STANDARD SPECIFICATION FOR FLOW TEE (BARRED TEE) GAIL (NDIA) LTD NEW DELHI STANDARD SPECIFICATION FOR FLOW TEE (BARRED TER) DOCUMENT NO, REVO $.04-02-016 Page | of 2 Cont GR, AT ris wenSI. No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 CONTENTS REFERENCE DOCUMENTS MATERIALS & REQUIREMENTS MANUFACTURE QUALIFICATION AND PRODUCTION TESTING INSPECTION AND TESTS COATING / PAINTING MATERIAL TESTING AND TRACEABILITY PREPARATION FOR SHIPMENT MARKING VENDOR DATA REQUIREMENT DESIGN OF BARRED TEE NEW DELHI {AIL (INDIA) LTD STANDARD SPECIFICATION FOR DOCUMENT NO, REVO FLOW TEE (BARRED TEE) $.04-02-016 Page 2 of IZ Cont GR, AT ris wen10 20 ‘SCOPE: This specification covers the basic technical requirements for design, manufacture, inspection, testing, coating and painting & supply of Pipeline Flow Tees (Barred Tees) (above ground / under ground) to be installed in pipeline system transporting Natural Gas. All Tees shall be suitable for Bi-directional movement of Inspection tools / pigs. REFERENCE DOCUMENTS: Reference has also been made in this specification to the latest edition of the following codes, standards and specifications: ASME B31.8 ASME B16.9 ASTM A370 ASTM E92 ASTM E 709 ASNT-SNT-TC-1A Gas Transmission and Distribution Piping System Factory made Wrought Steel Butt Welding Fittings Mechanical testing of steel products Standard test method for Vickers Hardness of metallic materials Standard guide for Magnetic particle examination ‘American society of Non-destructive testing APL SL Specification for Line Pipe MSS-SP-75 Specification for High Test Wrought Welding Fittings 1s0 9000 Quality Management and Quality Assurance Standards 1s0 9001 Quality Systems — Model for quality assurance in design, development, production, installation and servicing EN 10204 Metallic products — types of inspection documents 150 12094 Welded Steel tubes for pressure purposes — ultrasonic testing for the {AIL (NDIA) LTD STANDARD SPECIFICATION FOR DOCUMENT NO. av NEW DELHI FLOW TEE (BARRED TEE) $-0402.016 Page 3 oF 1 Cont GR, AT ris wendetection of laminar imperfections in strips / plates used in manufacturing of tubes OISD 141 : Design and Construction requirements for cross country hydrocarbon pipelines In the event of any conflict of data or requirements in any of the above documents, it is the Supplier's responsibility to resolve these conflicts before Proceeding with design, manufacture or purchase, In any case, the most stringent requirement shall prevail. However, client / client's representative interpretation shall be final. In case of conflict, the order of precedence of the documents shall be as follows: National and / or local regulations Technical Data Sheets This Specification Project Specifications & Company Standards International Codes as per Paragraph 2.1 3.0 MATERIALS & REQUIREMENTS: 3.1 The design code, design factor, rating, corrosion allowance, grade of material, nominal diameter and nominal wall thickness of mating main pipe and branch pipe shall be as stated in the Material requisition. 3.2 Tees with branches 25% or more than the main pipeline diameter shall have a configuration of bars as indicated in Annexure-A. The bars shall be made of mild steel, ASTM Grade hardness tested applications, and shall be full penetration welded using a qualified procedure. 3.3. The Tees shall be designed to the design code as stated in the material requisition, and shall be manufactured to MSS SP-75 as appropriate and the Tequirements 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 OMEN 7 ‘AIL (INDIA) LTD STANDARD SPECIFICATION FOR DOCUMENT NO. REV. NEW DELHI FLOW TEE (BARRED TEE) $-04.02.016 Page 4 oF 12 Cont GR, AT ris wen37 38 39 3.10 3.1 3.12 3.13 3.14 3.15 3.16 ends of the pipe will be acceptable, if the wall thickness of the body of the Tee exceeds this dimension. Vendor shall check & confirm the number of bars (as stated in Appendix-A) required for Tees. All pipeline Tees shall be suitable for passage of instrumented inspection tools in either direction. Fully killed carbon steel shall be used. 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. G+Mo+V Ni+ Cu 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, HVio, unless specified otherwise. 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. 