NATURAL GAS
SOUR SERVICE NO
POST WELD HEAT TREATMENT NO
OF FIELD WELDS
IF WALL THICKNESS OF TEE IS GREATER THAN
RADIOGRAPHY INSPECTION
20MM, RI SHALL BE REPLACED WITH UT
PAINTING AS PER CLAUSE 6.0 OF SPECIFICATION
NO. S – 04 – 02 - 016
MATERIALS:
TEE MSS SP-75, Gr. WPHY-70
GUIDE BARS MANUFACTURER TO SPECIFY
NO. OF BARS 3
TEST RING (1 NO.) 8” X 500MM X 6.4 MM
DESIGN CONDITIONS
DESIGN PRESSURE (KG/CM²) 99.93
DESIGN TEMPERATURE (ºC) -28 TO 65
DESIGN CODE ASME B31.8 & OISD 226
CORROSION ALLOWANCE (MM) 1.5
ANSI RATING (#) 600
DESIGN FACTOR 0.5
SERVICE NATURAL GAS
END CONNECTION BE
INSTALLATION ABOVE GROUND
IEC - ZONE-1, GAS GROUP-IIA & IB,
ELECTRICAL AREA CLASSIFICATION TEMP. CLASS - T3
Vendor to take the following data for sizing the actuator and furnish the filled in torque
figures in Table-1 after sizing the actuator.
1. Tag Nos. :
5. Process Condition:
a) Solenoid Valves : 24 V DC ± 15 %
b) Relays
Note:
Complete actuator including control panel/ systems shall be manufactured and supplied
by actuator manufacturer only. All circuit diagram / documents/ drawings pertaining to
actuator shall be furnished by actuator manufacturer. All inspection and testing shall be
carried out at actuator manufacturer’s shop as per clause 6.1 of Spec. No. S-04-02-012.
ACTUATOR
BALL VALVE TORQUE GENERATED TORQUE
DATA FROM BALL VALVE VENDOR FIGURES WITH A AT 10 KG/CM2 (G)
SAFETY FACTOR 1.25 REGULATED
ITEM TAG PRESSURE (NOTE 1) MODEL
NO. NO. MAX. SELECTED
BREAK RUNNING ALLOWABLE BREAK RUNNING BREAK RUNNING
TORQUE TORQUE STEM TORQUE TORQUE TORQUE TORQUE
(NM) (NM) TORQUE (NM) (NM) (NM) (NM)
(NM)
Notes:
1. These figures shall be used as basis for testing the actuator performance during
factory testing. The actuator acceptance would be carried out after verifying
successful testing complete of ball valves with actuator assembly.
1) Fasteners
7) Insulating Joints
- Forain S.R.L.
- GD Engineering, India
- Perry Equipment Corporation, India
- Pipeline Engineering, UK
- Siirtec Nigi SPA
- TD Williamson Inc., USA