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. 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. ‘The material shall be as per MSS SP-75 or suitable API Standard SL pipe to achieve tensile properties as indicated in the data sheet. The fittings shall be heat treated by normalizing, quenching and tempering to achieve the same strength of line pipe. DOCUMENT NO, REVO NEW DELHI {AIL (INDIA) LTD STANDARD SPECIFICATION FOR FLOW TEE (BARRED TER) $.04-02-016 Page 5 of 2 Cont GR, AT ris wen4.0 3.47 3.18 3.19 Fittings shall not be machined from bar stock or solid forged billets. Tees shall be supplied in normalized, normalized and tempered or quenched and tempered condition, A ring of material may be required from the main run of pipe for weld Procedure qualifications for the main pipeline. Rings shall be 400mm minimum in length and subject to the same forging and heat treatment as the supplied Tee. MANUFACTURE QUALIFICATION AND PRODUCTION TESTING: 4a 414 41.2 413 414 4.2 4.21 4.2.2 4.23 424 4.25 MANUFACTURE: 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. The chemical and physical properties of the material shall meet the line pipe specifications. ‘The manufacturer shall submit a manufacturing procedure for approval by purchaser prior to manufacture of Tees. Double sided submerged Arc welding is required for the longitudinal weld in the main run. Single sided weld requires specific approval from Purchaser. QUALIFICATION: ‘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. 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. 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. ‘The full penetration welds for the bars shall be qualified to ASME Sec. IX or other welding code approved by Purchaser. All welding, including weld repairs, shall be performed in accordance with the procedure approved by Purchaser and welders qualified in accordance DOCUMENT NO, REVO NEW DELHI {AIL (INDIA) LTD STANDARD SPECIFICATION FOR FLOW TEE (BARRED TER) $.04-02-016 Page 6 of 2 Cont GR, AT ris wenwith ASME Sec. IX and API 1104. Welding procedures required for non-sour service applications shall also include the hardness tests. 4.3 PRODUCTION TESTING: Destructive testing of fittings shall include the tests as given below. Specimens and testing shall be carried out in accordance with clause 6.2 of API 5L and shall meet the acceptance of relevant line pipe specification. ‘Test frequency shall be once per heat, per heat treatment batch, per grade of material for each size of Tee. The minimum test temperature shall be orc, 431 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. 43.3 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. 5.0 INSPECTION AND TESTS: 5.1 GENERAL: 5.1.1 All personnel, performing the non-destructive tests (NDT) shall be qualified in the technique applied, in accordance with ASNT-TC-1A Level II by a third party, or equivalent approved by the Purchaser. 5.1.2 Original certificates shall be made available for inspection by purchaser / purchaser's representative at the Vendor's premises, if required. Personal interpreting results of any NDT shall be qualified by a third party to SNT-TC- 1A, Level IT or III. 5.1.3 All NDT shall be performed in accordance with written procedures. These procedures shall have the prior approval of the Purchaser. 5.1.4 NDT shall be carried out on Tees after all mechanical testing, manufacturing stages and heat treatment have been completed. OMEN 7 ‘AIL (INDIA) LTD STANDARD SPECIFICATION FOR DOCUMENT NO. REV. _ NEW DELHI FLOW TEE (BARRED TEE) $-04.02.016 Page Tor Tz Cont GR, AT ris wen5.2 5.24 5.2.2 5.2.3 5.2.4 5.3 53.1 53.2 533 53.4 53.5 5.3.6 VISUAL INSPECTION: 100% Visual inspection shall be carried out. The body of every fitting shall be inspected internally and externally for surface defects. ‘The surfaces of the fitting shall be free from all dents, gouges, laps, score marks, arc strikes, under cuts or other detrimental defects. 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. 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. NON-DESTRUCTIVE TESTING OF FITTIN' 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. 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 The manufacturer shall record on review form accompanying the radiograph, the interpretations of each radiograph and disposition of the fitting inspected. 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. 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 £709. 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. 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 {AIL (INDIA) LTD STANDARD SPECIFICATION FOR a NEW DELHI FLOW TEE (BARRED TEE) S0e02-016 rage B of 12 DOCUMENT NO, REVO Cont GR, AT ris wen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 100°C, unless the qualification test shows that a higher temperature is necessary. 5.3.8 Each repair welding procedure shall be qualified on a pipe section under realistic conditions in accordance with API 5L Appendix-C and this specification. 5.4 DIMENSIONAL INSPECTION: 5.4.1 Each Tee shall confirm to the dimensional requirements of ASME B 16.9 or MSS SP-75 as appropriate and the additional requirements of this section. 5.4.2 The ends of each fitting shall be tested for out of roundness using an internal ring gauge with a diameter of 5mm (0.2 inch) less than the nominal internal diameter. The gauge shall pass freely into each end of the fitting for a distance of 100mm when held perpendicular to the fitting axis. 5.4.3. The tolerance for the internal diameter of the run pipe part of the Tee shall be within 0 to +1.5mm (0 to 0.059 inches) of the nominal dimension of the connecting pipe at the ends. 5.4.4 End bevel preparation for the Tees shall be in accordance with API SL. 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, COATING / PAINTING: After sand blasting and cleaning the surface (SA 2 Ya) of the Barred Tee, the following coating shall be applied. For under ground Barred Tees: DOCUMENT NO, REVO {AIL (INDIA) LTD STANDARD SPECIFICATION FOR NEW DELHI FLOW TEE (BARRED TER) $.04-02-016 Page 9 of 2 Cont GR, AT ris wen* Coal Tar Polyurethane or equivalent, which shall be approved by Purchaser. ‘The DFT shall be 875 microns. For above ground Barred Tees: Zinc rich epoxy primer. The DFT shall be 50 microns. 7.0 MATERIAL CERTIFICATION AND TRACEABILITY: 7.1 Material test certificates and manufacturer test reports shall be traceable to ition Book, which shall be part of the QC 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. 8.0 PREPARATION FOR SHIPMENT: The vendor shall submit shipping and handling procedures to Purchaser for approval. The procedures should adequately address storage, shipping and handling in view of the long voyage from manufacturing locations and climatic extremes at the job site. An appropriate design of end cap shall be fitted to each opening to protect the butt weld ends and prevent ingress of foreign material 9.0 MARKING: The vendor shall mark each fitting with the information specified below as a minimum. The markings shall be painted on the outside surface and shall be executed white block capitals of minimum height 34 inch. Project Name Manufacturer's name and unique identification number of the fitting Nominal header pipe diameter (inches) and wall thickness (mm) Nominal branch pipe diameter (inches) and wall thickness (mm) Material Grade Design Pressure and test Pressure (when applicable) Purchase Order and Item Number Cast number 10.0 VENDOR DATA REQUIREMENTS: During the fabrication, the Vendor shall submit certification and inspection documents to the Purchaser as specified in the Purchase order. Documents shall include the following as minimum. + Quality Plan OMEN 7 ‘AIL (INDIA) LTD STANDARD SPECIFICATION FOR DOCUMENT NO. REVO NEW DELHI FLOW TEE (BARRED TEE) $-04.02.016 Page 10 of12 Cont GR, AT ris wen+ Manufacturing Procedures covering steel making, chemical composition, welding and forming procedure. * Certified material test reports, 3.18 to EN 10204, for all sizes. . NDT test reports and operator qualifications + All mechanical test reports + Certificate of conformance and dimensional check reports . Heat treatment procedure reports + Allconcession requests * Design . Burst test information GAIL (NDIA) LTD STANDARD SPECIFICATION FOR DOCUMENT NO. REV-0 NEW DELHI FLOW TEE (BARRED TEE) '$-04-02-016 Page II of 12 a ORT AT a eTDESIGN OF FLOW TEES (BARRED TEES) Ss oe TYPICAL WELDOETAL tet sare seanon sue Sana wroa armas ENTS 7 GAIL aNDIA) LTD STANDARD SPECIFICATION FOR DOCUMENT NO. REVO NEW DELHI FLOW TEE (BARRED TEE) $-04.02.016 Page 12 fT Cone GAIL AT rg